Electricians work in environments that require precision and safety. Risks can range from minor shocks to life-threatening electrocution. When an electrical circuit cannot be de-energized, one of the primary ways electricians protect themselves is by using insulated hand tools. These tools are meant to be used in conjunction with electrical safety protocols and are specifically designed to provide protection against electric shocks when working on or near live electrical circuits. This article explores why we should use insulated tools, the differences between them and standard tools and how to properly care for them.

Why use insulated tools

Safety is the biggest reason electricians should use insulated tools when working on energized circuits. According to safety regulations and standards, such as those set by OSHA and the International Electrotechnical Commission (IEC), insulated tools are necessary when working in environments where there is a potential for electrical exposure. OSHA 1910.333(c)2 specifies that electricians must use insulated tools when there is a risk of electric shock, and IEC 60900 outlines the requirements for insulated tools, including their design, construction and testing procedures.

These standards are in place because even a small amount of electric current passing through the human body can cause serious injuries or fatalities. For electricians who regularly work with high-voltage equipment, this risk is even greater. Even a brief lapse in concentration can lead to accidental contact with live parts. Insulated tools help mitigate these risks by providing a nonconductive barrier. The tools’ entire surface, except for the part in direct contact with the material being worked on, is covered with an electrically safe coating. 

By using insulated tools that comply with these standards, electricians meet their legal and professional obligations, which reduces liability and maintains a safe working environment.

The insulation is composed of different nonconductive materials and is generally thicker than the “comfort grips” found on standard tools, but it is not impervious to damage. While this thicker material may appear to make insulated tools more robust and able to handle more abuse than noninsulated tools, any gouge, nick or cut will reduce the insulative properties and could result in the user receiving a shock. Remember, current flows through a conductor but not an insulator, so keeping the insulation intact and undamaged is important to keeping the tools’ safety function in good working order.

Standard versus insulated tools

Noninsulated hand tools are typically made from materials such as steel, with handles usually covered in basic plastic or rubber to provide better grip and a level of comfort. These tools are not designed to offer any electrical protection and should not be used for energized electrical work. The covering on noninsulated tools is often mistaken for insulation; however, they are not tested or certified for electrical safety and can conduct electricity, which poses a risk of electric shock if used on energized circuits.

Insulated tools are made with nonconductive materials, such as specific plastics or rubbers, which provide a better barrier against electric shock. These tools are often rated to withstand voltages up to 1,000V AC and 1,500V DC. This makes them suitable for electricians who work in environments where there is an elevated risk of accidental contact with energized circuits. The insulation on these tools is usually a bright color, such as red or orange, which helps to quickly identify them as safe for energized work.

Another key difference is that for noninsulated tools, typically the conductive parts are only covered where the tool is in contact with a user’s hands, leaving the remaining part (usually metal) exposed.

Klein Tools 9-in. lineman’s pliers	Klein Tools Journeyman series 9-in. lineman’s pliers

The ergonomics and design of insulated tools also differ significantly from noninsulated tools. Insulated tools are often designed with additional safety features, such as finger guards and wider handles, which prevent slippage and ensure the user’s hands do not come into contact with the conductive parts of the tool. Better grip also reduces hand fatigue and increases accuracy. These design elements elevate user safety when working in potentially hazardous electrical environments.

Finally, the cost difference between insulated and noninsulated tools can be significant. Insulated tools are generally more expensive due to the specialized materials, rigorous testing and certification processes. This cost is an investment in safety and compliance with electrical safety standards. Noninsulated tools, being simpler in design and construction, are typically less expensive and only meant for general use. Insulated tools are best kept safely put away until needed to work on an installation that is, or has the potential to become, energized.

Proper care and maintenance

As insulated hand tools are designed and manufactured to provide the most protection available, they do require an additional level of care to keep them in good working order. 

Before each use, electricians should inspect their insulated tools for any signs of damage, such as cracks, cuts or abrasions in the insulation. Even small nicks or cracks can compromise the tool’s insulating properties, making it unsafe for use. Tools with damaged insulation should be removed from service immediately and replaced. In addition to visual inspections, electricians should also perform regular dielectric testing on their insulated tools to ensure they have not been compromised due to use or abuse. This testing involves applying a high voltage to the tool and measuring its ability to resist electrical current. Tools that fail dielectric testing should be immediately removed from service and replaced.

   

Keeping insulated tools clean is also important for keeping their insulative properties intact. Dirt, oil, grease and other contaminants can degrade the insulation material, reducing its effectiveness. These tools should be cleaned regularly with mild soap and water, followed up with a thorough rinsing and drying. Harsh cleaning chemicals should not be used as this can damage the insulation. The tools should be stored in a clean, moisture-free environment because dampness can cause the insulation to swell, crack or degrade.

Tools should be properly stored in a clean and dry environment, away from direct sunlight, extreme temperatures or anything that could damage the insulation. Many electricians use dedicated tool bags or cases specifically for insulated tools that keep them separate, organized and protected. 

In addition to protecting the tools from environmental factors, proper storage also helps prevent accidental damage. Tools that are just thrown into a toolbox or left lying around are much more likely to become damaged through impact, or by coming into contact with other tools and materials. Storing insulated tools properly ensures they remain in good condition and provide the maximum protection they are designed for.

Insulated tools are meant to provide protection against electrical shocks, but they are not indestructible. Avoid using excessive force with these tools, as this can damage the insulation or the tool. For example, using an insulated screwdriver as a pry bar can cause the insulation to crack or become damaged, which reduces its safety properties. In the same vein, electricians should also avoid using insulated tools in ways that they were not intended. Each tool is designed for a specific purpose, and using it incorrectly can lead to damage or injury.

Conclusion

Insulated hand tools are an indispensable part of a seasoned electrician’s toolkit, providing essential protection against electrical shocks and helping to ensure a safe working environment. By using insulated tools when working on energized circuits, electricians can perform their work safely, comply with safety standards and improve work efficiency. Proper care and maintenance are crucial to ensuring they provide maximum protection. Electricians who prioritize safety by using insulated tools and following proper care practices can significantly reduce their risk of injury while maintaining a safer work environment for themselves and their colleagues.

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