Striking tools are widely used in industrial maintenance, fabrication, construction and heavy engineering. Hammers, mallets and sledgehammers deliver force, while chisels, punches, drift pins, wedges and slogging spanners receive that force to complete the work.
The danger begins when a worker must hold, support or position the struck tool by hand. Fingers may remain only a short distance from the point where the hammer lands. One missed strike, glancing blow or unexpected movement can place the supporting hand directly in the impact path.
Good striking tools safety therefore involves more than careful hammering. Workers need the correct tools, proper inspection, suitable personal protective equipment, clear communication and a controlled striking method. Where the task permits, a no-touch holder can create physical distance between the hand and the hammer impact zone.
PSC FingerSaver™ supports this approach by helping workers hold selected tools while keeping their hands away from the immediate striking point.
What Are Striking Tools?
Striking tools are hand tools designed to deliver controlled impact force. A worker swings or moves the tool so that its striking face contacts another object, component or tool.
They are commonly used to:
- Drive or remove components
- Shape or separate material
- Align machine parts
- Loosen or tighten heavy fasteners
- Drive chisels, punches, pins and wedges
- Support repair, assembly and shutdown work
Common Examples of Striking Tools
Metalworking hammers
Ball-peen, cross-peen and club hammers are used for shaping, driving and mechanical work.
Heavy-impact hammers
Sledgehammers deliver greater force for heavy maintenance, demolition and component movement.
Soft-face hammers
Rubber, brass, plastic or other approved faces are selected where surface damage or sparking must be controlled.
Mallets and dead-blow tools
These tools provide controlled impact for selected fitting, positioning and assembly tasks.
The hammer must be selected according to the task, the material being struck, the available working space and the manufacturer’s guidance. An unsuitable hammer may damage the tool, reduce control or create a greater chance of a glancing blow.
What Are Struck Tools?
Struck tools, sometimes called hammered tools, are designed to receive the hammer blow. Common examples include:
- Cold chisels
- Punches
- Drift pins
- Nail sets
- Wedges
- Alignment tools
- Striking-face spanners
- Slogging or flogging spanners
Both tools must be compatible. A hammer with an unsuitable face, weight or hardness may cause poor contact, damage or unexpected deflection.
Why Is the Hammer Impact Zone Dangerous?
The hammer impact zone is larger than the exact point where the hammer contacts the tool. It includes the hammer’s travel path, the striking point, the area around the struck tool, the supporting hand, the possible movement of the workpiece and the path of any flying particles.
Direct Hand Exposure
Direct hand exposure occurs when a worker uses their fingers to:
- Hold a chisel upright
- Position a punch
- Stabilise a drift pin
- Support a slogging spanner
- Align a wedge
- Reposition a tool between strikes
This may appear to provide control, but it places the hand close to the point where impact energy is being delivered. The risk is especially high in two-person work, where one worker holds the tool and another swings the hammer.
Line-of-Fire Exposure
A line-of-fire hazard exists when a person or body part is positioned in the expected or possible path of moving energy. During hammering, that path may include:
- The downward path of the hammer
- The direction of a missed or glancing strike
- The movement of a slipping chisel or punch
- The possible rotation of a spanner
- The release path of a wedge or pin
- Flying fragments from damaged metal
The line of fire may change after every strike. A tool that was stable at the start may shift after repeated impact. Workers must therefore assess the complete operating area, not only the intended contact point.
Common Hazards When Using Striking Tools
Missed Hammer Strikes
A missed strike occurs when the hammer does not contact the intended area. Poor visibility, limited access, fatigue, an awkward stance, incorrect hammer size or movement of the struck tool may all contribute. When the tool is held directly by hand, the fingers may become the next object in the hammer’s path.
Glancing Blows
A glancing blow occurs when the hammer face contacts the struck tool at an angle rather than squarely. It may cause the hammer to deflect, the struck tool to move or metal fragments to break away. Controlled, square contact is essential.
Tool Slipping or Moving
A struck tool may move because the contact surface is curved, oily or unstable; the tool is worn; or repeated impacts change its position. Hammering must stop immediately when the tool moves. Reposition only after the striker has lowered the hammer and both workers have confirmed that the operation is paused.
Mushroomed or Damaged Tool Heads
Repeated impact may deform the head of a chisel, drift pin or wedge. Mushroomed edges can become sharp, interfere with square contact or release fragments. Damaged tools must be removed from service and handled through an approved repair or replacement process.
Flying Chips and Fragments
Impact between metal surfaces can create flying particles, especially when a tool is chipped, mushroomed, brittle or struck with the wrong hammer. Suitable eye and face protection must be selected through the task risk assessment. Screens may also be required to protect nearby workers.
Poor Coordination Between Workers
Two-person striking work requires clear control of the sequence. Problems occur when the holder is not ready, the striker cannot see the hand position, commands are unclear or either worker assumes that the other is prepared. Use one agreed strike command and allow either worker to stop the operation immediately.
Where Are Striking Tools Used in Industry?
Mechanical Maintenance
Maintenance teams use striking tools to remove seized pins, drive or remove keys, align holes, release corroded components and position machine parts. The risk rises when access is restricted or components are difficult to move.
Flange and Bolting Operations
Slogging and flogging spanners are designed with a striking face that can receive controlled hammer blows. They may be used for heavy flange maintenance, large fasteners, shutdown bolting and equipment repair. Only a wrench specifically designed to receive impact should be used in this way.
Fabrication and Assembly
Fabrication tasks may include chiselling, punching, marking, driving pins, aligning components and separating joined material. Wherever practical, the workpiece should be secured so that the worker does not need to use one hand as a temporary clamp.
Shutdown and Turnaround Maintenance
Shutdown work often combines restricted spaces, high noise, temporary lighting, repeated hammering and several teams working nearby. These conditions make tool inspection, exclusion zones, communication and no-touch methods especially important.
Industries That Commonly Use Striking Tools
- Oil and gas
- Petrochemical plants
- Steel and cement
- Power generation
- Mining
- Marine and offshore facilities
- Construction
- Manufacturing
- Heavy engineering
- Shipyards and workshops
Common Hand Injuries During Striking Operations
When a hammer hits or traps the supporting hand, the result may range from a minor injury to a serious loss of function. Possible injuries include:
- Bruising and swelling
- Cuts and lacerations
- Crushed fingertips
- Nail-bed injuries
- Finger fractures
- Joint, tendon and soft-tissue damage
- Injuries caused by sharp metal fragments
The hand may also be trapped when the struck tool slips against nearby equipment. Even when a glove is worn, the force of a heavy hammer blow may still be transferred to the fingers.
Why Gloves and Careful Hammering Are Not Enough
Gloves Do Not Remove the Hand
Gloves may help protect against selected cuts, abrasion, rough surfaces or temperature hazards. However, gloves do not create distance between the fingers and the hammer. They cannot prevent every crush, fracture, direct impact or tool movement.
Hammer Accuracy Can Change
Even an experienced worker may deliver an inaccurate strike when conditions change. Fatigue, poor lighting, restricted access, repetition, tool movement, unstable footing, incorrect hammer weight and miscommunication may all affect accuracy.
Training Does Not Create Physical Distance
Training is essential for tool selection, inspection, positioning and communication. However, training alone does not change the distance between the hand and the hammer impact zone.
Engineering Controls for Striking Tools Safety
An engineering control changes the equipment, workplace or process so that workers have less direct exposure to a hazard. For striking operations, engineering controls may include:
- Mechanical clamps
- Fixed holding devices
- Guards and shields
- Tongs
- Chisel and punch holders
- Extended no-touch tool holders
- Jigs and fixtures
- Alternative methods that remove manual hammering
Create Physical Distance
A suitable holding method should allow the worker to position the struck tool, maintain control, observe alignment and keep hands outside the immediate hammer path. Distance does not replace inspection, PPE or correct hammering, but it reduces direct exposure.
Secure the Struck Tool
Where practical, secure the tool or workpiece using a vice, clamp, jig, fixture, tong or purpose-designed holder. The selected method must not create a new pinch, slip or ejection hazard.
Improve Control and Positioning
The holding method should keep the tool stable without demanding excessive hand force or awkward posture. Confirm that the striking point remains visible and that the holder does not obstruct the hammer path.
Use a No-Touch Method
A no-touch method reduces the need for direct hand contact with the tool or object exposed to impact. It moves the hand to a separate control point instead of placing fingers beside the striking area.
How PSC FingerSaver™ Helps Keep Hands Away
PSC FingerSaver™ is a no-touch hand-safety tool designed to help workers hold or support suitable tools while maintaining greater separation from the hammer impact area.
It should form part of a complete safe system of work that includes:
- Task assessment
- Correct tool selection
- Pre-use inspection
- Proper worker positioning
- Suitable PPE
- Clear communication
- Training and supervision
- Manufacturer-approved use
Creates Separation from the Striking Point
The extended design provides a separate gripping point away from the end exposed to impact. This can reduce the need to position fingers directly beside a compatible slogging spanner, punch, chisel or other approved tool.
Supports Tool Positioning
Industrial striking work often requires the struck tool to remain at a specific angle or location. PSC FingerSaver™ gives the worker a separate handling point so the tool can be supported without gripping the immediate striking area.
Reduces Direct Hand Exposure
PSC FingerSaver™ does not replace the hammer, struck tool, PPE or safe procedure. Its purpose is to change where the supporting hand is positioned. It helps create physical separation, reduces the need for direct hand contact and supports safer positioning.
Trusted No-Touch Hand-Safety Solution
PSC FingerSaver™ has been promoted as a no-touch hand-safety tool since 2014. Compact, standard and long versions are available for different approved applications and working-distance needs. Always confirm the correct model and current specifications on the official product page before use.
How to Use Striking Tools More Safely
Identify the Task
Confirm what must be struck, why impact is required, whether a non-impact method is available, which hammer and struck tool are suitable, and whether a clamp or no-touch holder can be used.
Inspect Every Tool
Check for cracks, chips, mushroomed heads, bent sections, loose hammerheads, damaged handles, worn grips, oil, grease and unauthorised repairs. Remove unsafe tools from service.
Establish the Impact Zone
Identify the area in which the hammer, struck tool, workpiece or fragments may move. Keep unnecessary workers outside the swing, impact and fragment paths.
Position the Struck Tool
Secure or support the tool using an approved method. Confirm that it is seated correctly, the contact surface is visible and the holder does not interfere with the swing.
Keep Hands Away
Before the first strike, check whether any finger could be reached by a missed blow or a moving tool. Use a holder, clamp, jig or tong where suitable.
Establish Clear Communication
Agree on simple commands such as “Ready,” “Strike” and “Stop.” Only the designated holder should give the strike command. Either worker may stop the operation.
Strike Squarely
Use the correct hammer, maintain stable footing, confirm adequate swing space, watch the contact point and use controlled force. Avoid glancing blows.
Stop If the Tool Moves
Stop hammering, lower the hammer, reassess and reposition with the approved holder. Never reach toward the tool while another strike is being prepared.
Inspect and Store After Use
Clean and inspect the equipment, remove defective tools, record damage or near misses and store the hammer, struck tool and holder correctly.
Striking Tools Pre-Use Inspection Checklist
| Inspection point | What to check | Required action |
|---|---|---|
| Hammer face | No chips, cracks, dents or mushrooming | Remove damaged hammer |
| Hammerhead | Firmly attached to the handle | Do not use if loose |
| Hammer handle | No cracks, splinters, sharp edges or contamination | Repair or replace through an authorised process |
| Struck-tool head | No mushrooming, burrs or chipped edges | Remove or properly redress as permitted |
| Tool body | No bending, cracks or severe wear | Remove from service |
| Tool compatibility | Hammer and struck tool suit the task | Select correct equipment |
| Workpiece | Stable and properly supported | Clamp or secure where practical |
| Work area | Clear of debris and obstructions | Clean before starting |
| Swing space | Clear above, behind and beside the striker | Reposition workers or equipment |
| Lighting | Contact point clearly visible | Improve lighting |
| Eye and face protection | Suitable for impact and flying particles | Wear before starting |
| Nearby workers | Outside impact and fragment zones | Establish exclusion area |
| No-touch holder | Suitable, clean and undamaged | Replace if defective |
| Communication | Ready, strike and stop commands agreed | Brief the team |
| Hand position | All hands outside the possible hammer path | Do not proceed until corrected |
Common Mistakes to Avoid
Holding the Struck Tool Directly by Hand
Use a clamp, holder, tong, fixture or another approved method where practical.
Using the Wrong Hammer
A hammer that is too large, too small or unsuitable for the material can reduce control and damage the equipment.
Using Damaged Tools
Do not continue with chipped, cracked, bent or mushroomed tools.
Striking from an Unstable Position
Do not swing while overreaching, standing on an unstable surface or working without adequate clearance.
Continuing After the Tool Moves
Stop, lower the hammer and reposition the tool before continuing.
Striking One Hammer with Another
Do not strike one hammer with another or strike hard objects that are not designed to receive impact.
Striking an Ordinary Wrench
Only use a spanner or wrench specifically designed with a striking face.
Depending Only on Gloves
Gloves support protection, but they do not remove the hand from the impact zone.
Using a Holder Incorrectly
Verify compatibility, grip, size, condition, position and manufacturer-approved use.
Working Without Clear Communication
Never rely on assumptions during two-person hammering. Use one agreed command system.
How to Introduce No-Touch Striking Tools at a Worksite
Identify High-Risk Tasks
Review work involving heavy hammers, chisels, punches, drift pins, wedges, slogging spanners, two-person striking, restricted access and repeated hammering. Prioritise tasks where workers currently place their fingers close to the impact point.
Observe Actual Hand Positions
Watch how the work is really performed. Record where each person stands, how the tool is held, when it is repositioned, whether the striker can see the supporting hand and what happens when the tool moves.
Select the Correct Holding Method
The control must suit the struck tool, dimensions, angle, expected impact, working height, access restrictions and manufacturer limitations. Confirm the correct PSC FingerSaver™ version for the approved application.
Conduct a Controlled Demonstration
Demonstrate tool inspection, correct grip, positioning, hand distance, hammer clearance, communication, stop-work conditions and post-use inspection. Workers should practise the complete sequence under supervision.
Update the Risk Assessment and Procedure
After approval, update relevant documents such as:
- Risk assessments
- Job safety analyses
- Standard operating procedures
- Work instructions
- Toolbox talks
- Training records
- Pre-use inspection forms
- Shutdown planning documents
Frequently Asked Questions About Striking Tools
What are striking tools?
What is the difference between striking tools and struck tools?
What hazards are associated with striking tools?
How can hand injuries from striking tools be prevented?
What is the hammer impact zone?
Are gloves enough for striking tools safety?
Why should mushroomed struck tools be removed from use?
What PPE should be used with striking tools?
What is a no-touch striking-tool holder?
How does PSC FingerSaver™ support safer hammering?
Conclusion: Create Distance Before the First Strike
Striking tools remain necessary for many industrial maintenance, fabrication, bolting and assembly tasks. However, the supporting hand should not be treated as the only available way to hold a chisel, punch, drift pin or slogging spanner.
Missed strikes, glancing blows, damaged tools and unexpected movement can place fingers directly in the impact path. Inspection, training, correct hammer selection and PPE remain essential, but the strongest practical improvement is often to create physical separation.
PSC FingerSaver™ supports a no-touch approach by helping workers hold selected struck tools from a more distant control point.
Keep Hands Away from the Hammer Impact Zone
Explore PSC FingerSaver™ and strengthen your no-touch approach to approved industrial striking operations.