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Power tools and all tools longer than 7 inches (measured from end to end when assembled) are prohibited in carry-on baggage; these items must be packed in your checked bags.

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Having traveled with thirty or so cordless drills and tens of other tools recently, I decided to look a bit closer into what the rules are when it comes to flying with power tools, hand tools, bolts, nuts, and other hardware.

If you are looking for a quick answer, here you go: in vast majority of cases, you can travel with your tools and hardware. Depending on the tool, you might be able to carry it on, however, I recommend checking all of them in to avoid any potential issues at security. The only exception to that are batteries from your cordless tools which need to be carried on.

While this article is based on FAA and TSA rules for traveling with tools and batteries, they can serve as a rough guideline for your other travels as well. In either case, though, if you are not sure whether or not you can travel with a certain tool or piece of hardware, make sure to get in touch with the local authority as well as your airline.

The general rule when it comes to flying with power tools – whether corded, battery-powered, or engine-powered – is that all of them need to be in your checked in luggage and are prohibited in your carry on.

Battery-powered tools such as cordless drills and saws can technically travel in checked in luggage with their batteries attached, but they have to be prevented from shorting and from accidentally activating.

As such, when it comes to battery-powered tools, I recommend you to remove their batteries and put them in yourcarry on luggage – only putting the tool itself in your checked in luggage.

While most power tool batteries should be within that limit, if you are unsure – and if there is no Whcapacity mentioned on the battery – you can calculate it as follows:

Engine-powered tools such as chainsaws, trimmers and generators are prohibited from both carry on and checked in luggage if there is any fuel left in them – even in the form of residual vapors.

Just like the drills themselves, you cannot carry drill bits in your hand luggage. And, given that sharp objects are prohibited from carry on luggage in general, things such as power saw blades should be packed in your checked luggage as well.

On the other hand, given that – as you will see below – tools under 7-inches long are allowed, in theory you should be able to carry on Phillips and socket bits. However, I would still pack everything in checked luggage to avoid any potential delays at the security check since the final decision rests on the security screening officer.

However, given that there is also the general rule of not being able to carry on sharp items and the fact that the security screening officer makes the final decision about whether or not you can carry something on, I recommend you to put all tools in your checked in luggage.

If you, for one reason or another, you insist on taking your tools into the cabin, here’s a list of some of the tools that are technically allowed in the cabin based on TSA’s website as long as they are under 7 inches long:Multi-tool without blades

As you can see above, in most cases, you will have to check your tools and hardware in. The notable exception being hand tools shorter than 7 inches and scissors with blades shorter than 4 inches.

One last tip: if for some reason you decide to carry on tools, make sure that you arrive at the airport early enough to have enough time to go back from the security check to the check-in counters in case the security staff determines that you must check the tools in.

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You can pack almost all tools in checked bags. If you are bringing power tools any spare or loose lithium-ion batteries cannot be packed in checked baggage and much be packed in carry-on bags.

Gas powered tools can be packed in checked bags too. However, if they contain any residue or vapors of gas/oil, they would be considered a hazardous material & prohibited from being transported on the airplane. Even brand new tools can have residues because they are tested before sale. Check with your airline about bringing any gas powered tool in hold luggage.

You cannot bring power tools in carry-on luggage. Fans of the horror movie genre will understand why. Power tools can be used as weapons and that’s why they are not allowed in carry-on bags.

Regular hand tools must be shorter than 7 inches. This is because longer heavier tools could be used to knock someone over the head. Hammers or knives of any size are not allowed in hand luggage.

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Recalled batteries and devices - Lithium batteries recalled by the manufacturer/vendor must not be carried aboard aircraft or packed in baggage. Battery-powered devices recalled because of lithium battery safety concerns also should not be carried aboard aircraft or packed in baggage unless the device or its battery has been replaced, repaired or otherwise made safe per manufacturer/vendor instructions. The FAA and your airline may offer further public guidance on individual recalled products. Product recall information is available at http://www.cpsc.gov/recalls. Learn more.

Any common object that could be used as a weapon should be packed in your checked bag. This includes anything sharp, baseball bats, canoe paddles, hiking poles, hockey sticks, power tools, and hand tools over 7 inches end-to-end fully assembled.

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Safety clips or retainers shall be securely installed and maintained on pneumatic impact (percussion) tools to prevent attachments from being accidentally expelled.

All fuel powered tools shall be stopped while being refueled, serviced, or maintained, and fuel shall be transported, handled, and stored in accordance with Subpart F of this part.

When fuel powered tools are used in enclosed spaces, the applicable requirements for concentrations of toxic gases and use of personal protective equipment, as outlined in Subparts D and E of this part, shall apply.

The fluid used in hydraulic powered tools shall be fire-resistant fluids approved under Schedule 30 of the U.S. Bureau of Mines, Department of the Interior, and shall retain its operating characteristics at the most extreme temperatures to which it will be exposed.

Tools shall not be loaded until just prior to the intended firing time. Neither loaded nor empty tools are to be pointed at any employees. Hands shall be kept clear of the open barrel end.

Powder-actuated tools used by employees shall meet all other applicable requirements of American National Standards Institute, A10.3-1970, Safety Requirements for Explosive-Actuated Fastening Tools.

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More than one million people are hurt using hand and power tools every year, according to the Consumer Product Safety Commission (CPSC). Not only do people suffer physically, but their injuries also often hurt them financially. Their employers lose money, too. The CPSC reports injuries with hand and power tools cost $15.4 million a year in medical bills and lost work. Many of the visits to hospitals and doctors’ offices could be prevented with more attention to hand and power tool safety.

HSI’s mission is to make the workplace safer and smarter. Thus, we offer the following tips for hand and power tool safety. According to OSHA, these are the leading causes of injuries from using hand and power tools:

Accidents on the job happen more frequently when employees are doing a repetitive job, something unexpected happens, or they are inexperienced or overconfident about using the tool. These tips for hand and power tool safety help employees stay safe and perform well.

OSHA protects employees by requiring companies to ensure their employees use safe tools and equipment and follow safety guidelines. No matter how many years an employee has under his belt, reviewing the following tips for hand and power tool safety regularly is critical to staying safe.

Because of the potential dangers involved in using power tools OSHA provides specific safety guidelines for their use. OSHA requires many handheld power tools

to be equipped with a constant-pressure switch button that cuts off the power when pressure drops including drills, tappers, angle grinders, saws, and sanders. Many power tools with blades must have safety devices that allow the user to shut the tool off in a single motion.

One of the most serious workplace injuries involving tools is electrical shock from power tools. Electrical shocks can cause heart failure and burns. Sometimes a worker is shocked while on a ladder, then loses their balance and is injured in a fall. Tips for preventing electrical shock are at the top of the list of ways to stay safe using power tools.

Safety experts urge construction companies to take steps to improve safety if necessary. These tips for hand and power tool safety related to pneumatic tools are a good place to improve your attention to safety.

Using tools safely includes more than knowing the tools. Employees must pay attention to what they wear, how they carry their tools, and where they stand. To protect employees from the dangers of slips and electrical shock, managers should ensure floors are kept as clean and dry as possible. Tips for hand and power tool safety include choosing the right clothing:

OSHA requires employers to train employees on the proper use of tools and equipment. Go over these tips for hand and power tool safety regularly with your employees and consider taking safety management a step further by partnering with HSI. We provide tools for engaging your employees in training and making safety top-of-mind at your company.

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Spare lithium batteries on planes such as power banks and smartphone chargers must be kept in carry-on baggage only. When the bags are checked at the planeside, these batteries must be removed and kept lithium batteries on planes cabin with the passenger.

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Employees using hand and power tools may be exposed to falling, flying, abrasive and splashing objects, flying dusts, fumes or mists, vapors or gases, and should be fitted with the appropriate PPE necessary to protect them from hazards.

All hand tool and portable power tools and similar equipment, whether furnished by Caltech or by or the employee, will be maintained regularly and kept in a safe working condition.

Hand tools are non-powered or operate only through physical exertion by hand. The greatest hazards posed by hand tools result from misuse and improper maintenance.

A portable tool is one that requires a power source to operate, such as electric, pneumatic, liquid fuel, hydraulic, explosive-actuated, and powder-actuated device or power supply. Power tools can be hazardous if used improperly.

Power tool general precautions include the following:Read the owner"s manual to understand the tool"s proper applications, limitations, operation, and hazards

Electric power tools will be either three-wire grounded or double-insulated and must be listed by Underwriters" Laboratories or another recognized listing agency.

Disconnect tools and ensure a zero-energy state when not in use, prior to servicing and cleaning, and when changing accessories such as blades, bits, and cutters.

Remove all damaged or defective portable electric tools from use and tag them: "Do Not Use." If not repairable, cut off power cord and discard/recycle.

Always plug cord-connected, hand-held electric tools into ground-fault circuit interrupter (GFCI)-protected receptacles or in compliance with the facility"s assured electrical grounding conductor program.

Hazardous moving parts of a power tool need to be safeguarded. For example, belts, gears, shafts, pulleys, sprockets, spindles, drums, fly wheels, chains, or other reciprocating, rotating, or moving parts of equipment shall be guarded if such parts are exposed to contact by employees.

Power tool guarding precautions include the following:Always consult supervisor when the manufacturer recommendations for guarding a specific power tool are not available or cannot be implemented.

Operate power tools only when all guards are in place and properly attached according to the manufacturer"s recommendations, and are functioning properly.

All hand-held power tools will be fitted with any one of the following safety switch methods as appropriate for the particular tool:A momentary contact "on-off" control.

A pressure switch which requires constant pressure to run and will shut off when the pressure is released, such as required for hand-held gasoline-powered chain saws.

Portable electric tools will be of the approved double-insulated type and used with an approved grounding device such as a GFI (Ground Fault Indicator) to prevent the unlikely event of an electrical shock.

Pneumatic tool precautions include the following:Pneumatic power tools will be secured to the hose or whip by some positive means such as a tool retainer to prevent the tool from becoming accidentally disconnected.

Safety clips or retainers will be securely installed and maintained on pneumatic impact (percussion) tools to prevent attachments from being accidentally expelled.

All pneumatically-driven nailers, staplers, and other similar tools provided with automatic fastener feeds which operate at more than 100 psi pressure to the tool will have a safety device on the muzzle end to prevent the tool from ejecting fasteners unless the muzzle is in contact with the work surface.

The fluid used in hydraulic powered tools will be fire-resistant and must retain its operating characteristics at the most extreme temperatures to which it will be exposed. The manufacturer"s safe operating pressures for hoses, valves, pipes, filters, and other fittings will not be exceeded.

Powder-actuated tools are also known as "explosive-actuated." Such tools are actuated by explosives or any similar means, and propel a stud, pin, fastener, or other object for the purpose of affixing it by penetration to any other object.

Fasteners will not be driven directly into materials such as brick or concrete closer than 3 inches from the unsupported edge or corner or into steel surfaces closer than ½ inches from the unsupported edge or corner, unless a special guard, fixture, or jig is used. (Exception: Low-velocity tools may drive no closer than 2 inches from an edge in concrete or ¼ inches in steel).

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If you"re planning a trip, you may bring your laptop computer, cell phone, camera, personal digital assistant, or other battery-powered devices as these items are still safe to fly! Batteries pose little risk when contained within the devices they power if steps are taken to prevent inadvertent activation. Spare batteries can be packed in carry-on baggage if steps are taken to protect against short circuits.

Every rechargeable battery-powered device comes with a charger that is right for that device. When you travel, locate the charger that is compatible with the device - don"t mix and match!

If you must carry a battery-powered device in any baggage, package it to prevent inadvertent activation. For instance, you should pack a cordless power tool in a protective case, with the trigger lock engaged.

Damaged or recalled batteries and battery-powered devices, which are likely to create sparks or generate a dangerous evolution of heat may be carried aboard an aircraft by passenger or crew only if packaged and/or handled in a manner which would preclude such an occurrence. Such batteries and devices should not be placed in checked baggage. Check battery or battery-powered device recall information at the manufacturer’s website, or visit the Consumer Product Safety Commission at www.cpsc.gov.