U.S. Department of Labor t www.osha.gov t (800) 321-OSHA (6742)

Safe Use of Portable and Hand‐Held 

Power Tools

Portable and hand-held power tools that grind, cut, polish, and wire buff help workers in shipyard 

employment perform difficult tasks in a more efficient manner. However useful, if these tools are not 

used properly or poorly maintained, workers can be severely injured. 

Approximately 200 workplace incidents involving portable and hand-held power tools occur in the maritime industry each year. 

This document focuses on the hazards associated with such equipment and how employers can prevent worker injuries. For 

guidance on other types of hand and power tools, see OSHA’s informational booklet on Hand and Power Tools as well as Safety 

and Health Topics Page, which outline associated OSHA standards, hazards and solutions, and additional resources. 

Identifying and Preventing Hazards

Employers must assess work activities to determine hazards or 

potential hazards, and implement measures to protect workers. 

The assessment must include evaluation of the equipment 

necessary (e.g., portable and hand-held power tools) for the 

task and any hazards that they might produce. Noise, respirable 

dust, flying projectiles, contact with sharp objects, as well as 

fire from heat generation and sparks, are some of the hazards 

associated with the use of portable and hand-held power tools. 

OSHA’s Shipyard Employment eTool provides detailed guidance on 

conducting an assessment, personal protective equipment (PPE) 

selection, and the use of PPE. 

To prevent injuries with the use of portable and hand-held power 

tools, employers should train workers to: 

• Keep all tools in good condition with regular maintenance; 

• Use the right tool for the job; 

• Examine each tool for damage before use and do not use 

damaged tools;

• Operate tools according to the manufacturers’ instructions, 

including proper tool orientation and use of accessories or 

attachments; and

• Use the right PPE provided for the task (e.g., gloves, respiratory 

protection, safety glasses, goggles, or face shield)

Employers and workers should work together to establish and 

maintain safe working conditions. If a hazardous situation arises, 

it should be brought immediately to the attention of the appropriate 

individual(s) for hazard abatement.

Portable Abrasive Wheel Tools

Portable abrasive wheel tools create safety concerns, such as 

ejecting wheel and workpiece fragments that can strike workers 

in the eyes, face, and other exposed skin. To protect workers, 

employers must ensure that abrasive wheel tools are equipped with 

guards that: (1) cover the spindle end, nut, and flange projections; 

(2) maintain proper alignment with the wheel; and (3) do not 

exceed the strength of the fastenings. 

The orientation of the tool with respect to the work surface is 

an important aspect for ensuring safe operation. During use of 

horizontal and vertical grinders, the full grinding face width of the 

wheel should contact the grinding surface. For right-angle grinders, 

the grinding face of the wheel or disc should be held at an angle 

between 5 and 15 degrees from the grinding surface. 

OSHA standards prohibit the use of accessories that are not 

specifically designed or recommended by the manufacturer for use 

with that equipment. For example, accessories such as saw blades 

are often used in place of abrasive wheels (e.g., grinding or cut-off 

wheels, sanding disks, and wire brushes) to make equipment 

more versatile. Although a saw blade may fit in an abrasive wheel 

tool, this does not assure safe operation. The substitution of 

manufacturer-intended fittings with saw blades can lead to loss of 

control and injury, including lacerations and amputations. 

Before an abrasive wheel is mounted, it must be inspected for 

damage and sound or ring tested to ensure that it is free from 

cracks or defects. To test, first suspend the wheel by placing a rod 

through its arbor hole. Then, using a light, non-metallic instrument 

(e.g., handle of a screw driver), tap the wheel gently at a point of 

Shipyard

Employment Fact Sheet
U.S. Department of Labor t www.osha.gov t (800) 321-OSHA (6742)

45 degrees from the vertical center line and one to two inches 

from its edge on each side. Do not use wheels that sound cracked 

or dead, which have the potential to fly apart during operation and 

cause injury. A sound and undamaged wheel, when tapped, will 

give a clear metallic tone or ring. However, sound or ring testing is 

ineffective for wheels four inches in diameter or less or for wheels 

shaped like plugs and cones.

To prevent an abrasive wheel from cracking, it must fit freely on 

the spindle. The spindle nut must be tightened sufficiently to hold 

the wheel in place without distorting the flange. Always follow the 

manufacturer’s recommendations. Also, monitor the spindle speed 

of the machine to ensure that it does not exceed the maximum 

operating speed designated on the wheel.

An abrasive wheel may disintegrate during start-up and operation. 

To help prevent injury, never stand in the plane of rotation of the 

wheel as it accelerates to operating speed and allow the tool to 

come up to operating speed prior to grinding or cutting. Portable 

grinding tools must be equipped with safety guards to protect 

workers not only from the moving wheel surface, but also from 

flying fragments in case of wheel breakage.

Where Can I Get More Information? 

OSHA’s On-Site Consultation Program offers free and confidential 

occupational safety and health services to small and mediumsized businesses in all states and several territories, with priority 

given to high-hazard worksites. On-Site Consultation services 

are separate from enforcement and do not result in penalties or 

citations. Consultants from state agencies or universities work 

with employers to identify workplace hazards, provide advice on 

compliance with OSHA standards, and assist in establishing and 

improving safety and health programs. To locate the OSHA On-Site 

Consultation Program nearest you, call 1-800-321-6742 (OSHA) or 

visit www.osha.gov/consultation.

Workers’ Rights

Workers have the right to:

• Working conditions that do not pose a risk of serious harm.

• Receive information and training (in a language and vocabulary the

worker understands) about workplace hazards, methods to prevent

them, and the OSHA standards that apply to their workplace.

• Review records of work-related injuries and illnesses.

• File a complaint asking OSHA to inspect their workplace if they

believe there is a serious hazard or that their employer is not

following OSHA’s rules. OSHA will keep all identities confidential.

• Exercise their rights under the law without retaliation, including

reporting an injury or raising health and safety concerns with

their employer or OSHA. If a worker has been retaliated against

for using their rights, they must file a complaint with OSHA as

soon as possible, but no later than 30 days.

For additional information, see OSHA’s Workers page

(www.osha.gov/workers).

How to Contact OSHA

Under the Occupational Safety and Health Act of 1970, employers 

are responsible for providing safe and healthful workplaces for their 

employees. OSHA’s role is to ensure these conditions for America’s 

working men and women by setting and enforcing standards, 

and providing training, education and assistance. For more 

information, visit www.osha.gov or call OSHA at 1-800-321-OSHA 

(6742), TTY 1-877-889-5627.

This is one in a series of informational fact sheets highlighting OSHA programs, policies or standards. It does not impose any 

new compliance requirements. For a comprehensive list of compliance requirements of OSHA standards or regulations, refer 

to Title 29 of the Code of Federal Regulations. This information will be made available to sensory-impaired individuals upon 

request. The voice phone is (202) 693-1999; teletypewriter (TTY) number: 1-877-889-5627.

DSG FS-3950 06/2018

When using power grinders: 

• Always use eye or face protection.

• Disconnect tools when not in use, before servicing or

cleaning, and when changing accessories.

• Never disable the pressure switch or control, such as

by clamping the hand-held grinder in a vise.

• Ensure that angular exposure of the grinding wheel

periphery and sides do not exceed 180 degrees of

safety guards in place.

• Only replace accessories with those recommended by

the manufacturer.