The tools we use have come a long way since the caveman. To get a better appreciation for the beloved tools we use every day, let’s look at the evolution of a few of the most common in an electrician’s arsenal.

Evolution of drills

The first type of truly portable drill we would recognize is known as the brace and bit. It consisted of a shaft that was bent in the middle to form an offset. At the top is a round handle that spins independently from the shaft, while the bottom of the shaft has a chuck to hold the bits. Once the desired drill bit was inserted into the chuck of the brace, the user turned the offset portion to drill a hole.

   

While it does produce a hole, the tool has its limitations and is far from efficient. First, drilling with a brace and bit is generally limited to softer materials such as wood or thin sheet metal. Since the drill is hand-powered, another limitation is the user—the process would be exhausting if kept up for an extended period.

Black + Decker’s original portable electric drill	Makita’s first cordless, rechargeable drill, the 6010D

Incorporating electric motors dramatically changed the tool. In 1917, Black & Decker, Towson, Md., introduced an invention—the basis of which we now consider a power drill. Roughly shaped like a pistol, it had a finger trigger switch, a handle and a cord to plug the drill into a receptacle. This allowed the user to still benefit from the mobility of a portable tool while harnessing the power of electricity to perform the work.

Even though the portable drill was hugely improved by adding electricity, it still required the user to be near a power source. And while Black & Decker technically invented the first cordless drill in 1961, it was not marketed or widely available.

Makita, La Mirada, Calif., developed its first rechargeable cordless drill, the 6010D, in 1978 and marketed it to the general public and construction industry. While limited in power, the cordless drill drastically improved productivity by giving workers a small, portable tool free from being tethered to an extension cord. This invention formed the basis of the cordless drills we use today.

A fitting example of the current type of cordless drills is Milwaukee Tool’s, Brookfield, Wis., 18V ½-inch drill driver. This tool encompasses all the advancements made in the past 100 years into a single platform. The powerful brushless motor delivers 1,200 inch-pounds of torque and is capable of spinning at up to 2,000 RPMs. The design is small, measuring a bit under 7 inches in length, allowing it to fit into tight spaces and reducing user fatigue. The 18V battery allows the operator to use the tool for longer periods without having to recharge, while still providing the power necessary for strenuous tasks.

   

Evolution of hand, circular and reciprocating saws

Egyptians made saws out of copper about 6,000 years ago. Just like their drill counterparts, early modern versions (some of which still have use today) were hand-powered. They consisted of a handle and a thin metal blade. Once placed against the medium to be cut, the blade was drawn back and forth against the material repeatedly, until the cut went all the way through. The process, while satisfying, was labor-intensive and lengthy.

Wood hand saw	Metal-cutting hacksaw

Portable circular saws were born in the early 20th century. This produced a much quicker, less strenuous way to cut material, and gave the user the freedom to move around that material, which resulted in much higher efficiency. While there have been improvements, the basic concept has remained the same. A circular blade, with notches for teeth, is attached to a shaft and turned by a motor at a high rate of speed. The rotating blade allows for a much more compact design than the linear sawing function of a traditional hand saw.

Reciprocating saws rely on the same basic back-and-forth motion as a hand saw, but are electrically powered. Not every sawing action is conducive to using a circular blade, so a need remained unfilled for a time. 

In 1951, the invention of Milwaukee Tool’s Sawzall—a tool that virtually every electrician is familiar with—hit the market. A thin, narrow blade is fixed parallel with the shaft, opposite from a circular saw’s perpendicular attachment. This design allows the user to make complex, circular or plunge cuts. In addition, the multitude of blade types available makes it versatile and capable of cutting wood, metal or plastic, round or square. It is a must-have tool for any electrician.

   

Today’s variants are mostly battery-powered options, though some corded platforms remain available. Towson, Md.-based DeWalt’s 20V MAX combo saw kit is an example of modern cordless tool options. Both tools in the kit operate on a lightweight 20V brushless motor that reduces weight and improves overall performance. The 20V battery gives both saws increased torque and battery life, which minimizes the need for frequent battery changes.

   

   

Additional tools and accessories

Drills and saws are not the only tools that have improved with advances in technology. Fish tapes are a perfect example of a tool that has been adapted to users’ needs over time. Early fish tape styles, still in use today, consist of a thin coiled spring steel tape with some type of rounded head on one end to glide through the conduit and a housing on the other side to hold the coiled tape. To use, uncoil the length needed, insert it through the conduit to the desired location, attach the conductors to the looped end, and pull it back.

Polyester fish tape	Stainless-steel fish tape

However, using a standard steel tape that is conductive and potentially damaging to existing conductors is not always the best choice. Ideal Industries, Sycamore, Ill., developed a fiberglass type that eliminates this problem and can be used around energized components or where existing conductors are present. For wet or more corrosive environments (near saltwater, for example), there are stainless-steel fish tapes with better rust resistance that are much more durable than standard steel tapes.

Milwaukee Tool recently released a powered fish tape that runs on its 18V cordless battery. This drastically reduces user fatigue by negating the need to manually feed into a conduit and is durable enough to pull wire through 200 feet of conduit with 360 degrees of bends. With several interchangeable cartridges of steel or nonconductive materials, this tool is versatile enough to adapt to different job-site conditions.

   

Batteries for cordless tools

Batteries have also changed radically since their introduction to the construction industry. Initial battery platforms used in early cordless tools were 7.2V and powered by nickel-cadmium batteries (NiCd). While this vastly improved productivity by extending the user’s reach past the length of an extension cord, it was limited in what it could do. The 7.2V battery was not terribly powerful, so many tasks still needed the torque, speed and longevity that only a corded tool could provide. NiCd batteries would also develop a memory effect that, over time, reduced the batteries’ capacity if not properly maintained.

Today’s battery-powered tools generally use either a 12V or 18V platform, although there are other options available. The 12V platforms are lighter weight and easier to manage, while the 18V systems provide the power and longevity needed for long-term use on most job sites. 

Arguably, the biggest improvement in today’s batteries is the development of lithium-ion (Li-ion) components. This technology results in much higher energy consumption density, lighter weight, longer run times and no memory effect. Li-ion has quickly become the standard for cordless tools.

Conclusion

Everything we touch in the construction industry has benefited from changes in technology, and tools are no exception. Many of the tasks that were once manual only are now powered by batteries. This enables us to accomplish much more work in a shorter amount of time with greater safety and less user fatigue overall. Limited only to imagination and the technology available, it is intriguing to think of what is next on the horizon.

Photos: electrician u / black + decker / Makita / milwaukee tool / Cindynhiart / Dewalt