How to Inspect Hand Tools

Why inspect hand tools?

Hand tools are simple, but they can still cause serious injuries when they are damaged or used for the wrong job. Safety guidance from workplaces and universities consistently makes two points: use the right tool for the task, and examine tools for damage before each use. Damaged tools are more likely to slip, snap or throw fragments, and a few seconds of checking is a small price to pay.

This guide gives a general approach and then goes through specific tool types. It is not a substitute for manufacturer instructions or workplace rules, which should take priority where they apply.

A simple routine before each use

Pick the right tool for the job. Using a chisel as a screwdriver or a wrench as a hammer is a common cause of breakage and injury.
Look the tool over. Check the handle, the working end and any moving parts.
Test the fit. Heads should be tight on handles, jaws should close properly, and adjustable parts should hold their setting.
Clean off grease, oil and debris. A slippery grip is a hazard in itself.
Take damaged tools out of use. Tag them, set them aside, and either repair or replace them. Do not put a questionable tool back in the toolbox where someone else may pick it up.

What to look for on common tools

Hammers and mallets

A loose head is the key hazard. Check that the head does not wobble on the handle and that any wedge is in place.
Look for cracks, splinters or deep dents in wooden handles. Fibreglass and steel handles should be checked for cracks or bends.
Inspect the striking face for chips and heavy mushrooming. A badly damaged face can throw fragments.

Chisels, punches and wedges

Tools that are struck with a hammer can develop a flared, “mushroomed” head over time. These edges can chip off, so the head should be dressed or the tool replaced.
Check the cutting edge for chips and rolling. A dull or chipped chisel needs more force and slips more easily; see why sharpening matters.
Wooden handles on chisels should be free from cracks and firmly attached.

Screwdrivers

The tip should be square and the right size for the screw. Rounded, twisted or chipped tips tend to slip out of the screw head.
Handles should be intact and not cracked or loose on the shank.
A bent shank is a sign the screwdriver has been used as a pry bar and should be retired.

Pliers, wrenches and snips

Check that jaws meet properly and that the teeth are not worn smooth.
Look for cracks near the pivot, spread jaws or a pivot that is loose or stiff.
On adjustable wrenches, the moving jaw should slide smoothly and stay tight when set.
Insulated tools used for electrical work should have no cuts, cracks or exposed metal in the coating. If the insulation is damaged, stop using the tool for electrical work.

Saws

Look along the blade for bent sections, rust pits and missing or damaged teeth.
Handles should be tight and free from cracks.
Use a blade guard or cover when a saw is stored so teeth are protected.

Files, rasps and knives

Files should always have a handle fitted, because the tang can injure your hand.
Utility knife blades should be changed when they are dull or chipped. See utility blade types for choosing the right blade.
Check that the handle locks the blade securely.

Clamps and vises

Screw threads should turn smoothly, and the jaws should align.
Look for bent bars or cracked castings.

Wear signs that mean replace, not repair

Cracks in metal, especially near handles or pivots.
Heavily mushroomed or chipped striking heads.
Bent shanks or blades that cannot be straightened safely.
Wooden handles with deep cracks. Handles can sometimes be replaced, but if the head or eye is damaged the whole tool should go.
Severe rust that has pitted the working surface.

Minor rust on a surface can often be cleaned off with abrasive pads or a rust remover. A loose wooden handle can sometimes be re-wedged. If you are unsure whether a tool is safe, treat it as unsafe.

Inspecting tools stored in a garage or workshop

Tools in unheated spaces collect moisture and dust. Every few months it helps to:

Wipe metal parts down and apply a thin coat of oil to prevent rust.
Check wooden handles for dryness or cracking. A light coat of oil can help but is not a cure for damage.
Make sure tools are returned to their place so you can spot missing items.

The tools on your basic hand tools list are the ones you will probably check most often, so build the habit with those first.

Hand tool inspection checklist

Is this the right tool for the job?
Is the handle intact, clean and tight?
Is the head, blade or tip free from cracks, chips, mushrooming and bends?
Do moving parts work smoothly?
Is the cutting edge sharp enough?
Is protective gear (safety glasses, gloves where appropriate) ready?
If something is wrong, have I removed the tool from use?

Frequently asked questions

What is one of the key safety precautions for hand and power tools?

Examining the tool for damage before each use and using it only for its intended purpose are two of the most commonly given precautions. Wearing suitable eye protection is another.

What counts as a hand tool?

A hand tool is one that is operated by human effort rather than a motor, such as a hammer, screwdriver, pliers, saw or chisel.

What is a safety checklist?

It is a short list of items to confirm before starting work, such as tool condition, work area, and protective equipment, so that nothing is overlooked.

How often should I inspect my tools?

Before each use is the standard guidance, with a more thorough check when you put tools away or at regular intervals for tools used heavily.