You know that trusty drill you’ve had since your apprenticeship? Or that hammer that’s been with you on every job site for the past decade? We Aussies tend to hang onto our tools – they’re like old mates, reliable and familiar. But here’s the thing: just because a tool still works doesn’t mean it’s still safe to use.

Whether you’re a tradie who lives by your kit or a weekend warrior having a crack at some DIY project, knowing how to properly check your tools can be the difference between a job well done and a trip to the emergency ward. Let’s walk through the easiest ways to make sure your old tools are still up to scratch.

Why Safety with Tools Really Matters

Think realistically for a second: how many of us have ever seen someone use some dodgy tool? Maybe it’s one that has a cracked handle that is basically held together with electrical tape, or maybe it’s a frayed power cord that has seen much better days. Sure, it might get you through the job today, but is it worth the risk?

According to workplace safety data, thousands of tool-related injuries happen every year across Australia, and many could’ve been prevented with a simple inspection. We’re talking cuts, crush injuries, electrical shocks, and worse. Plus, if you’re running a business, using faulty tools can land you in hot water with WorkSafe – not to mention the insurance headaches if something goes wrong.

The Two Types of Tools You Need to Check

When it comes to safety checks, your tools generally fall into two camps: electrical tools and hand tools. Each has its own inspection requirements, so let’s break it down.

Electrical Tools: Testing and Tagging Requirements

If you’re working in construction, manufacturing, or basically anywhere that’s not your own home workshop, there’s a good chance your electrical tools need to be professionally tested and tagged. This isn’t just a “nice to have” – in many Australian workplaces, it’s the law.

Here’s what you need to know about testing and tagging:

What needs testing?

Most electrical equipment rated under 20 amps needs regular testing. This includes your power drills, angle grinders, circular saws, extension leads, and basically any tool you plug into a power point.

How often?

The testing frequency depends on your work environment:

• Construction and demolition sites: Every 3 months
• Manufacturing and factory work: Every 6 months
• Office environments where equipment moves around: Every 12 months
• Low-risk environments: Up to every 5 years

Who can do it?

Only a competent person can test and tag equipment. In Queensland and other states, this means someone who’s completed proper training (like the UEERL0003 unit) and has the knowledge and experience to do the job properly. If you’re offering testing services to other businesses, you’ll need the appropriate electrical contractor licence.

What happens during testing?

A proper test and tag involves both a visual inspection and electrical testing to check things like earth continuity, insulation resistance, and polarity. If your tool passes, it gets a tag showing when it was tested and when the next test is due. If it fails, it should be immediately taken out of service and tagged as faulty.

The colour-coded tag system (red, green, blue, yellow) helps you quickly spot whether a tool’s test is still current. This is especially important on busy construction sites where dozens of different workers might be using shared equipment.

Hand Tools: Your Daily Inspection Checklist

Now, your hand tools – the spanners, hammers, screwdrivers, and chisels that make up your everyday tool kits – don’t need formal testing and tagging. But that doesn’t mean you can ignore them. In fact, hand tools for mechanics and tradies take an absolute beating, and regular checks are crucial.

Here’s your simple inspection routine:

Hammers

• Check the handle isn’t cracked, chipped, or split
• Make sure the head is firmly attached and not loose
• If you see tape on the handle, that’s a red flag – it probably means it’s broken and needs replacing, not a quick fix
• Look for mushrooming on the striking face, which can send metal fragments flying

Screwdrivers

• Inspect the handle for cracks or chips
• Check the tip isn’t worn, rounded, or damaged
• Make sure the shaft isn’t bent
• Never use a screwdriver as a chisel or pry bar – that’s asking for trouble

Wrenches and Spanners

• Look for cracks, chips, or excessive wear on the jaws
• Check they’re not bent out of shape
• A worn or damaged wrench can slip off bolts, causing nasty hand injuries

Chisels and Punches

• Watch out for mushroomed heads – these can shatter under impact
• Check the cutting edge isn’t too worn or damaged
• Make sure there are no cracks in the metal

Pliers and Cutters

• Check the jaws align properly and aren’t worn
• Make sure the pivot point isn’t loose
• Look for cracks or damage to the handles

Power Tool Cords and Plugs

• Inspect for fraying, cuts, or exposed wires
• Check the plug prongs aren’t bent, loose, or missing
• Make sure the cord isn’t kinked or damaged near the plug
• Feel for any unusual heat when the tool’s running

The ‘Tape Test’ – Just Say No

Here’s a hard truth: if you’ve taped up a broken tool handle, you’re kidding yourself. Tape is not a manufacturer-approved repair method, full stop. It might seem like a quick fix, but it compromises the tool’s integrity and puts you at risk. If a tool needs tape to hold together, it needs replacing.

The same goes for improvising with tools – using a screwdriver as a chisel, a wrench as a hammer, or pliers as vice grips. Every time you use a tool for something it wasn’t designed to do, you’re rolling the dice. It might work fine 99 times, but that 100th time could cost you a finger.

Trade Tools and Mechanics’ Special Considerations

If you’re working in the automotive trade or as a mechanic, your hand tools for mechanics face some unique challenges. You’re dealing with tight spaces, heavy components, and lots of torque. That means:

• Impact wrenches and sockets need special attention – look for cracks in the sockets and wear on the drive ends
• Trolley jacks and jack stands are critical safety equipment – inspect them every single time before use
• Oil and grease can make tools slippery and hide damage, so keep them clean
• Check your toolbox or roller cab for rust or damage that could affect your tools

Setting Up a Simple Inspection Routine

The secret to keeping your tools safe isn’t doing one massive inspection once a year – it’s building quick checks into your daily routine. Here’s how:

Before every job:

• Do a quick visual check of the tools you’ll be using
• Test power tools briefly before starting work
• If something looks or feels off, don’t use it

Weekly (for heavy users):

• Spend 10 minutes giving your most-used tools a proper once-over
• Check power cords and plugs carefully
• Test your safety switches

Monthly:

• Go through your entire tool collection systematically
• Clean tools properly so you can spot damage
• Check your storage is keeping tools dry and secure

When you notice something:

• Don’t ignore that weird noise or vibration
• Act on your gut feeling – if it doesn’t feel right, it probably isn’t
• Remove dodgy tools from service immediately

What To Do With Failed Tools

So you’ve found a tool that’s not up to scratch – what now?

For electrical tools that have failed a test, they need to be tagged as unsafe and taken out of service immediately. Don’t just stick them in a drawer – make sure no one can accidentally use them. Depending on the issue, they might be repairable by a licensed electrician, or they might need to be properly disposed of.

For hand tools, assess whether repair is possible and economical. A quality tool with a damaged handle might be worth repairing, but a cheap tool that’s worn out is probably better replaced. Consider the cost of a new tool versus your safety – it’s not even close.

Never try to modify tools yourself to “fix” them. That bent wrench might seem fine if you bend it back, but you’ve compromised the metal’s integrity. Same with grinding down a mushroomed chisel head yourself – you need the right equipment and knowledge to do it safely.

Storage: The Unsung Hero of Tool Safety

Here’s something a lot of people overlook: how you store your tools affects their safety just as much as how you use them. Tools left lying around on the floor, thrown loosely in a ute tray, or stored in damp conditions are going to deteriorate faster.

Good storage means:

• Keeping tools dry to prevent rust and corrosion
• Protecting cutting edges and sharp points
• Preventing tools from getting damaged by other tools
• Making it easy to spot when something’s missing or not returned properly
• Keeping electrical cords properly coiled, not kinked

A decent toolbox or wall storage system isn’t just about organisation – it’s about keeping your investment safe and ensuring your tools are ready to work safely when you need them.

The Bottom Line

We understand that tools are expensive, and nobody wants to chuck out something that’s “still got a bit of life left in it.” But the truth is that a good tool inspection routine does not involve chucking it all in at the first sign of wear. It means catching problems before they become dangerous, maintaining your gear properly, and knowing when something genuinely needs replacing.

Think of it this way: your tools are how you make your living. If you’re a tradie, they’re essential to your business. If you’re a DIY enthusiast, they’re your way to save money on home maintenance, your creative outlet, or both. Either way, they deserve proper care and respect.

The easiest way to check if your old tools are still safe? Make it a habit. Do quick checks regularly, pay attention to warning signs, and don’t cut corners when it comes to testing and tagging requirements. Your future self – and your fingers – will thank you. 

At Norva Tools, we are dedicated to ensuring that Australian tradies, mechanics, and serious DIYers can get on with the job safely and efficiently. Whether it’s a first tool kit build-up or just replacing worn-out trade tools, we stock quality gear that will last. But even the best tools require proper maintenance and safety checks.

Stay safe out there, and remember – if you’re not sure about a tool’s condition, don’t use it. It’s always better to be safe than sorry.

FAQs

How do I quickly check if an old tool is still safe?

Do a quick visual once-over before each use. Check for cracks, loose parts, frayed cords, or dodgy handles. Give it a shake – if anything rattles or feels loose, don’t use it. For power tools, test them briefly before starting work. Trust your gut; if something feels off, it probably is.

What damage should I look for before using an old tool?

Watch for cracked or split handles, loose tool heads, mushroomed striking surfaces, worn jaws or cutting edges, frayed power cords, bent shafts, and rust. Also, check that plugs aren’t damaged and electrical tags are current. Any tape holding things together is a massive red flag – that tool needs replacing, not a dodgy repair.

Is a rusty tool still safe to use or should I replace it?

Surface rust you can clean off is generally fine, but deep rust that’s pitting the metal or compromising structural integrity means it’s time to replace it. Rust weakens any tool and can cause it to fail under load. For that reason, clean them regularly and store them properly to prevent rust in the first place.

When is it better to discard an old tool rather than repair it?

If the repair costs more than half the replacement price, bin it. Also, chuck it if there’s structural damage like cracks, bent metal, or compromised handles. Never try repairing anything that affects safety – mushroomed heads, damaged electrical components, or weakened striking surfaces. Cheap tools generally aren’t worth repairing; quality ones sometimes are.

How often should I inspect my tools at home or in the workshop?

Quick visual check before every use. Do a proper inspection weekly if you’re using tools daily, and monthly for occasional users. Power tools need professional testing and tagging every 3–12 months, depending on your work environment. Basically, the more you use them, the more often you should check them properly.