Hand and power tool safety

Employers and employees are responsible for ensuring hand and power tools are maintained in a safe condition; "safe condition" means the tool is free from defects that could cause injury during normal use. OSHA's general requirement states that "All hand and power tools and similar equipment, whether furnished by the employer or the employee, shall be maintained in a safe condition" (1926.300(a)).

• Maintain tools by inspecting before use, repairing or removing defective tools, and following manufacturer instructions.
• Remove from service tools with cracked housings, frayed cords, broken guards, or loose parts.
• Keep written procedures or checklists if your program requires periodic inspections.

Power-operated tools that are designed to accommodate guards must be equipped with those guards whenever they are in use. OSHA requires that "When power operated tools are designed to accommodate guards, they shall be equipped with such guards when in use" (1926.300(b)(1)).

• Do not operate a power tool where a guard is provided but removed or bypassed.
• Ensure guards are correctly installed, secured, and not modified in ways that defeat protection.

Belts, gears, shafts, pulleys, sprockets, spindles, drums, flywheels, chains, or other reciprocating, rotating or moving parts that are exposed to employee contact or create a hazard must be guarded, and the guarding must meet the American National Standards Institute standard referenced. OSHA specifies these parts "shall be guarded if such parts are exposed to contact by employees or otherwise create a hazard" and that guarding shall meet ANSI B15.1-1953 (R1958).

• Inspect for exposed moving parts and install fixed or interlocked guards as appropriate.
• Use barrier guards, enclosure guards, or other methods that comply with recognized industry standards.

One or more machine-guarding methods—such as barrier guards, two-hand tripping devices, or electronic safety devices—must be used to protect operators and others from hazards like point of operation, ingoing nip points, rotating parts, and flying chips and sparks. OSHA states that "One or more methods of machine guarding shall be provided" and lists examples including barrier guards and electronic safety devices (1926.300(b)(3)).

• Choose guarding based on the hazard: physical barriers for rotating parts, guards or screens for flying chips, and presence-sensing devices or two-hand controls where appropriate.
• Ensure guards do not create additional hazards (e.g., pinch points) and allow safe maintenance access with lockout/tagout procedures.

Machines whose operation exposes an employee to injury at the point of operation must have guarding designed so the operator cannot place any part of their body in the danger zone during the operating cycle. OSHA requires that "The point of operation of machines whose operation exposes an employee to injury, shall be guarded" and that the guarding "shall be so designed and constructed as to prevent the operator from having any part of his body in the danger zone during the operating cycle" (1926.300(b)(4)(ii)).

• Use fixed, interlocked, adjustable, or self-adjusting guards depending on the task.
• Verify guards function across all operating modes and during automated cycles; use presence-sensing or two-hand controls where guards cannot provide protection.

Special handtools designed to keep the operator's hands out of the danger zone may be used to supplement guarding but cannot replace other required guarding. OSHA states that such special handtools "shall not be in lieu of other guarding required by this section, but can only be used to supplement protection provided" (1926.300(b)(4)(iii)).

• Use push sticks, material handling jigs, or holding tools only as additional protection when guards are present or where guards cannot function.
• If a tool leaves any exposure to the danger zone, install or design appropriate machine guarding.

Yes, portable power tools are listed among machines that usually require point-of-operation guarding. OSHA includes "Portable power tools" in its list of machines which usually require point-of-operation guarding (1926.300(b)(4)(iv)(h)).

• For portable tools, apply guards that are compatible with portability (e.g., blade guards on saws, guard attachments for grinders).
• Follow manufacturer's guarding instructions and do not remove guards for convenience.

Fan blades must be guarded when the blade periphery is less than 7 feet above the floor or working level, and the guard must have openings no larger than ½ inch. OSHA requires that "When the periphery of the blades of a fan is less than 7 feet... the blades shall be guarded" and specifies "openings no larger than ½ inch (1.27 cm)" (1926.300(b)(5)).

• For portable or fixed fans under 7 feet, install guards that protect hands and fingers while allowing airflow.
• Regularly inspect guards for damage and secure attachment.

OSHA requires that machines designed for a fixed location be securely anchored to prevent walking or moving. The standard states, "Machines designed for a fixed location shall be securely anchored to prevent walking or moving" (1926.300(b)(6)).

• Anchor heavy equipment to concrete or appropriate foundations per manufacturer and engineering guidance.
• Check anchors periodically and after maintenance or relocation.

Abrasive wheel safety guards must be adjustable to fit the decreasing wheel diameter as the wheel is used, and guarding on bench and floor stand grinders must limit angular exposure to not exceed 90° of the wheel periphery with specific positioning limits. OSHA requires guards that "can be adjusted to the constantly decreasing diameter of the wheel" (1926.300(b)(7)) and that "The angular exposure of the grinding wheel... should not exceed 90°" for bench and floor stands (1926.300(b)(8)).

• Ensure adjustable tongues and peripheral guards are positioned per the figures and dimension limits in the standard.
• Replace guards or components that cannot be adjusted to maintain the required protection as wheels wear.

The maximum angular exposure of the grinding wheel periphery and sides for cylindrical grinders shall not exceed 180°, beginning at a point not more than 65° above the horizontal plane of the wheel spindle. OSHA specifies this limit for cylindrical grinding machines (1926.300(b)(9)).

• Arrange guards so the exposed portion of the wheel does not exceed the specified angle.
• Inspect guard adjustment when wheel sizes change.

Employers must provide PPE to employees using hand and power tools when they are exposed to hazards such as falling, flying, abrasive, splashing objects, or harmful dusts, fumes, mists, vapors, or gases. OSHA states, "Employees using hand and power tools and exposed to the hazard of falling, flying, abrasive, and splashing objects... shall be provided with the particular personal protective equipment necessary to protect them from the hazard" (1926.300(c)).

• Perform a hazard assessment to determine the specific PPE needed (eye protection, face shields, respirators, gloves, etc.).
• PPE must meet and be maintained according to applicable OSHA subparts (see 1926.28 and maintenance requirements in 1926.95).
• For guidance on employer hazard assessment and written certification for PPE selection, see OSHA's interpretation on PPE hazard assessment requirements (March 28, 2024 LOI).

Employers must provide PPE that conforms to required standards, ensure it is maintained, and make sure employees use it when hazards are present. OSHA directs compliance with PPE maintenance and use via 1926.28 (personal protective equipment requirements) and 1926.95 (maintenance and sanitation). The hand-and-power-tool PPE rule 1926.300(c) cross-references these obligations.

• Provide, fit, and maintain PPE at no cost to employees.
• Train employees in proper use, limitations, and care of PPE; inspect PPE before use and repair or replace defective items.
• Keep records or written hazard assessments when PPE is required, consistent with OSHA's interpretation on PPE hazard assessments (March 28, 2024 LOI).

A positive "on-off" control is acceptable for hand-held powered platen sanders, grinders with wheels 2-inch diameter or less, routers, planers, laminate trimmers, nibblers, shears, scroll saws, and jigsaws with blade shanks 1/4 inch wide or less. OSHA allows that these tools "may be equipped with only a positive 'on-off' control" (1926.300(d)(1)).

• Ensure the control is readily accessible and functions properly.
• For higher-risk tools, use momentary contact or constant pressure switches as required in other paragraphs.

Hand-held powered drills, tappers, fastener drivers, grinders with wheels greater than 2 inches, disc sanders, belt sanders, reciprocating saws, saber saws, and similar powered tools must be equipped with a momentary contact "on-off" control; they may have a lock-on control only if turning the tool off can be accomplished by a single motion of the same finger(s) that turn it on. OSHA specifies these switch requirements in 1926.300(d)(2).

• Use tools with compliant switches or retrofit controls where feasible.
• Train workers on how to operate and release lock-on features safely.

Circular saws, chain saws, and percussion tools without positive accessory holding means must be equipped with a constant pressure switch that shuts off power when pressure is released. OSHA requires a "constant pressure switch that will shut off the power when the pressure is released" for these tools (1926.300(d)(3)).

• Never modify or bypass the constant pressure switch.
• If a tool's intended use or accessory changes, reassess switch compliance and worker training.

Concrete vibrators, concrete breakers, powered tampers, jack hammers, rock drills, and similar hand-operated power tools are excepted from the switch requirements in paragraph (d). OSHA lists these exceptions in 1926.300(d)(5).

• Even though these tools are excepted from switch-type rules, employers must still maintain them in safe condition and provide appropriate PPE and controls to mitigate hazards.

Power saws usually require point-of-operation guarding that prevents contact with the blade or cutting element during operation. OSHA specifically includes "Power saws" in the list of machines that usually require point-of-operation guarding (1926.300(b)(4)(iv)(f)).

• Use fixed blade guards, riving knives, anti-kickback devices, and push sticks where appropriate.
• Follow manufacturer's guarding instructions and verify guards work for all blade sizes and cutting operations.

Milling machines generally require point-of-operation guards that prevent the operator's hands or body from entering the cutting zone; OSHA lists "Milling machines" among machines usually requiring such guarding (1926.300(b)(4)(iv)(e)).

• Employ fixed guards, adjustable guards, or proper work-holding devices so operators do not need to place hands near cutters.
• Use interlocks, two-hand controls, or presence-sensing devices when appropriate to the operation.

Yes. Employers must assess the workplace to determine whether hazards are present that require PPE and provide written certification of that assessment when PPE will be required. OSHA's hand-and-power-tool PPE requirement references PPE provisions in 1926.300(c), and OSHA's March 28, 2024 Letter of Interpretation clarifies that employers must perform a hazard assessment and produce a written certification when PPE is required (referring to 29 CFR 1910.132(d)(1)).

• The assessment should identify tool-related hazards (eye/face, respiratory, hand/arm) and the PPE necessary to control them.
• Keep the written certification on file and update the assessment when job conditions change or new hazards are identified.

Power presses typically require point-of-operation guarding designed to prevent any part of the operator's body from entering the danger zone during the operating cycle. OSHA specifically lists "Power presses" among machines that usually require point-of-operation guarding (1926.300(b)(4)(iv)(d)).

• Use appropriate press safeguarding such as barrier guards, two-hand tripping devices, pullbacks, or diesetting blocks per the operation.
• Ensure safeguarding is compatible with safe die setup and maintenance procedures and paired with lockout/tagout for servicing.

If a tool's guard is damaged or missing, the employer must remove the tool from service until the guard is repaired or replaced and ensure employees do not operate it unguarded. OSHA's general guarding requirement states tools designed to accommodate guards "shall be equipped with such guards when in use" (1926.300(b)(1)) and tools must be maintained in a safe condition (1926.300(a)).

• Tag and lock out unguarded or defective tools until repaired.
• Document repairs and inspections, and retrain workers if the hazard contributed to unsafe use.