Top 9 Do’s and Don’ts of Tool Tethering

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Tethered equipment on leg of worker

The main objective of a safety engineer in setting up proper tethering procedures is to ensure that everything is in proper balance. This means the tool, recoil/retraction force, and application are stable.

When using the tool in an extended manner, it is necessary to only use minimal force. This will cause fatigue on the worker. On the other hand, it will not result to a kick when retracted.

With proper tool tethering, there is minimal danger of entanglement, annoyance, and fatigue while maximizing worker output and satisfaction.

Having said that, following are the top Do’s and Don’ts of tool tethering to keep in mind:

The Do’s of Tool Tethering

  1. Verify the tether’s integrity before you set out to use it. Check for signs of fatigue or excessive wear. If you are in doubt, replace the tether. This will help keep you away from accidents in case your doubt is proven positive.
  2. Verify the attachment point of the tool to make sure that it is durable enough to handle the tool for the tether’s full drop distance.
  3. Weigh the tools you will be using. This way, you can choose a properly rated lanyard for the particular application. It is never a good idea to assume the tool’s weight by feel alone.
  4. Make sure to anchor all tools that weigh in excess of 10 lbs. to a structure, and not to a person.
  5. Always make use of a lanyard that is properly rated for the particular tool’s weight. It is important that the lanyard is designed to have at least a 25% margin for a drop at full extension.
  6. Use a tether with a quick release feature whenever you are using a number of small tools for a particular application.
  7. Whenever possible, use a retractable tether in case you need to use multiple tethers at the same time. This way, you can prevent possible entanglement problems.
  8. Always use lanyards with as low stretch force as possible at full extension. Just make sure they have the right recoil degree for both the application and the tool.
  9. Whenever possible, shift the shock load from a person to a sturdy structure.

Whenever you are in doubt, always check with a reputable safety expert. Do not make any assumptions as this may endanger lives.

Equipment Tethering Don’ts

  1. Never use a tether that has a lower weight limit that the tool you are tethering.
  2. Never tether a tool to a person if the tool weighs more than 10 lbs.
  3. Avoid tethering tools to a person if you aren’t sure about their impact on the person’s PFP (Personal Fall Protection) devices.
  4. Refrain from attaching a tether to a structure if you are unsure about the anchor point’s shock load capability and strength.
  5. Never use lanyards or tethers that require extreme force for full extension. This may only result to possible muscle injuries and lower worker output.
  6. Avoid modifying the lanyard in any manner. This includes replacing or removing the lanyard’s components like side release disconnect clips or shock absorbing components as this may negatively affect the lanyard’s load rating.
  7. Avoid customizing the tool lanyard such as equipping it with hardware that don’t have the load ratings appropriate for the tool. For example, a key ring is often used as a tool attachment point. But, it will often not work for heavier tools that weigh over 1 lb.
  8. Never assume that any particular tool tether is fool proof. What MAY go wrong, WILL go wrong. This is particularly true in the workplace.
  9. It is never a good idea to use a tool lanyard as a Personal Fall Protection (PFP) lanyard. Both are safety tools, but they must be used properly.

Bear in mind that a tool tether won’t break away against a person’s weight. Thus, you should never use a tool tether if there is a possibility for machine entanglement.     

Tool tethers are designed to protect the workers and their tools, as well as the work environment from falling objects. Accidents happens. But, they are always avoidable. Following the do’s and don’ts of tethering provided in this post will help minimize accidents in the workplace, while at the same time promoting worker productivity.

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How Tool Tethering Products Keep Your Workers Safe

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Dropped objects do not just pose a hazard to workers and other people on the ground, but also those working at height. Workers can fall when a tool drops and they reach out to catch it.

Dropped objects can also result in financial losses. These can be due to damage caused by the falling object as well as lost productivity resulting from stopped work. Therefore a tethering policy should be implemented.

There are three steps in choosing the appropriate tethering product:

What is the weight of the tool?

Lighter tools weighing less than 2lbs should use tethers that can be attached to the individual. These may be attached to belts or harnesses and have retractable tethers, or be attached to their wrist.

More substantial tools weighing up to 25lb should have a tether that is attached to a structure using an anchor strap. These allow the tools to be used within a specified working radius while still ensuring that they remain secured.

Will the tether be used for single or multiple tools?

If only a single tool needs to be secured, you can use a fixed lanyard system. Otherwise, you should use a clip system or lanyard that can quickly be released so that you can easily change tools.

What is the attachment point?

If the tool has a lanyard, you can attach the tether to it or attach a ring to the lanyard. You can also use shrink wrap to connect rings to tools with small ends. For tools with large ends, you can loop the lanyard around it, and then cinch it tightly so it will be secure.

If there is no way to attach a tether to the tool, then you will have to get a custom tethering solution for it. 

Here are some of the best practices that must be followed for personal tool tethering.

  • Make sure that the tether you use is rated for the tool you will attach it to. If you are unsure of the tool’s weight, weigh it to be sure. Never try to estimate the weight just through feel.
  • Make sure that you confirm the integrity of the tether through visual inspection and testing. Don’t use tethers that seem to have excessive wear.
  • Make sure that the attachment point is strong enough to support the tool in case it drops.
  • Make sure that the tether has very low stretch force when it is at full extension. This is to avoid accidents since a tether with high stretch force may still cause injury if the tool hits a person.
  • Make sure that tools weighing over 10lb are anchored to a structure, and not a person. This is to avoid accidental falls in case the tool is dropped.
  • If you are using multiple tethers, use ones with retractable lanyards to ensure that they don’t get entangled.
  • Whenever possible, make sure you transfer shock loads to a structure rather than a person.
  • Only use the tether as is without modifying it in any way. Modification may threaten the integrity of the tether and make it less effective in case a tool is dropped.
  • Don’t use hardware with the tether that does not have the proper load ratings. For instance, do not use keychain rings as attachment points, since these can only handle weights of around 1lb.
  • Don’t use tethers in situations where there is a risk they may become entangled in machinery. These tethers are not designed to be breakaway in case of accidents.
  • If you tether a tool to a structure, make sure that it is strong enough to not break in case the tool is dropped.
  • Avoid using tethers that require too much force to fully extend, since these will cause worker fatigue, reduced productivity, and potential muscle injury.
  • Don’t take the tether for granted. You should not automatically assume that it is foolproof in case a tool is dropped.
  • If you tether a tool to a worker, make sure it does not adversely affect their personal fall protection equipment. 
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4 Reasons Why You Need an Effective Tool Tethering Policy

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Tool tethering policy is a set of safety rules that you apply in work at height areas. This is where you require all workers, including yourself, to use tool tethering devices when working at height.

Tool tethering is securing or attaching handheld tools to workers or specific anchor points around the workplace. It involves the use of fall-arrest tethers, lanyards, and other accessories. These tethers prevent tools from falling on people or objects when dropped below.

There are four main reasons why you need an effective tool tethering policy in your workplace. Read about them below.

Implementing an Effective Tool Tethering Policy

Tool tethering minimizes the dangers related to falling objects.

There are always risks associated with working at height. This job involves the use of portable yet heavy tools that are potentially dangerous when dropped from a height.

The danger is not only limited to workers. It can stretch to unknowing bystanders, nearby mechanical equipment, and breakable structures. Depending on the distance and weight of the object, falling tools can cause injuries (or fatalities) and structural damage.

Hammers, in particular, are one of the most straightforward tools used in works at height. However, it is also one of the most dangerous objects to drop from a height. If it falls on someone’s head, it can cause serious head injury, or worse, death.

With the use of appropriate tethers, tools won’t fall on someone or something when dropped. That is why a tool tethering policy is crucial in works at height.

Tool tethering is required by regulation.

Occupational Safety and Health Administration (OSHA) requires work at height companies to have a tool tethering policy in place.

According to the Bureau of Labor Statistics, more than 50,000 cases of falling objects-related injuries are reported to OSHA every year. That is why tool tethering is strictly required and regulated by OSHA to help reduce the number of such cases.

By regulation, OSHA requires that:

  • Work tools and materials must be secured to prevent them from falling on people below.
  • Hazardous areas must be barricaded to prevent people from falling off those areas.
  • Warning signs must be posted where necessary to inform people about the hazards.
  • Toeboards and protective screens must be placed around guard rails and scaffolds. These can stop or arrest dropped objects or materials when they fall.
  • Debris nets, canopies, and catch platforms must be placed around the area. These help to deflect or stop debris and materials from falling on people.

If companies fail to enforce tool tethering policies in their workplaces, OSHA can cite them under the “General Duty Clause.” That’s why some companies are very strict with their tool tethering policies and even fire workers who disobey and drop tools.

Tool tethering minimizes the costs associated with injuries and damages caused by falling tools.

Inflicting physical injuries and damages not only causes trouble for the affected people. It can likewise cost the company a lot of money. Compensation for injuries and damages can range from hundreds to thousands of dollars per victim.

By making sure that your workers comply with your tool tethering policy, you can minimize incidents of falling tools. Thus, you also reduce the chances of causing injury or damage to others that require compensation.

Tool tethering helps you keep your people and reputation safe.

Your workers’ outlook can affect your company’s reputation. 

If you keep your workers safe by tethering tools, your workers will know that you care about them. This encourages positive thoughts about your company. However, if you don’t prioritize safety in the workplace, workers will complain and affect your company in a negative way.

By enforcing a tool tethering policy, you encourage a safer working environment that your workers will like. And when workers like you, the public (and OSHA) also will.

How to Ensure an Effective Tool Tethering Policy

The biggest challenge in enforcing a tool tethering policy is how to keep it effective. There are specific issues that can make your policies ineffective, such as negligence and improper use of tool tethers.

To maintain an effective tethering policy, everyone must follow these safety guidelines:

  • Workers themselves should ensure that protective barriers are placed where needed.
  • Workers should practice the proper use of tethering devices and inspect them regularly before use.
  • Workers should take extra care in using tools and disposing materials from a height.
  • Workers must avoid placing unsecured tools against nearby structures or over barricaded areas.

The effectiveness of a tool tethering policy, therefore, starts with the people involved. By training workers in proper tool tethering, you can promote a safer workplace for everyone.

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