Easy Ergonomics:

A Guide to

Selecting

Non-Powered

Hand Tools

Department of Industrial Relations

Cal/OSHA Consultation Service

Research and Education Unit

DEPARTMENT OF HEALTH AND HUMAN SERVICES

Centers for Disease Control and Prevention

National Institute for Occupatonal Safety and Health
This booklet is a joint effort between

the California Occupational Safety and Health Administration (Cal/OSHA)

and the National Institute for Occupational Safety and Health (NIOSH),

Centers for Disease Control and Prevention (CDC).

Disclaimer

Mention of any company name or product does not constitute

endorsement by Cal/OSHA or NIOSH/CDC.

This document is in the public domain and may be freely copied or reprinted.

For information about occupational safety and health topics contact NIOSH at:

1-800-35-NIOSH (1-800-356-4674)

Fax: 513-533-8573

E-mail: pubstaft@cdc.gov

National Institute for Occupational Safety and Health

Publications Dissemination

4676 Columbia Parkway

Cincinnati, OH 45226-1998

Download this publication from Cal/OSHA or NIOSH:

http://www.dir.ca.gov/dosh/puborder.asp

http://www.cdc.gov/niosh

Easy Ergonomics: A Guide to Selecting Non-Powered Hand Tools was developed and prepared

for publication by the Research & Education Unit, Cal/OSHA Consultation Service, California

Department of Industrial Relations and the National Institute for Occupational Safety and Health.

It was distributed under the provisions of the Library Distribution Act and Government Code

Section 11096.

Published by the California Department of Industrial Relations and the

National Institute for Occupational Safety and Health, 2004.

DHHS (NIOSH) Publication No. 2004-164
Easy Ergonomics:

A Guide

to Selecting

Non-Powered

Hand Tools

About This Booklet

The purpose of this booklet is to help you select or purchase the best available ergonomically

designed non-powered hand tool. The information and the hand tool checklist are based on peerreviewed articles and expert input. The checklist has been evaluated for reliability in identifying

the presence or absence of basic ergonomic design features (Dababneh et al.*). The right tool

will help you reduce your risk of injury, such as carpal tunnel syndrome, tendonitis, or muscle

strain.

*Dababneh A, Lowe B, Krieg E, Kong Y, and Waters T, A Checklist for the Ergonomic

Evaluation of Non-Powered Hand Tools, accepted for publication in the December 2004 issue of

the Journal of Occupational and Environmental Hygiene.

Note: This booklet covers most ergonomic features that should be considered when selecting or

purchasing hand tools, but does not cover all features. Specifically, it does not address tool

weight, tool balance, vibration or tool maintenance.

No one is required to use the information in this booklet. This booklet is not intended to

provide employers with information on how to comply with Cal/OSHA regulations.
Foreword

John Howard, M.D.

Director, NIOSH

Len Welsh, M.S., J.D.

Acting Chief, Cal/OSHA

Non-powered hand tools are widely used in a variety of industries including construction,

manufacturing, and agriculture. National data suggests that a large number of injuries known as

musculoskeletal disorders are attributable to hand tool use in occupational settings, resulting in

unnecessary suffering, lost workdays, and economic costs. Prevention of work-related

musculoskeletal disorders is a high priority for both the National Institute for Occupational Safety

and Health (NIOSH) and the California Occupational Safety and Health Administration (Cal/OSHA).

Both agencies recognize the importance of design and selection of hand tools in strategies to reduce

injuries of this type.

To the untrained eye, however, it may be difficult to evaluate tools from an ergonomic point of view.

The purpose of this document is to demystify the process and help employers and workers identify

non-powered hand tools that are less likely to cause injury--those that can be used effectively with

less force, less repeated movement, and less awkward positioning of the body. Presented here are

the ergonomic basics of hand tool use. These principles are meant to complement the ordinary

process of deciding on what tool to select by knowing how it is used and the task to which it will be

applied.

The reasonable and common-sense approaches outlined in this document can be directly applied to

challenges like these:

• deciding whether to stay with traditional tool designs or opt for new designs

• evaluating the effectiveness of different designs

• choosing a tool of the right size and shape for the task and the user

This document also contains an easy-to-use checklist for comparing tools against several design

characteristics that have been shown to reduce physical stresses on the user. We hope this checklist

and the accompanying background material will be of practical use to all who wish to select tools

that get the job done more safely, comfortably, and productively.
?

Is this an

hand tool?

ergonomic

You be the judge . . .

Some tools are advertised as “ergonomic” or are designed with ergonomic features. A tool

becomes “ergonomic” only when it fits the task you are performing, and it fits your hand without

causing awkward postures, harmful contact pressures, or other safety and health risks. If you use

a tool that does not fit your hand or use the tool in a way it was not intended, you might develop

an injury, such as carpal tunnel syndrome, tendonitis, or muscle strain. These injuries do not

happen because of a single event, such as a fall. Instead, they result from repetitive movements

that are performed over time or for a long period of time, which may result in damage to muscles,

tendons, nerves, ligaments, joints, cartilage, spinal discs, or blood vessels.

1
DEFINITIONS

Awkward Postures

Postures that strain the neck,

shoulders, elbows, wrists,

hands, or back. Bending,

stooping, twisting, and

reaching, are examples of

awkward postures.

Contact Pressure

Pressure from a hard surface, point, or

edge on any part of the body.

Single-Handle Tools

Tube-like tools measured by handle length

and diameter.

Diameter

The length of a

straight line

through the center

of the handle.

Power Grip

The hand grip that

provides maximum hand

power for high force

tasks. All the fingers wrap around

the handle.

Pinch Grip

The hand grip that

provides control

for precision and

accuracy. The tool is gripped between

the thumb and the fingertips.

Double-Handle Tools

Plier-like tools measured by

handle length and grip span.

Grip Span

The distance between the

thumb and fingers when the

tool jaws are open or closed.

2
The best tool is one that:

• Fits the job you are doing

• Fits the work space available

• Reduces the force you need to apply

How do you know if you have a problem?

You may have a problem if you have any of these symptoms:

• Tingling

• Swelling in the joints

• Decreased ability to move

• Decreased grip strength

• Pain from movement, pressure, or exposure to cold or vibration

Reduce your risk of injury by using

these guidelines to select hand tools:

Use the Checklist on pages 13 and 14 to select the best tool. The features listed on the Checklist

correspond to the tips found on pages 8 to 11, “Tips for Selecting Hand Tools.”

The cost of an injury can

be high, especially if the injury

prevents you from doing your job.

These symptoms may not appear immediately because they develop over weeks,

months, or years. By then, the damage may be serious. Take action before you notice

any symptoms.

A. Know your job (pg. 4).

B. Look at your work space (pg. 6).

C. Improve your work posture (pg. 7).

D. Review the “Tips for Selecting Hand Tools” (pg. 8) and then Select the Tool (pgs. 13,14).

• Fits your hand

• Can be used in a comfortable work position

• Continual muscle fatigue

• Sore muscles

• Numbness

• Change in the skin color of your hands or fingertips

3
Driving tools Struck or

hammered tools

Examples:

• Punches

• Chisels

• Nail sets

Striking tools

Before you select a tool, think about the job you will be doing. Tools are designed for specific

purposes. Using a tool for something other than its intended purpose often damages the tool and

could cause you pain, discomfort, or injury. You reduce your chances of being injured when you

select a tool that fits the job you will be doing.

The list of tools in each category shows a few examples of tools that are most frequently used.

Examples:

• Pliers

• Snips

• Cutters

Cutting, pinching,

gripping tools

Examples:

• Screwdrivers

• Hand wrenches

• Nut drivers

• T-handle wrenches

Example:

• Hammers

A. Know your job

4
Next, consider whether you need the tool to provide power or precision. Then select the tool with

the correct handle diameter or grip span.

HANDLE

DIAMETER

for power tasks

is 1 1/4 inches to

2 inches

CLOSED GRIP SPAN

for power tasks is not

less than 2 inches

Double-Handle Tools

OPEN GRIP SPAN

for power tasks is not

more than 3 1/2 inches

Single-Handle Tools

HANDLE DIAMETER for precision

tasks is 1/4 inch to 1/2 inch

Double-Handle Tools

CLOSED GRIP SPAN

for precision tasks is not

less than 1 inch

OPEN GRIP SPAN

for precision tasks is

not more than 3 inches

For POWER tasks

For PRECISION tasks

Single-Handle Tools

5
B. Look at your work space

Now look at your work space. Awkward postures may cause you to use more force. Select a tool

that can be used within the space available. For example, if you work in a cramped area and high

force is required, select a tool that is held with a power grip. A pinch grip will produce much

less power than a power grip. Exerting force with a pinch grip means you will work harder to get

the job done.

pinch grip power grip

If you work in a cramped space, you may not be able to use a long-handle tool. Use of a

long-handle tool may cause awkward postures or harmful contact pressure on your hand as you

use more force. Instead, use a tool that fits within the work space. A short-handle tool can help

you reach your target directly as you keep your wrist straight.

long-handle tool short-handle tool

6
Awkward postures make more demands on your body. In some cases, the placement of the work

piece will affect your shoulder, elbow, wrist, hand, or back posture. Whenever possible, choose a

tool that requires the least continuous force and can be used without awkward postures. The right

tool will help you to minimize pain and fatigue by keeping your neck, shoulders, and back

relaxed and your arms at your sides.

For example, avoid raising your shoulders and elbows. Relaxed shoulders and elbows are more

comfortable and will make it easier to drive downward force.

Reposition your

work piece

Work on a lower

work surface

If you are sitting ...

If you are standing ...

Stand

C. Improve your work posture

7
Over time, exposure to awkward postures or harmful contact pressures can contribute to an

injury. You can reduce your risk of injury if you select hand tools that fit your hand and the job

you are doing.

Tips for Selecting Hand Tools

Tools used for power require high force. Tools used for precision or accuracy require low force.

D. Select the tool

Tool with sleeve

For single-handle tools used for precision tasks: Select a tool

with a handle diameter of 1/4 inch to 1/2 inch.

1

2

3

Closed grip span Open grip span

For single-handle tools used for power tasks: Select a tool that feels comfortable with a

handle diameter in the range of 1 1/4 inches to 2 inches. You can increase the diameter by

adding a sleeve to the handle.

For double-handle tools (plier-like) used for power tasks: Select a tool with a grip span

that is at least 2 inches when fully closed and no more than 3 1/2 inches when fully

open. When continuous force is required, consider using a clamp, a grip, or locking

pliers.

8
4

Closed grip span

Select a tool without sharp edges or finger grooves on the handle. 6

Open grip span

Select a tool that is coated with soft material. Adding a sleeve to the

tool handle pads the surface but also increases the diameter or the grip 7 span of the handle (see 1, 2, 3, or 4 above).

For double-handle tools (plier-like) used for precision tasks: Select a tool with a grip span

that is not less than 1 inch when fully closed and no more than 3 inches when fully open.

5 For double-handled pinching, gripping, or cutting tools: Select a tool with

handles that are spring-loaded to return the handles to the open position.

9
Select a tool with an angle that allows you to work with a straight wrist. 8

Straight

handle

Straight handle Bent handle

Select a tool that can be used with your dominant hand or with either hand. 9

Tools with bent handles are better than those with straight handles when the force is

applied horizontally (in the same direction as your straight forearm and wrist).

Tools with straight handles are better than those with bent handles when the force is

applied vertically.

10

Bent

handle
10 For tasks requiring high force: Select a tool with a handle length longer than the

widest part of your hand – usually 4 inches to 6 inches.

Prevent contact pressure by making sure the end of the handle does not press on the

nerves and blood vessels in the palm of your hand.

4” - 6”

If the handle is too

short, the end will press

against the palm of

your hand and may

cause an injury.

American Industrial Hygiene Association, “An Ergonomics Guide to Hand Tools”, p. 18

Dababneh A, Lowe B, Krieg E, Kong Y, and Waters T, A Checklist for the Ergonomic Evaluation of NonPowered Hand Tools, accepted for publication in the December 2004 issue of the Journal of Occupational and

Environmental Hygiene.

Eastman Kodak Company, “Ergonomic Design for People at Work”, Vol. 2, p. 350

Eastman Kodak Company, “Ergonomic Design for People at Work”, Vol. 1, p. 146

Kodak’s Ergonomics Design for People at Work, 2nd Edition, p. 349

Select a tool that has a non-slip surface for a better grip. Adding a sleeve to the

tool improves the surface texture of the handle. To prevent tool slippage within 11 the sleeve, make sure that the sleeve fits snugly during use.

Tools and sleeves

These guidelines are from the following resources:

11

ent

ndle

Remember: A sleeve

always increases the

diameter or the grip span

of the handle (see 1, 2, 3,

or 4 above).
Acknowledgments

Writers, Editors and Photographers

Richard Hight, Associate Safety Engineer, Cal/OSHA

Consultation, Research & Education Unit

Kristy Schultz, CIE, Certified Industrial Ergonomist,

Cal/OSHA Consultation, Research & Education Unit

Fran Hurley-Wagner, MS, CRC, CIE, Certified

Industrial Ergonomist, First Response Ergonomics

Mario Feletto, MS, MPH, Area Manager

Cal/OSHA Consultation, Research & Education Unit

Brian D. Lowe, PhD, CPE, Research Industrial

Engineer, National Institute for Occupational Safety

and Health

Yong-Ku Kong, PhD, Associate Research Fellow,

National Institute for Occupational Safety and Health

Tom Waters, PhD, CPE, Chief, Human Factors &

Ergonomics Research Section, National Institute for

Occupational Safety and Health

The authors thank the following persons and

organizations for their review and comments in the

development of this document:

Editorial and Technical Reviewers

Tom Anderson, Milwaukee Tools

Dave Bare, Cal/OSHA Consultation Service

Paul Bischofberger, Barbosa Cabinets, Inc.

Scott Boggess, CSP, CIE, State Compensation

Insurance Fund

Richard DaRosa, MS,

Cal/OSHA Consultation Service

Felipe Duran, Justin Framing, Inc.

Victor Duraj, University of California, Davis

Fadi Fathallah, PhD, University of California, Davis

Marti Stroup Fisher,

Associated General Contractors of California

Jim Lopes, MSPH, CIH,

Cal/OSHA Consultation Service

John Howard, MD, MPH, JD, LL.M, Director,

National Institute for Occupational Safety and Health

Ira Janowitz, PT, CPE,

University of California, Berkeley

Klein Tools

Mary Krost, RPT, OTR, Mary Krost and Associates

Faye Ong, Associate Editor, CDE Press

California Department of Education

David Patzer, MS, MHMM, CUSA, California

Sanitation Risk Management Authority

Suzanne H. Rodgers, PhD, Consultant in Ergonomics

Augie Sotelo, Sacramento Valley Sheet Metal

Workers’ JATC

Dave Thomas, Sacramento Area Electrical

Apprenticeship

Len Welsh, MS, JD, Acting Chief, Division of

Occupational Safety and Health, California

Department of Industrial Relations

Jason Whipple, Sacramento Area

Electrical Apprenticeship

Layout and Design

Ken Jackson, Graphic Designer, Link One

Jitan Patel, Graphic Designer,

Cal/OSHA Consultation Service

12
Use BOTH sides of the checklist to compare similar tools. For example, if you have two pliers

and want to select the best of the two, compare each tool against the features on the checklist.

The more “Yes” answers the tool has, the better the tool.

Refer to Section D, Tips for Selecting Hand Tools, for more details.

Checklist for Hand Tool Selection

Select the tool that has the most “YES” answers.

Singlehandle tools

Tool 1 Tool 2

 1 For single-handle tools used for power tasks:

Does the tool feel comfortable and have a handle

diameter between 1 1/4 inches and 2 inches? (pg. 8)

2 For single-handle tools used for precision tasks:

Is the handle diameter between 1/4 inch and

1/2 inch? (pg. 8)

3 For double-handle tools used for power tasks:

Is the grip span at least 2 inches when closed and

no more than 3 1/2 inches when open? (pg. 8)

4 For double-handle tools used for precision tasks:

Is the grip span no less than 1 inch when closed

and no more than 3 inches when open? (pg. 9)

Examples

COMPLETE BOTH SIDES

Doublehandle tools

Tool 1 Tool 2

5 For double-handle tools:

Is the handle spring-loaded? (pg. 9)

Check if “YES”

S T O P --- Skip to #6

13

✃cut here
COMPLETE BOTH SIDES

Dababneh A, Lowe B, Krieg E, Kong Y, and Waters T, A Checklist for the

Ergonomic Evaluation of Non-Powered Hand Tools, accepted for publication in the

December 2004 issue of the Journal of Occupational and Environmental Hygiene.

 9 Can the tool be used with your dominant hand or

with either hand? (pg. 10)

6 Is the tool handle without sharp edges or finger

grooves? (pg. 9)

7 Is the tool handle coated with soft material?

(pg. 9)

10 For high-force tasks:

Is the handle longer than the widest part of

your hand (usually 4 inches to 6 inches)? (pg. 11)

 8 Can the tool be used while keeping your wrist

straight? (pg. 10)

11 Does the tool handle have a non-slip surface?

(pg. 11)

Checklist for Hand Tool Selection

Select the tool that has the most “YES” answers

Tool 1 Tool 2

Examples Check if “YES”

for all tools

14

✃cut here
NOTES:

Cal/OSHA and NIOSH value and welcome your comments about our booklet. Send your comments

to us at: dosheducation@dir.ca.gov. We want to provide the best possible service to employers

and employees.
Cal/OSHA Consultation Service

Toll-free number: 1-800-963-9424 (California Only)

Download this and other Cal/OSHA publications at:

http://www.dir.ca.gov/dosh/puborder.asp

Delivering on the Nation’s Promise:

Safety and health at work for all people

through research and prevention

To receive other information about

occupational safety and health topics, call:

1-800-35-NIOSH (1-800-356-4674)

or visit the NIOSH Website at:

www.cdc.gov/niosh

SAFER HEALTHIER PEOPLE

DHHS (NIOSH) PUBLICATION No. 2004-164

18 REU August 2004

TM