A Quick Guide to Non-Sparking Tools - tradesafe

Non-sparking tools are essential in industries where flammable gases, liquids, dust, or other combustible materials are present. They are designed to prevent the creation of sparks, which could cause ignition and potentially lead to an explosion. In this article, we will explore everything you need to know about non-sparking tools including their benefits, applications, and more.

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What are Non-Sparking Tools?

Non-sparking tools, also known as spark-resistant tools, are hand tools made of materials that do not create sparks. They are made of non-ferrous metals, such as copper alloys, aluminum bronze, or beryllium copper. These metals do not contain iron, which means they do not produce sparks when struck against another metal surface. The design of non-sparking tools also eliminates any sharp edges or corners that could cause sparks.

Benefits

The use of non-sparking tools has several benefits, including:

• Reducing the risk of fire and explosion in hazardous environments.
• Minimizing the risk of injury to workers due to spark-related accidents.
• Complying with safety regulations and standards.
• Increasing efficiency and productivity by allowing work to continue uninterrupted.

Applications

Spark-resistant tools are used in a wide range of industries, including:

• Oil and gas exploration and production
• Refineries and petrochemical plants
• Chemical manufacturing
• Mining and metallurgy
• Aerospace and defense
• Shipbuilding and marine industries
• Automotive and transportation

Types of Non-Sparking Tools

There are three main types of non-sparking tools, each made of a different non-ferrous metal.

Copper Alloy

Copper alloy tools are the most commonly used non-sparking tools. They are made of a copper alloy that contains a small amount of beryllium, which gives them the necessary spark-resistant properties. Copper alloy tools are ideal for use in environments where flammable gases or vapors are present.

Aluminum Bronze

Aluminum bronze tools are made of an aluminum bronze alloy that contains a small amount of nickel. They are ideal for use in environments where there is a risk of ignition due to friction or impact.

Beryllium Copper

Beryllium copper tools are made of a copper alloy that contains a small amount of beryllium. They are ideal for use in environments where there is a risk of ignition due to static electricity or friction.

How to choose the right non-sparking tool?

When choosing a non-sparking tool, there are several factors to consider, including:

• The type of material being worked on
• The type of work being done
• The specific requirements of the work environment
• The size and shape of the tool needed

It is essential to choose the right tool for the job to ensure maximum safety and efficiency.

Safety Tips for Using Non-Sparking Tools

While non-sparking tools are designed to reduce the risk of fire and explosion, it is still essential to follow safety guidelines when using them. Here are some safety tips to keep in mind:

• Always inspect tools before use to ensure they are in good condition.
• Use the right tool for the job.
• Use the tool as intended and avoid modifying it.
• Store tools properly when not in use.
• Wear appropriate personal protective equipment.
• Follow all safety regulations and guidelines.

Maintenance

Proper maintenance of spark-resistant tools is essential to ensure their continued safety and effectiveness. Here are some tips for maintaining these tools:

• Clean tools after each use to remove any debris or contaminants.
• Store tools in a dry, cool place to prevent corrosion.
• Inspect tools regularly for signs of wear or damage.
• Replace any damaged or worn tools immediately.

Regulations and Compliance

When working in hazardous environments, it is important to comply with regulations and standards to ensure maximum safety. Non-sparking tools are no exception. Here are some regulations that cover non-sparking tools and beryllium:

1. OSHA’s Hand and Portable Powered Tools and Equipment Standard 29 CFR 1910.242: The Occupational Safety and Health Administration (OSHA) requires employers to provide workers with hand and portable power tools that are safe to use. Under 29 CFR 1910.242(a), employers must ensure that tools are free from defects, properly maintained, and used in a safe manner. Non-sparking tools can help employers meet this standard by reducing the risk of fire and explosion.
2. ANSI Committee B107: The American National Standards Institute (ANSI) Committee B107 sets standards for non-sparking tools. These standards cover the design, manufacturing, and testing of non-sparking tools to ensure their safety and effectiveness.
3. Other Regulations: Other regulations that cover non-sparking tools include those related to hazardous materials, such as the Hazardous Materials Regulations (HMR) of the Department of Transportation (DOT), and those related to chemical manufacturing, such as the Occupational Safety and Health Administration (OSHA) Process Safety Management (PSM) standard.

By complying with these regulations and standards, employers can create a safer work environment for their employees and reduce the risk of accidents and injuries.

FAQs

1. Are non-sparking tools more expensive than regular tools?

Yes, they are generally more expensive due to the specialized materials and manufacturing processes used to make them.

2. Can non-sparking tools be used in wet environments?

Yes, non-sparking tools can be used in wet environments, but it is essential to dry them thoroughly after use to prevent corrosion.

3. Are non-sparking tools required by law in certain industries?

Yes, some industries, such as oil and gas and chemical manufacturing, require the use of spark-resistant tools by law.

4. Can spark-resistant tools be used on any material?

No, spark-resistant should only be used on materials that are compatible with the specific tool and its material.

5. How often should non-sparking tools be inspected?

Non-sparking tools should be inspected before each use and regularly throughout their lifespan to ensure their safety and effectiveness.

1.What is the meaning of non-sparking?

Non-sparking in the context of hand tools is defined as metals/tools that do not generate sparks (or cold sparks) when the tool hits or strikes another metal or concrete. They are commonly Copper-based alloys and are used to manufacture tools that do not generate sparks and are hence commonly referred to as non sparking.

2.What are non-sparking tools?

To begin, non-sparking tools, as their name implies, do not produce (hot) sparks. As a result, they are ideal for jobs involving flammable materials. When working in facilities/areas containing flammable solids, liquids, or gases regular steel tools cannot be used. If a steel tool slips/strikes equipment it will generate a hot spark – which can lead to a fire. Therefore, hand tools commonly made of copper-based alloy like Copper Titanium, Aluminum Bronze, Beryllium Copper or Copper-Nickel Alloys are referred to as non sparking tools.

3.Is brass considered as a non sparking material?

Brass is primarily a copper-based alloy, for any material or alloy to be classified as non-sparking – it has to be tested and certified as per relevant testing Standards (Read more about IS4595 safety standard). Fundamentally, brass may be non-sparking depending on the composition. However, if it is not certified or tested - It should not be used. Secondly Brass is a soft material, making hand tools of brass will not serve the desired purpose of Non-Sparking Hand Tools – they will bend or wear out very quickly thereby defeating the purpose.

4.Non sparking tools are made up from which material?

Non sparking tools are made up from copper based alloys like copper-titanium alloys, copper-nickel alloys, copper-aluminum alloys (or Aluminum Bronze), bronze or brass. The tools made from these materials are softer than conventional steel tools since they are made of non-ferrous metals (primarily Copper). However, they have one advantage that no other tool can match i.e., they produce cold sparks with little heat and thus do not ignite any flammable material present in the environment.

5.Why is aluminum NOT Non-Sparking?

Pure Aluminum or an aluminum-based alloy (where primary metal is Al) are NOT classified under Non Sparking materials. Whereas Copper-based alloys containing aluminum commonly known as Aluminum Bronze, Aluminum Copper is Non-Sparking. Aluminum Bronze contains about ~ 11% Aluminum, ~ 5% Iron, 10% Nickel, and Remaining Copper.

6.Does stainless steel come under non-sparking?

Any material that produces frictional sparks when struck against a hard metal surface or concrete/stone cannot be classified as Non Sparking or suitable for use in flammable environments. Stainless Steel if a ferrous-based alloy and will produce sparking when struck and hence cannot be classified as Non-Sparking. Test certificates for any alloy should be validated before classifying them as non-sparking.

7.Who should use tools that are non-sparking?

Industries, where there is a high risk of explosion or fire, should use non-sparking tools. Industries that process, manufacture, store or transport flammable solids (propellants, explosives, ammonium perchlorate etc.), liquids (MSD, ethane etc) or gases (LPG, Hydrogen etc) have to take additional safety precautions as they are working in a high-risk environment. Non-Sparking hand tools are one such important safety measure that reduces the possibility of spark and therefore fire. Thus, industries like Oil & Gas, chemicals and pharmaceuticals, Paint Manufacturing, Power Plants, Explosives should make use of non-sparking tools. (Read how an Oil depot caught fire because of use of steel tools)

8.Why use non sparking tools?

Non-sparking tools exhibit unique property which makes them ideal for using in a flammable environment. Sparks created by iron and steel hand tools are a dangerous source of ignition when used near flammable materials. Non sparking tools made of Copper-based alloys like Copper Titanium, Aluminum Bronze or Copper Beryllium (Hazards of Beryllium) will keep you safe where this threat exists.

9.Can copper generate a spark?

The Spark is being referred to here as a mechanical or frictional spark. Copper - because of its excellent thermal and electrical properties does not produce frictional spark, whereas copper can produce electrical sparks. Non-Sparking Hand Tools should not be confused with Insulated Tools.

10.Is galvanized steel considered non sparking material?

No. Galvanized steel is not considered as non sparking material or alloy. It will produce frictional sparks when stuck with another metal/hard surface.

11.Why are Non Sparking tools sometimes referred to as Non magnetic?

Non Sparking Tools are also sometimes referred to as non magnetic because they allow magnetic fields to pass through them without being affected by them. Copper Titanium and Copper Beryllium allow complete magnetic fields to pass through them and can be classified as non magnetic. However, Aluminum Bronze contains two metals Iron and Nickel both of which demonstrate magnetic properties, therefore, when it comes to using non sparking tools in non magnetic applications use only copper titanium or beryllium copper tools. Aluminum bronze is not completely non-magnetic and can interfere with the magnetic field (Video of Copper titanium and Aluminum Bronze subjected to a magnetic field).

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12.Which standard is used for non-sparking tools?

There are three major standards defined globally that test and determine whether an alloy can be categorized non-sparking or not. First is the Indian Standard i.e. IS 4595-1969(2006) which was constituted on January 29, 1969 and later re-affirmed in 2006. The second is FM Approval (USA) i.e. FM 7190. Third is BAM Certification by an institute in Germany. All three standards primarily check the spark generation capability of the material/alloy. The certification of any one or more of the standards should be acceptable. (Read how an alloy is tested for Non Sparking properties as per IS 4595 Standard)

13.When working with flammable gases or explosive chemicals, what kind of tools should be used?

Hand tools made of iron or steel can emit sparks and therefore should NOT be used. Only certified or tested alloys for Non-Sparking properties should be used. Common Hand tools like spanners, wrenches, screwdrivers, hammers, slogging spanners should be used based on the torque range and type of Nuts, bolts etc. (download a catalog of over 2500 standard Non-sparking Hand Tools). If standards tools do not do the job, you can get customized Non-Sparking Hand Tools designed and manufactured based on your needs. Never use fabricated or ‘jugaad’ tools when working with flammable gases or explosives because safety is paramount.

14.What factors contribute to a metal to be non-sparking?

The primary factor that contributes for a metal to be non sparking is the fundamental property of Copper. Copper has excellent thermal and electrical properties and can therefore transfer heat quickly. When a friction spark occurs between copper and a hard surface the energy generated at the point of friction is quickly absorbed by copper allowing only cold sparks to be generated – thus making the alloy non sparking. Alloying elements like Titanium, Beryllium are added to strengthen copper.

15.Why non sparking tools are considered as safety tools?

Non Sparking Tools as the name suggests do not produce sparks (or cold sparks) that are recommended to be used in flammable environments this helps protect the safety of the plant, equipment and most importantly – human life. Hence, they are called safety tools. Earlier, many companies used to buy non-sparking to complete a safety audit point, but used steel tools in the field. The increase in fire accidents and with loss of life, companies are now mandating the use of Non-sparking hand tools.

16.What is the correct way to use non sparking tools?

There, certain recommended practices for use of Non-Sparking Hand Tools which are as follows:

A. Follow the DO and DONTs.

Non-Sparking Hand Tools do not exhibit the strength characteristics of steel tools because they are primarily copper based tools. While Non-Sparking tools are strong and durable they cannot take the abuse that a steel tool can take. When tools are used as per recommended practices then they can give very good life. For example, a qualifying torque of a steel wrench of 25 mm has a torque rating of 496 Nm (as per IS 6131 Standards). A Copper Titanium Non-Sparking tool will pass that standard and will probably break at 900~1200 Nm with is ~50% more than the qualifying torque, whereas a steel tool can take up ~2400 Nm (~200%). Overloading of Non-Sparking tools should not be done at any cost. It can not only lead to the failure of tools but can injure the operator or damage the equipment. Watch a video of how copper titanium non-sparking tools are torque tested.

B. Check for damages, chipping or wear and tear

Over time the tools will undergo wear and tear. Always inspect your tools before use for any chipping, damages etc. Do not use such tools as they can break during use.

C. Keep Tools Clean and Dry

After you have used the tools, there is a chance that chemicals, solvents, powders etc which are flammable in nature have got stuck to the tools – this is not safe. Always clean your tools with dry cotton cloth to remove anything that may be stuck, this will also increase the longevity of the tools.

D. Maintain a tools box or a bag:

After use, keep the tools properly is a dedicated toolbox or a tool bag so that they are not lost among other steel tools or equipment. It is highly recommended that heavier tools like pipe wrenches, or hammers be kept at the bottom and light duty tools like screwdrivers, pliers etc be kept on the top, this will not damage the tools and give long life.

E. Dispose of your tools properly.

Dispose of worn-out tools properly to an authorized recycle agent. For example, where beryllium copper tools are being used, after the end of life, the worn out tools should be given someone who is authorized or has the necessary safety equipment and technology to process beryllium alloys. Beryllium is carcinogen and can cause cancer. Copper titanium which is a safer one-to-one replacement to Beryllium Copper

17. Which are the countries that manufacture Non-Sparking Tools?

Non-Sparking Hand Tools were first developed in the United States over 75 years ago, where they manufactured Copper Beryllium and Aluminum Bronze Non Sparking and tools. As the demand for Non-Sparking Tools increase a few companies in Europe started manufacturing and marketing these tools.

With the world recognizing the hazards and dangers of dealing with beryllium. Companies in the USA and Europe shifted to manufacturing only AlBr tools in their country. While there was a demand for Beryllium Copper tools and therefore all manufacturing of Beryllium Copper Non-Sparking tools shifted majorly to China.

Over the last two decades and with a shift of major manufacturing to China. Non-Sparking hand tools manufacturing also shifted to China. Majority of the companies get Non-Sparking tools manufactured under their brand name in China. Over the last decade, India has been added to the list as a manufacturer of Non-Sparking Hand Tools, with the launch a new alloy i.e. Copper Titanium. Non-Sparking hand tools of Copper Titanium are only made in India.

18. Can we use non-sparking tools for acetylene?

According to U.S. Department of Labor , Mine Safety and Health Administration “Acetylene forms explosive compounds with copper, brass, copper salts, mercury/mercury salts, silver/silver salts and nitric acid. Under no circumstances should acetylene gas come in contact with unalloyed copper, except in a torch. Any contact of acetylene with high-alloyed copper piping will generate copper acetylide, which is very reactive and may result in a violent explosion” All commonly know non-Sparking Hand tools i.e., Copper Titanium, Copper Beryllium and Aluminum Bronze have high copper content >85% which can be dangerous while working in environment containing acetylene. It is recommended to use Non-Sparking Tools with copper content less than 65% to avoid a reaction in case there is a leakage of acetylene gas.

19.Can we use non-sparking tools for electrical equipment maintenance?

No, you cannot use Non-Sparking Hand Tools with electrical equipment. Commonly misunderstood Non-Sparking Hand tools are used to prevent any frictional or mechanical sparks. Non Sparking tools are made of copper will conduct electricity. With electrical equipment you need Insulated tools to protect the user from electrical shocks.

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