By John Lowrey

Redesigned tools for lineworkers cut down on bodily wear and tear

When lineworkers hit their 40’s, many already feel job related wear and tear. It’s hard to find a mature lineworker who doesn’t suffer a back, knee, shoulder or carpel tunnel problem. That’s right- carpal tunnel is not a problem exclusive to keyboard pounding desk jockeys. But new tools and innovative lineworkers are making their jobs safer, more productive and easier on the joints, muscles and tendons.

Huskie Tools (www.huskietools.com) an early developer of ergonomically designed power tools for lineworkers, is producing its fifth generation of battery-operated crimping and cutting tools.

“We are talking about the fifth most dangerous job in America,” says Larry Kotars, national sales manager for Huskie Tools. “We need to work smarter, not harder,” he says. “The foreman who is reluctant to convert to new tools and techniques simply because ‘ this is how it has always been done’ is not only a poor leader but also costs the co-op time and productivity.

Using a battery-operated or hydraulic crimping tool can prevent the white-knuckle syndrome created by the 35 to 60 hand pumps necessary with a conventional 12-ton manual crimping tool. A normal job with multiple crimps may require 1,000 pump strokes, and lineworkers often are required to stretch or contort in awkward positions working from a bucket, pole and ladder or in a trench.

He admits that Huskie’s MD-6 battery operated crimping tool is 10 times more expensive than a wooden-handle crimping tool. But he says that the payback is often within nine months.

“Medical expenses form a blown elbow can hit $50,000,” Kotars notes. “We don’t make disposable tools. Utilities shouldn’t consider their lineworkers disposable, either.”

Kotars says 90 percent of all utilities have at least one battery-operated crimping tool. “The problem is they have just one per supply room. There may be 60,000 line trucks across America, but only 10,000 have a power-crimping tool, your crews will fight over it all the time.”

Huskie’s crimping tools also come with optional cutting heads. A quick-release pin allows the lineworker to change between compression and cutter head in a minute. A bypass cartridge pre-set at the factory ensures a consistent compression every time. Hand operated compression tools can leave the integrity of the crimp suspect, say Kotars. “It’s kind of like driving on a tire without enough air. Sooner or later, it’s going to pop.

Kotars also recommends co-ops consider Milwaukee’s impact wrenches. “Milwaukee has the best. You can put the sockets on and take deadbolts off all day long, “ he says.

This article is a shortened version of the original published article in Rural Electric Magazine Dated April 2004. Any reprints must have Rural Electric Magazines permission.

By Larry Kotars
Regional Sales Manager, Huskie Tools, Inc.

(From an article that appeared in the June 1998 issue of Utility Safety.)

Whether you are the worker using the tool or the person responsible for providing the right tools for your crew, ergonomic hand tools can provide healthy, long-term benefits for all. Selecting the right tool for the job not only increases efficiency, but also reduces the risk of injury.

Historically, a utility crew would have to head out to the work site with four employees, survey the situation, and have the lights back on within the hour. Over 750 products were on their truck so that the crew could make choices in order to resolve any type of problem they encountered. In today's world, that same call is handled by just one or two workers with only about a third of the problem-solving product on their truck. The workforce has certainly become more efficient, but are they working safer by selecting the proper tool for the task at hand?

Safety in the utility field is much like insurance for your car. Everyone thinks, "I won't have an accident, so why do I need insurance?" The majority of workers assume nothing will happen to them and they will remain safe and healthy. In reality, accidents and injuries do happen all too often. In an effort to reduce injuries on the job, utility companies hire employees with titles of Ergonomic Specialist, Tool Specialist, and Safety Manager. Now more than ever, companies are addressing safety concerns. Insurance underwriters, carrying large insurance premiums on utilities, are dictating that safety is more than just "keeping your shoes tied."

A Perfect Fit

Management and technicians have increasingly become aware of the benefits of using ergonomic power tools. Muscle strain, over-reaching, awkward positioning, sudden jarring and repetitive exertion can be avoided by simply choosing an ergonomically designed tool as opposed to a tool without the specialized design considerations.

In order for an ergonomically designed hand tool to provide the proper protection, it must fit correctly. Several considerations come into play when choosing the proper tool. For instance, the handle of the tool must distribute pressure evenly across the palm of the hand. This allows the worker's wrist to remain straight. Additionally, the tool must be designed to provide the required force necessary to perform the task at hand. Minimizing hand and arm vibration, reducing repetitive motion, and avoiding awkward positions are all requirements in properly fitting tools.

The selection and fitting process is easy, as tools come in varied weights and designs to accommodate virtually every utility worker's need. Cable cutters, crimpers and other ergonomically designed tools will make the job safer and easier to perform.

One example of how an ergonomic hand tool can increase productivity can be found in the use of battery-operated, ergonomic crimpers. When two electric lines must be fastened together, the lines are often tied together with a crimp connector. Traditionally, the crimp connector is secured to the wires by using a large, bulky, manually operated crimping tool. These types of crimping tools have led to strains in workers' arms and shoulders. At the same time, they are much slower to work with. Workers using the battery-operated crimping tool greatly reduce discomfort, risk of injury and increase productivity. As one worker claimed, "I made 29 splices with just a squeeze of my trigger finger!" The work is healthier, and management is happy about so much being accomplished in so little time.

Understanding Repetitive Stress Injuries

A clear understanding of the potential for injury and what actually occurs creates awareness. This can cause individuals to alter their behavior and avoid such occurrences. Carpal tunnel syndrome is the most common and disabling type of repetitive stress injury. Cumulative Trauma Disorder (CTD), Occupational Overrule Injury and carpal tunnel syndrome are all forms of work related musculo-skeletal disorders. These types of injuries cost American companies millions of dollars a year in lost work time and workers' compensation claims.

A combination of three factors causes CTDs. They are force, repetition and bad posture. All three can result in sudden injuries such as sprains, or slow-developing injuries such as carpal tunnel syndrome. The greatest risk occurs when a task or tool that requires a combination of force and precision is performed or used repeatedly without sufficient time for the body to rest.

It is critical that the worker remembers to keep the work-focus within their comfort range. A person can reduce their risk of CTD by protecting their joints. Extending a joint until it simply can't go any farther and "locking" it should always be avoided. Working in such an extreme position not only feels awkward, but this action can over-stress muscles, pull tendons and reduce power. Keep the work within easy reach to avoid stretching, twisting and bending beyond a safe range of motion.

Knowledge is power

Understanding the basics of ergonomics and the value in selecting a properly fitted tool will make you a much safer and efficient employee. Safety must be the choice of every worker as they are the ultimate benefactors. Ergonomic hand tools enable the worker to work smarter and not harder.