Ergonomic hand tools are an engineering control designed to minimize awkward and forceful hand exertions, and still maximize performance and work quality.  Such hand tools may include, for example, non-slip and soft handles, lightweight handle materials, operating mechanism that reduce the force required, or handles and grips sized to minimize forceful gripping or awkward wrist postures.

Ergonomic hand tools are designed to minimize awkward and forceful hand exertion.  The American Industrial Hygiene Association recommends that hand tool selection maximize performance and work quality, while minimizing physical demands placed on the worker.

Desirable hand tool features that make the tool more ergonomic:

• Grip Material
  • non-slip, soft material
  • a sleeve can be used to cover hard handles, but be cautious because a sleeve adds to diameter and/or grip span of the tool (see below for diameter/grip span recommendations)
  • make sure the sleeve fits snugly so that the tool doesn't slip out of the sleeve while someone is working.
• Handle Material
  • Lightweight material, such as titanium
  • In an impact tool, like a hammer, select a material that will transfer less recoil shock, such as titanium
• Operating mechanism
  • Select spring-loaded handles that automatically return t an open position for pinching, gripping or cutting tools.
  • Clamps, grips, or locking pliers can be used for tasks that require continuous application of force
• Handle diameter for single-handed tools, such as a screwdriver
  • Between 1.25 and 2 inches for power tasks (high force)
  • Between 0.25 and .5 inches for precision tasks (low force)
• Grip span for double-handled tools, such as pliers
• For power tasks (high force)
• Closed grip span at least 2.0
• Open grip span less than 3.5
• Spring loaded handles are preferred
• For precision tasks (low force)
  • Closed grip span at least 1.0
  • Open grip span less than 3.0
    spring-loaded handles are preferred
  • Handle length - longer than the worker's hand width
  • Handle shape –
    • Avoid finger grooves and sharp edges
    • Select a handle that helps to keep the wrist straight
      • For horizontal forearm motions a bend handle works well
    • For vertical movements a straight handle is usually the best choice.

The California Division of Occupational Safety and Health website and NIOSH's Simple Solutions report both have some useful guidelines for hand tool selection that include many pictorial examples. 

Using the appropriate tool with ergonomic features can improve productivity because workers may be able to complete tasks more quickly and with less mistakes. This increased productivity may be due to reduced muscle fatigue, fewer mistakes, the ability to use more powerful gripping positions, and less lost time due to worker musculoskeletal illnesses.

Although it is generally a good idea to have soft handles because it reduces grip force requirements and prevents slipping, in some situations a soft handle may increase risk. In particular, if small shards of glass or metal are present in the work environment then it is possible for those shards to become lodged in the soft handle material and cut workers.

Make sure that if you add a soft sleeve to a handle that the handle diameter is still no more than 2 inches. Also make sure that the sleeve does not slip on the handle.

Dan Anton, PT, PhD, ATC; Zack Sinner, SPT; Neil Morris, SPT – Eastern Washington University

• Structural Steel
  • Dismantle or demolish metal structures
    • Stressful hand & wrist activity
  • Drill, grind and saw materials
    • Hand-Arm Vibration
    • Stressful hand & wrist activity
  • Fabricate metal structures in shop and field
    • Hand-Arm Vibration
    • Stressful hand & wrist activity
  • Weld, plasma cut, air-arc and flame cut metal
    • Stressful hand & wrist activity