Figure 1 - Top Causes of Tool Failure & Injury.

 

 

Proper Hand Tool Use​

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• Select the correct tool designed for the task.

• Inspect tools for cracks, mushroomed heads, worn grips, or bent shafts before use.

• Ensure cutting tools (chisels, blades, cutters) are sharp – dull tools require excessive force and slip more easily.

• Never modify tools (grinding, welding, bending) unless approved by manufacturer.

•  Maintain a stable stance and avoid placing the body or hands in the line of fire.

• Use insulated tools when working near energized components.

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Proper Power Tool Use

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• Verify guards and safety mechanisms are in place and functioning.

• Check cords, plugs, batteries, and housings for damage.

• Match wheel, blade, or attachment RPM ratings to the tool.

• Secure workpieces using clamps or vises – never hold with one hand while cutting or grinding.

• Maintain both hands on the tool when required and use auxiliary handles when provided.

• Be aware of kickback hazards – especially with grinders, saws, and impact tools.

• Disconnect power or remove batteries before changing blades or accessories.

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Understanding Tool Failure Causes

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• Using the wrong tool for the job is the leading cause of tool-related injuries. Selecting the correct tool reduces force, improves control, and prevents unexpected breakage.

• Damaged or dull tools contribute to slips, line-of-fire injuries, and sudden tool failure.

• Excessive force increases the chance of tool breakage and loss of control.

• Missing PPE, especially eye and hand protection, allows minor injuries to become severe.

• Improper storage leads to rust, cracking, or dulling of edges, making tools unsafe before use.

• Missing guards on power tools exposes rotating parts and greatly increases the chance of severe injury.

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Tool Storage and Care

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• Store tools in designated locations to prevent damage and ensure availability.

• Clean tools after use to prevent rust, debris buildup, and contamination.

• Lubricate moving parts on adjustable and power tools as recommended.

• Remove damaged tools from service immediately and tag them as 'Do Not Use.'

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Discussion Questions

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• Do you understand how improper tool selection leads to injuries and tool failures?

• Are your tools inspected, sharp, and in good condition for today’s work?

• Do you have the correct PPE and tool-specific attachments required for the job?

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RATTLIR Takeaway

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​Tools are extensions of the worker – when they fail, it is usually because the wrong tool was selected, inspected poorly, or applied incorrectly. Proper tool use prevents dropped objects, line-of-fire injuries, and equipment damage. RATTLIR strikes before it bites by encouraging disciplined tool inspections, correct tool selection, and respect for the energy stored in every cut, strike, and rotation.