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.
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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.
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 IS 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.
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.
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.
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.
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)
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.
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.
No. Galvanized steel is not considered as non sparking material or alloy. It will produce frictional sparks when stuck with another metal/hard surface.
Non Sparking Tools are also sometimes referred to as non magneticbecause 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).
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 -() which was constituted on January 29, and later re-affirmed in . The second is FM Approval (USA) i.e. FM . 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 Standard)
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 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.
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.
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.
There, certain recommended practices for use of Non-Sparking Hand Tools which are as follows:
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 Standards). A Copper Titanium Non-Sparking tool will pass that standard and will probably break at 900~ Nm with is ~50% more than the qualifying torque, whereas a steel tool can take up ~ 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.
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.
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.
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.
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
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.
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.
According to the Directive /92/EC, steel tools are considered a source of ignition and therefore not safe to be used in the presence of an explosive atmosphere. In such environments, it is mandatory to use non-sparking tools.
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However, based on our experience in the global industrial sector, there are still many procurement, maintenance and even safety professionals who are still not fully familiar with what non-sparking tools are and what are the key criteria to use when procuring or using such tools.
The most common non-sparking alloys are Aluminum - Bronce (Al-Bron) and Copper – Beryllium (Cu-Be), but what should be the criteria when choosing one option or the other?
The type of gas in the environment
Despite its name, non-sparking tools do generate a spark (friction between all metals generate a spark). The difference between non-sparking tools and normal steel tools is the energy of the spark they generate.
They key objective to avoid an explosion is therefore for the energy of the sparks to be lower than the ignition point of the gas in the atmosphere.
In order to make sure that the right non-sparking tool is used, the first step is therefore to understand what kind of gas will be present in the atmosphere.
Gases are classified into four main groups as seen in the following table. The gases in group IIC are the most dangerous ones since they have the lowest ignition point.
Sparks generated by the Cu-Be non-sparking tools are the ones with the lowest energy level, and as a result, are the safest ones to be used across all gas groups (I, IIA, IIB and IIC).
The only exception is in the presence of Acetylene, in which case, both Al-Bron and Cu-Be tools would not safe due to the high amount of copper in their composition (copper reacts with the Acetylene gas to form highly explosive particles called acetylides). For safe operations in the presence of Acetylene gas, EGA Master has developed a proprietary alloy called ACETILEX®, which has less than 65% of copper in its composition.
Frequency of use
Even if Cu-Be non-sparking tools are the safest option, their purchase price is higher than that of Al-Bron tools. In the presence of group IIC gases there is no safe alternative to Cu-Be tools, however, Al-Bron tools could be a viable alternative when working in the presence of gases in groups I, IIA or IIB.
The key factor to be considered in such cases is the frequency of use of the non-sparking tools, mainly since Al-Bron tools are softer and therefore break easier (see table below).
If you use non-sparking tools frequently, Al-Bron tools may actually represent a more expensive option over time considering the replacement costs over time.
Certification
As with all safety critical products, trust is key.
If the energy of the spark generated by the non-sparking tools depends on the material composition of the tool, any variation of the material composition would have a direct impact on the energy levels of the spark generated.
In order to be 100% confident that the tool purchased and used will no generate a spark that will reach the ignition temperature of the gas, it is recommended that procurement managers request manufacturers to provide a third party certification of the material properties of the tools against the requirements of the Directive /92/EC.
Such a certificate is not related to the management systems of a company (e.g. ISO or ISO ) or to the mechanical properties of the tool (e.g. against DIN standards). A certification of the material properties focuses on the material composition of the tools, to ensure that the energy levels of the sparks generated are those that are considered safe to be used in the presence of the different gas groups.
Like with any certification, it is recommended that such a test is carried out by an independent third party (to avoid any conflicts of interests). The German Federal Institute for Materials Research and Testing (BAM) is one of the best-known laboratories approved by the European Union to certify according to the Directive /92/EC.
Marking of the alloy on every tool
Al-Bron and Cu-Be tools have similar colors and are therefore difficult to differentiate. Considering that choosing the right alloy is such a critical step to ensure safety, it is highly important that those procuring and using the products are 100% sure that they chose the right one.
The only way to achieve that is by having the allow laser marked on every non-sparking tool. This is the only way to ensure that the manufacturer has delivered the right alloy, and that the field teams take the right tools when starting their shifts.
EGA Master offers the widest range of BAM certified Al-Bron and Cu-Be non-sparking tools. EGA Master also marks the alloy on 100% of its non-sparking tools! Check the range here!
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Non-sparking tools: Learn the basic concepts and be safe!
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