Pneumatic Tool Operator: 7 Simple Steps To Ensure Safety

May 5, 2020

Grinders Safety Expert Corner Metalworking

Minimizing the risk of accidents in the workplace is a top priority in industry, and it is especially important when working with pneumatic power tools. Ensuring that all safety precautions have been taken to protect the health and wellbeing of operators is vital.

Pneumatic tools safety in operation

Pneumatic tools safety

Not all pneumatic tools need to be intrinsically safe. Intrinsic safety is a specific requirement in workplaces where there is a risk of explosion due to the presence of gases, vapours, mists or dust. Examples include chemical refineries, offshore platforms, flour mills and paint shops. In hazardous environments like these, pneumatic power tools can act as a source of ignition. In order to prioritize operator safety in hazardous environments, it is essential to choose pneumatic tools that have been specifically designed and certified for intrinsic safety Essentially, this means the tool has been designed to limit the energy - electrical and thermal - available for ignition.

Employers are legally obliged to perform a risk assessment to ensure safe working environments, which classifies areas into zones. These classifications can be used to identify the right type of tools that will perform safely in each zone. In Europe, the ATEX Directive defines the zones and outlines the requirements and certification procedures for equipment for use in potentially explosive atmospheres. Similar regulations are in place in other geographies, such as DSEAR in the UK and NEC and IEC in North America.

With this in mind, here are seven simple steps to reduce the risk of accidents and ensure a pneumatic tool operator safety

1. Limit vibrations and noise

A graphic representation of pneumatic tool operator safety

Excessive vibrations and noise can have devastating long-term consequences for a pneumatic tool operator. For example, prolonged exposure to vibrations can lead to hand-arm vibration syndrome (HAVS) which can result in a loss of sensation in the hand. At the same time, extremely loud noises or continued exposure to loud noises can result in loss of hearing. The tool’s vibration level and the length of exposure time are the two key factors that indicate whether an operator will be at risk from HAVS. Vibration and noise can both be minimized by choosing tools with low levels, evaluating the work pattern and wearing appropriate PPE, such as ear protectors.

You can read more on this topic in our "Handheld Virabting tools: protect your employees" expert article.

2. Check that the pneumatic tools have appropriate safety features:

Grinders – Key safety features on these pneumatic tools in action are overspeed shut-off functions, autobalancers and guards. The first – overspeed shut off – prevents a grinding wheel from speeding faster than it should, and therefore it reduces the risk of disc burst which would ultimately injure the user. Secondly, autobalancers stabilize a tool, greatly reducing vibration. Finally, guards protect the operator from any shrapnel in case the disc breaks apart.
Impact wrenches – An important feature to consider is the torque limited function which enables torque level control, mainly on tightening applications where torque control is essential, such as tire changing or shipyards. Tools whose torque is limited by an air flow modification have lower vibration than those with a mechanical modification, which therefore contributes to operator safety

3. Perform regular maintenance

Regular servicing is vital when ensuring the safety of equipment as a tool that is well looked after and properly maintained will have less risk of failing. Maintenance should be carried out according to the tool’s manual, for example, components that wear most frequently and therefore need maintaining in grinders are the blades and bevel gears. Blades should be inspected every 500 hours, and the interval for bevel gears is every 1,000 – 2,000 hours depending on the tool.

4. Know how to use the pneumatic tools safely

Always follow manufacturers’ recommendations and best practice on tool usage. Ensure operators are fully trained to use equipment safely and to follow the company’s agreed safety procedures. Furthermore, make sure you are using the right tool and abrasive for the job.

5. Operator safety: Wear appropriate PPE

Personal protection equipment (PPE) helps to shield the operator against potential hazards. It is critical that operators always use all recommended safety equipment when operating pneumatic tools, including sturdy gloves to protect hands from the elements, helmets and safety goggles in case of any debris, and ear protectors for noise.

6. Make sure the environment is safe

Consider the environment surrounding the job and ensure you take appropriate precautions. For example, is it a confined space, or is the job at height? Grinding can create fine dust particles, which if inhaled can cause health and safety issues for the operator. Therefore, always grind in a well-ventilated space. Also, always ensure that the workpiece is secure, and you have a stable operating position . For instance, if you are working at height, remember to implement the best practices to help preventing tool drops.

7. Ensure you have a good air line set up

Think about the whole tool system including the air line. All pneumatic tools require clean, lubricated air and a dynamic pressure of 90 PSI (6.3 bar) to work safely. If the pressure is any higher than this, it could negatively affect the tools’ lifespan and risk operator’s safety. Air pressure can be adjusted with an FRL (filter, regulator, lubricator) so it is important to include one in the air system near the tool. You can improve your installation safety by reading our air line installation guide and self-diagnostic check list. Also, you can enhance the safety of your air line by adding an air fuse to its set up, this will prevent you from hose whiplash.

By considering these seven points you will improve safety associated with using tools in the workplace, therefore protecting operators. An additional benefit to these responsible practices is that you will improve efficiency too!

Annabelle Bray - expert corner - head zoom

Limiting vibration, proper air line set-up and regular maintenance are just some of the key steps in ensuring operators safety.

Annabelle Bray , Global Marketing Manager

Additional safety tips

Pneumatic tool safety requirements consider the needs of the user and the wider working environment as well as the physical tool design. Assessing additional hazards will ensure that the correct level of protection is in place.

Tool safety: essential safety features include physical guards around blades or wheels, plus speed limiters and torque controls to prevent physical injury. A safety cut-off to prevent the tool being activated accidentally is another boon. Prolonged exposure to noise and vibration can lead to hand-arm vibration syndrome (HAVS) so look for tools with low noise profiles. Employees should also be provided with appropriate PPE, such as ear defenders and gloves.
Work environment safety: Look for tools that are ergonomically designed to aid safe working in these conditions. The potential presence of fine dust particles from grinding operations is a further safety consideration, so the workspace should be well ventilated.
Air hoses: air hoses connecting hand tools to the compressed air supply may cause a trip hazard if not correctly managed, so air supply design is another safety factor. The inclusion of an FRL (filter, regulator, lubricator) in the air system near the tool is necessary to ensure a consistent supply of clean, lubricated air and to maintain safe working pressures of 90 PSI (6.3 bar). Air line safety can be further improved by including an air fuse to prevent hose whiplash
Training: Safety requirements also extend to ensuring that employees are correctly trained in the correct use of pneumatic tools and that a regular maintenance regime is in place to ensure that hand tools and associated compressed air equipment are functioning properly at all times.

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