CHAPTER 40 POWER TOOLS – EXPLOSIVE

40 POWER TOOLS – EXPLOSIVE Blow-Through – When the base material does not
offer enough resistance, the fastener may pass
completely through and fly out the other side. This
Explosive-actuated tools use an explosive cartridge
is particularly dangerous when fasteners penetrate
or gas discharge to fire a fastener into hard
walls, floors, or ceilings where others may be
materials such as concrete, mild steel, and masonry
working. If necessary, keep areas behind, around,
(Figure 40-1). Used improperly, explosive-actuated
and under material clear of people. Fencing or
(or powder-actuated) tools pose obvious hazards.
barriers should be erected to prevent people from
The tools should be treated with the same respect
entering these areas.
as a firearm. Most jurisdictions—including Ontario—
require that operators be trained before using the
tools and carry proof of training on the job. Protective Equipment
In addition to the standard personal protective
equipment (PPE) required on construction projects
(see the chapters on PPE in this manual), the
operator of an explosive-actuated tool should
wear hearing protection, eye protection, and a face
shield. Heavy shirts and pants also provide some
protection against ricochets and flying fragments
of material and fasteners.
Figure 40-1: Explosive-Actuated Tools

Tool Types
Hazards High-Velocity Tools – High-velocity explosive-
Flying Particles – This is the major hazard. On actuated tools use the expanding gases from the
impact, materials may break up, blow apart, or spall exploding cartridge to propel the fastener. The
off. This often happens when fasteners are fired too gases push directly against the fastener. These
close to a corner of masonry or concrete or when tools are rarely used in construction, except in
they strike materials such as glazed tile, hollow tile, special cases to penetrate thick steel or very hard
or thin marble tile. material—they are usually used in military, salvage,
or underwater applications. No one should operate
Ricochets – These usually result when the tool is
high-velocity tools without special training.
not held at right angles to the base material, or
the fastener hits a particularly hard material such Low-Velocity Tools – Most explosive-actuated
as stone or hardened steel. Always check the type tools used in construction are low-velocity. The
of material to ensure that it can safely accept the expanding gases from the exploding cartridge push
fastening device. against a piston, which in turn drives the fastener
into the base material (Figure 40-2).
Noise – Explosive-actuated tools create an extreme
pulse of sound when fired. This can create a noise
hazard. The new Noise regulation (381/16) requires
employers to asses the risk to workers of noise
exposure and provide adequate controls to protect
them. Hearing protection devices such as earplugs
or earmuffs may be used if no other controls are
appropriate. Operators of the explosive-actuated
tool must be protected from noise as well as other
workers in the area—especially when the tool is Figure 40-2: Low-Velocity
operated in a confined space. Explosive-Actuated Tool

Sprains and Strains – These injuries usually result

Many different low-velocity tools are available, from
from using the tool repeatedly in awkward,
single-shot models to semi-automatic models using
cramped, or unbalanced positions. Operators
multiple cartridges in strip or disk holders. Some tools
should try to work from a balanced position on a
are specific to one size of fastener or type of cartridge.
solid surface.
Most can be fitted with various pistons, base plates,
Explosions – There is always the risk of explosion spall stops, and protective shields for different jobs.
or fire when the tools are used in atmospheres
contaminated by flammable vapour, mist, or dust.
The work area must be ventilated—mechanically if
necessary.

Tools and Techniques 40-1

POWER TOOLS – EXPLOSIVE

Tool Components
Pistons
Specialized pistons are available for different
fasteners. Such pistons are designed for the fastener
and should not be used with other types. Misusing
Figure 40-3: Types of Pins
a tool with a specialized piston can result in under-
or over-driven fasteners or fasteners that leave the Studs – These are fasteners consisting of a shank
barrel misaligned, leading to ricochets. Some general- that is driven into the base material and an exposed
purpose tools can take various types of pistons. portion to which a fitting or other object can be
attached (Figure 40-4). The exposed portion may
Fasteners be threaded for attachments made with a nut.
Fasteners used with explosive-actuated tools Studs are also available in an eye-pin configuration
are made of special steel to penetrate materials for running wire through the eye.
without breaking or bending. Never use any kind of
substitute for a properly manufactured fastener.
Generally pins and studs should not be used on
hard, brittle, or glazed materials such as cast iron,
marble, tiles, and most stone. The fastener will
either fail to penetrate and ricochet or the base
material will shatter.
Materials whose hardness or ductility is unknown Figure 40-4: Types of Studs
should be tested first. Try to drive a pin into the
material with a normal hammer. If the pin point is Clip Assemblies – Fastening to the base material
blunted or fails to penetrate at least 2 mm (1/16"), is done by a pin, but the pin is attached to a
an explosive-actuated tool should not be used. clip assembly configured to secure a uniquely
Fasteners are invariably fitted with a plastic guide shaped item (Figure 40-5). Clip assemblies are
device. Its purpose is twofold. When the fastener available, for instance, to hold conduit. One ceiling
is inserted into the barrel, the guide keeps the configuration comes with pre-tied 12-gauge wire.
fastener from dropping out. It also aligns the
fastener inside the barrel so it will penetrate the
base material at right angles.
There are two basic types of fasteners:
1. Pins
2. Studs.
Figure 40-5: Types of Clip Assemblies
Pins – These are fasteners designed to attach one
material to another, such as wood to concrete.
They resemble nails, but there the similarity stops. Cartridges
Ordinary nails cannot be used as fasteners in Manufacturers recommend certain cartridges for
explosive-actuated tools. certain applications. Because recommendations
Head diameters for pins are available between 7 mm cannot cover every possibility, testing may be
(1/4") and 9 mm (3/8"). Lengths vary from 12 mm required with unfamiliar base materials.
(1/2") to 76 mm (3"). Washers of various types and Cartridges come in .22, .25, and .27-calibre sizes.
diameters are available for different applications. Larger calibres hold more powder, which drives the
Pins should be selected for appropriate length, fastener in further—or into harder base materials.
head size, and application. As a general rule, pins In addition, all three calibres are available with
need not be driven into concrete more than 25 mm different levels of powder charge. For some tools,
(1"). Using a longer pin is generally unnecessary and there may be as many as six different powder
also requires a stronger cartridge. charges available. Some manufacturers produce
tools that use a long-case version of the .22-calibre
Follow the manufacturer’s directions on length, cartridge. It is critical that operators understand
penetration, and appropriate material (Figure cartridge selection and cartridge identification
40-3). For example, one cut-nail fastener is systems (Table 40-1).
available for fastening drywall to relatively soft
base materials, but is recommended for virtually
no other application. Testing may be necessary
on some masonry materials that vary widely in
hardness and durability.

40-2 Construction Health and Safety Manual

 POWER TOOLS – EXPLOSIVE

Table 40-1: Cartridge Identification System Don’t try to fire a fastener any closer than 13 mm
(1/2") to the free edge of steel. Keep in mind that
COLOUR NUMBER CARTRIDGE POWER
this applies only to steel. When fastening steel to
Grey 1 Lowest concrete, you must consider the allowable margin
Brown 2 for concrete as well: 63 mm (2 1/2 ").
Green 3 When fastening two pieces of thin sheet steel to a
Yellow 4 base material, hold the sheets together. Gaps caused
Red 5 by bending may lead to ricochets (Figure 40-6).
Purple 6 Highest

Shots may be packaged or loaded as single

cartridges, strips of ten in a plastic holder, or a
round disk holding ten cartridges. The tool model
will determine the calibre and how the tool is to
be loaded.
Number identifications are printed on the outside of Figure 40-6: Ricochet
cartridge packages. Cartridge tips are colour-dipped
for identification. Some strip cartridges are held in a Special spall stops or protective shields are required
plastic strip the same colour as the cartridge tips. for applications such as fastening sheetmetal to
The general rule is to start with the weakest masonry or sheetmetal to structural steel. Consult the
cartridge and increase one cartridge colour/load operating manual or the manufacturer to ensure that
number at a time to reach the penetration required. the right components are being used for the job.
Too strong a charge may cause shattering,
ricochets, or blow-through. Too weak a cartridge Fastening Concrete and Masonry
will keep the fastener from seating itself properly.
Concrete and masonry materials are not always
Gas Canister uniform in consistency or hardness. As a result, they
may spall, chip, or cause a ricochet when the fastener
Some explosive-actuated models are powered by strikes a spot or layer harder than the rest. Use the
a replaceable fuel cell. The cell contains a mixture spall guard recommended by the manufacturer.
of gases typically composed of butane, propylene,
propane, dimethyl ether, butylene, etc. Consult Once material is spalled or left with a ricochet
the manufacturer’s Safety Data Sheet (SDS) for hole, do not fire a second pin any closer than 50
complete details about chemical composition. mm (2") to the damaged area. The area may be
weakened and spall further or cause a ricochet off
When the nose of the tool is depressed, a specific its sloped edge (Figure 40-7).
amount of gas is released into a combustion
chamber and ignited by a spark when the trigger is
pressed. This action causes the piston to drive the
fastener to a set depth.

Tool Power Controls

Some tools feature a “power control” device. This
allows an operator to make a tool adjustment so Figure 40-7: Ricochet off a Sloped Edge
that either all or only part of the available cartridge
power is used. Power controls may ultimately Pins tend to cause breaks near the edges of
let manufacturers market only one cartridge concrete and masonry. Don’t drive pins closer than
in each calibre. The goal would be to handle 63 mm (2 1/2 ") to a free edge (Figure 40-8).
every application that the calibre is capable of
performing with one cartridge, power-controlled to
the appropriate driving force needed.

Fastening Steel
Low-velocity explosive-actuated tools should not
be used on hardened steels, tool steels, or spring Figure 40-8: Pins Driven
steels. Where the grade of steel is unknown, test Close to the Edge Can Cause Breaks
by trying to hammer the fastener in. If the pin is
blunted, bent, or fails to enter at least 2 mm (1/16"),
do not use a low-velocity explosive-actuated tool—
it’s not up to the job.

Tools and Techniques 40-3

POWER TOOLS – EXPLOSIVE

Misfires • Firing explosive-actuated tools from ladders

is not recommended. From a ladder, it can be
With misfired cartridges, follow the procedures difficult to press the tool muzzle against the
stated in the operating manual for the tool you are base material with enough pressure to fire while
using. Because of the wide variety of tools available, maintaining three-point contact with the ladder.
procedures for misfires may differ. When such Consider using a platform ladder or scaffold.
information is not available, take the following steps. For tasks overhead or at heights, work from a
• Continue to hold the tool against the base scaffold or another approved work platform to
material for at least 30 seconds. This protects ensure solid, balanced footing. As an alternative,
against a delayed discharge of the cartridge. use a manufacturer’s pole accessory if the
reach is normal ceiling height (8–10 feet). The
• Remove the cartridge from the tool. During
pole secures the tool and permits firing by the
removal, keep the tool pointed safely toward soft
operator standing below.
material such as wood. Never use any kind of
prying device to extract the cartridge from the • Fasteners should not be fired through pre-drilled
chamber. If the cartridge is wedged or stuck, tag holes for two reasons.
the tool “DEFECTIVE and LOADED” and lock it in 1) U
 nless the fastener hits the hole accurately, it
its storage container. Never try to dismantle a tool will probably shatter the edge.
with a cartridge stuck or wedged in it. Again, tag
it “DEFECTIVE and LOADED,” lock it away, and call 2) T
 he fastener derives its holding power from
the manufacturer’s representative for help. compressing the material around it. A pre-
drilled hole reduces this pressure and therefore
• Regulations require that a misfired cartridge be the fastener’s holding power. (This is why studs
placed in a container of water. and pins driven into steel should penetrate
• Keep the misfired cartridge separate from completely through the metal. Otherwise the
unused cartridges and return it to the compressed steel trying to regain its original
manufacturer for disposal. Never throw misfired position can loosen the fastener by pushing
cartridges in the garbage. against the point. With the tip completely
through the metal the same pressure only
• Be cautious. The problem may be a misfired
works to squeeze the pin tighter.)
cartridge, but the tool may also be defective. Check
the tool for obvious damage, perform function
tests, and use the tool only if it operates properly. Maintenance
Tools in regular use should be cleaned daily. Tools
General Safeguards used intermittently should be cleaned after firing. All
• Workers who pick up an explosive-actuated parts of the tool exposed to detonation gases from the
tool must immediately prove to themselves that cartridge should be cleaned and lightly oiled according
the tool is not loaded. This action must become to the manfuacturer’s instructions. The cartridge
instinctive and be carried out before anything magazine port, cartridge chamber, and piston sleeve
else is done with the tool. Even after watching should be wiped clean but never be oiled.
someone else handle the tool before passing it
The tool brush supplied is adequate for most
on, make sure that it’s not loaded.
cleaning tasks. Stubborn carbon should be loosened
• Explosive-actuated tools should be used, handled, with a manufacturer’s spray detergent oil. Tools
and stored properly. being checked for immediate use should be wiped
• Never put your hand or fingers over the end of dry of oil. Failure to clean the tool as recommended
the muzzle for any reason, even when the tools can lead to corrosion, pitting, fouling, and failure to
are not loaded with fasteners. work properly. Ideally, the tool should be cleaned
before being returned to storage.
• Tools must be inspected and function-tested
before work starts. Proper training and the Tools with a power control adjustment will
operator’s manual will describe how to carry out accumulate additional powder residue from firing—
both of these requirements. especially when the control is set to restrict the
amount of cartridge strength being used. Semi-
• Operators must be trained on the explosive- automatic tools may also accumulate powder
actuated tools they are using and must wear all residue. These tools need to be cleaned more often.
the required personal protective equipment.
Sluggish performance may indicate that a tool
• Do not leave the tool unattended unless it’s needs cleaning. Tool action will slow to the point
locked in a box. where a competent operator can detect the
• Load the tool immediately before firing. Don’t difference. Most manufacturers recommend major
walk around with the tool loaded. maintenance, inspection, and cleaning every six
months. This involves stripping, inspecting, and
• Do not use explosive-actuated tools in areas
cleaning parts not covered in daily maintenance.
where there may be exposure to explosive
vapours or gases.

40-4 Construction Health and Safety Manual

 POWER TOOLS – EXPLOSIVE

Storage • Wear protective clothing such as gloves and

coveralls.
Regulations require that both the tool and the
cartridges be stored in a locked container with • Wash hands with soap and water before
explosive loads of different strengths in separate breaks, eating, drinking, or smoking, and do
containers. Cartridges should only be removed not chew gum.
from the locked container when they are going to • NEVER TAKE CONTAMINATED WORK
be used immediately. CLOTHES HOME.
If you suspect that you are suffering symptoms
Regulations from lead exposure, see your family doctor and
• Any worker using an explosive-actuated tool ask for a blood test to determine the presence of
must be instructed in its safe and proper use. lead. Lead contamination in the human body can
accumulate over time. It also takes the body time
• Before using the tool, the operator must check to expel this lead after exposure.
to ensure that it is in good working order. This
means inspection and function testing.
• Tools firing fasteners at a velocity of more than
90 metres/second must have a protective guard
at least 75 mm in diameter, mounted at right
angles to the barrel of the tool and centered on
the muzzle end of the tool, if practical.
• The tool must require two separate actions before
it will fire:
1) Pressure against the surface of the material
2) Action of the trigger.
• Explosive-actuated tools must be stored in a
locked container when not in use or when left
unattended.
• The tool must not be loaded until ready for
immediate use.
• Whether loaded or unloaded, the tool must never
be pointed at anyone.
• Cartridges must be marked or labelled for easy
identification. Cartridges of different strengths
must be stored in separate containers.
• Misfired cartridges must be placed in a container
of water and be removed from the project.

Lead Exposure
There is the potential for overexposure to lead
when using explosive-actuated fastening tools in
indoor applications with poor ventilation.
Hands and skin may also become contaminated
by lead. This could lead to ingestion if skin is not
covered and hands are not washed.

Controlling Lead Exposure

1. Consider alternative fastening methods such as
gas-powered systems.
2. If you must use explosive-actuated tools, follow
the Ministry of Labour’s Guideline “Lead on
Construction Projects”. Some recommendations
for the operator include:
• The guideline recommends at least an N95
respirator. However, refer to the manufacturer’s
specifications to determine if the respirator
can protect against lead.

Tools and Techniques 40-5