Safety in the use of hand tools – A guide for professional users
Using hand tools is part of daily practice in workshops, industry, and construction. Although these tools may seem simple and easy to handle, data shows they are often the cause of serious injuries. According to NIJZ, more than 14,000 work-related injuries were reported in Slovenia in 2023, with finger injuries being the most common. The usual cause is the loss of control over machinery, tools, or equipment. EU-wide statistics reflect a similar picture: common causes of accidents include contact with sharp or moving objects, improper tool use, and loss of control over work procedures.
For professionals, this means that basic knowledge of safe use is not enough – mastering the entire risk system associated with hand tool use is essential.
Workplace injury data - Slovenia
NIJZ and Eurostat data highlight that injuries related to hand tools are more than minor accidents. These include lacerations, tendon injuries, and even amputations, often leading to permanent loss of function. Case studies confirm that the most dangerous injuries involve cutting and grinding, where direct contact with fast-moving blades occurs, and hydraulic or pneumatic presses, where finger entrapment risks are high. Vibrating tools pose another challenge, as prolonged use leads to chronic conditions like Hand-Arm vibration syndrome (HAVS).
Types of workplace injuries
Blades of saws, axes, cutters, utility knives, or grinders can cause deep cuts or amputations in a split second. Presses and vises pose crushing hazards for fingers or hands, while debris from grinding, stapling, chiseling, and hammering threatens the eyes and face. There is also the risk of electric shock when working with conductors using inappropriate or damaged insulated tools.
Common tool use mistakes
Even experienced professionals often repeat mistakes that lead to accidents:
- Poor risk assessment: tasks such as cleaning, maintenance, or storage are not included in the safe work plan.
- Improper use of personal protective equipment (PPE) – for example, gloves that are too thick when working near rotating parts, which can increase hazards.
- Lack of maintenance and calibration: torque and measuring tools that are not regularly calibrated can cause technical errors in assembly, affecting both worker safety and product quality.
- Insufficient training for unplanned procedures, such as quick interventions during shutdowns or maintenance, and working under time pressure – which has been proven to increase accidents.
Solutions and recommendations
Key steps include: systematic risk assessment, regular calibration and maintenance of tools, proper training in emergency procedures, consistent use of certified PPE, and adopting a workplace culture that prioritizes safety over speed.
- Proper use of dedicated holders for workpieces – such as a vise or woodworking clamp – is essential. Holding workpieces by hand during cutting poses a significant risk of tool kickback and immediate injury. Safety features like interlock systems, two-hand controls, and protective visors are a standard that every professional workshop must meet.
- When working with electrical conductors, it is mandatory to use electricians tools certified according to IEC/EN 60900 and insulated gloves. All POPAR hand tools intended for electrical work are marked with the VDE symbol and comply with all standards.
- Regular visual and functional inspections of tools. This means checking the sharpness of blades, wear on grinding wheels, joint stability, and insulation on electrician’s tools before every use. Torque tools must be calibrated at least once a year or after a defined number of cycles, and even more frequently in critical industries such as energy and aerospace.
- Proper selection of protective gloves. Gloves protecting against mechanical risks must comply with EN 388, while those for cut resistance must be tested according to ISO 13997.
- For welding, gloves must comply with EN 407, and for working with chemicals, gloves must comply with EN ISO 374. The basic PPE rule applies: protective equipment must match the type of hazard, since the wrong choice can be just as dangerous as no protection at all.
- In welding, certified protective welding masks must always be used, along with proper knowledge of welding procedures. You can read more about this in our blog Everything you need to know to become a Master welder.
Maintenance and calibration
Tool maintenance is just as important as the choice of tool itself. Damaged electrician tools – such as those with chipped insulation or a loose blade – can cause more serious injuries than the work process itself. Therefore, regular inspections must include visual checks, functional testing, and immediate replacement of damaged parts or entire tools when necessary.
You can read more about tool maintenance in our blog Hand tool maintenance: A Comprehensive guide.
The calibration of tools intended for precision work is mandatory and must be documented. Maintenance must be designed as an ongoing process, not a one-time event, as only this ensures safety and reliability at work.
Professional use of hand tools requires more than just technical skill. It involves systematically combining correct tool selection, thoughtful use of personal protective equipment, regular maintenance, and continuous employee training. Statistics clearly show that hand tools account for a large share of injuries, so even small improvements in practice can significantly reduce risks.
For professionals, safe use of hand tools is inseparably linked to the quality and reputation of their work. Safety measures are not only a legal requirement but a professional standard that distinguishes responsible workers from average ones.
Sources:
- NIJZ, Zdravstveni statistični letopis Slovenije 2023 — Poškodbe pri delu (PPD)
- Eurostat, Accidents at work — statistics on causes and circumstances (2022 data)
- OSHA, ISO / EN ISO 6789, IEC/EN 60900, EN 388, EN ISO 13997, EN 407, EN ISO 374