Using insulated tools is not always a priority for professionals working in the presence of live electrical current. From a performance standpoint, the same task can be accomplished with regular tools. With one important difference: insulated tools offer user protection against electrical shock up to 1000 V.

No modifications made to regular tools (like using garden hose to cover the handles, or covering the exposed part with a coating of ordinary rubber) will provide the same level of protection as fully certified insulated tools.

Insulated tools are typically more expensive than comparable regular tools. The process each tool goes through to provide full user protection against electrical shock is both complex and time consuming.

The most common methods used to manufacture insulated tools are dipping and injection moulding. Since the end benefit is the same (user protection against electrical shock), choosing one design over the other comes down to personal preference and habit.

The dipping process is used primarily by North American manufacturers; including Gray Tools. This multi-step process ensures each insulated tool meets ASTM F1505 standards for adhesion, dielectric properties, flammability, and durability.

The final process in the dipped manufacturing method requires that each tool is trimmed, cleaned, polished and laser engraved. Most of the steps in this insulating process require a precise and often lengthy amount of curing time to achieve optimum results.

Insulated tools manufactured using the dipping process feature two layers of insulation in contrasting colours (red and yellow, or orange and yellow). Besides its insulation properties, the inner layer also acts as a safety indicator. When this layer becomes visible through the outer layer the tool is no longer safe to use and has to be replaced.

European and Asian insulated tool manufacturers favor the injection moulding process. Unlike the North American method where the tool is dipped in insulated material these tools feature handles moulded from insulation material.

The “dipped” versus “injection moulding” comparison has no obvious winner. Similar to "chrome versus matte" tool finish or "chrome versus comfort" handle, in the end it is a matter of personal preference. Regardless of the insulation process, both tool lines guarantee user protection up to 1000V and come with a lifetime warranty.

Once you have decided what tool design you are most comfortable with, here are some important things to consider when choosing an insulated tool:

• Choose a reputable tool manufacturer. The overall quality of an insulated tool cannot be judged solely on the insulation method. The quality and performance of the base tool is fundamental. Brands that specialize solely in insulated tools source their non-insulated product from various sources, which are not disclosed. Established tool manufacturers, such as Gray Tools, use the tools from within their portfolio. These tools have been field-tested by people who do extraordinary work for more than 100 years.
• Check the grip. Choose an insulated tool that provides a secure grip of the tool. This reduces the possibility of tool drop or slippage, thus reducing the risk of personal injury.
• Compare the warranties. All things being equal, a tools warranty (and how warranty is handled) can make the difference between efficiency and time lost with warranty claims. A reputable brand will guarantee its insulated tools for life.

Another important aspect in choosing an insulated tool brand is the ability to offer a custom tool that is not part of its standard assortment. This is particularly valuable in the case of professional users, who might encounter applications where the use of a custom size or tool design is required.

Reputable manufacturers have the capability to satisfy almost any insulated tool need beyond the standard assortment. If the client job requires a tool that is not available as part of the standard assortment, they can probably insulate it.

If you study an insulated tool carefully, you will notice the symbols and marks engraved on them. The two most popular symbols are the VDE logo and the double triangle symbol.

Popular in North America, ASTM F1505 certifies each tool that goes through the insulation process. An ASTM F1505-certified tool has the “1000V” and double triangle symbol engraved, as well as the year the tool was insulated.

VDE (Verband der Elektrotechnik - Association for Electrical, Electronic & Information Technologies) is a private compliance organization that will come into an organization and certify that the proper procedures are being followed in terms of testing.

Based in Frankfurt, Germany, VDE certification is mainly used by European and Asian manufactures. Once the insulation process is VDE certified, each tool that is manufactured using the process is automatically engraved with the VDE symbol.

Similar to the “dipped” versus “injection moulding” comparison the certification authority has no clear winner. Both ASTM & VDE require comprehensive testing before any tool can be marked as insulated. The key is to choose a tool that bears a symbol clearly indicating it is certified and tested to provide the level of protection expected.

• Perform a visual inspection of the insulated tool each time you plan to use it. If any cracks, nicks, cuts or other damage to the outer orange layer is visible, don’t use that tool and bring it to the attention of your supervisor.
• Use insulated tools only in areas whose ambient temperatures are compatible with the manufacturer’s specifications.
• Do not touch any un-insulated part of the tool that might come into contact with an energized source.
• Keep insulated tools away from sharp objects such as utility knives, to avoid damage to the insulated material.
• Keep insulated tools away from heat sources.
• Clean and maintain your insulated tools regularly to ensure many years of reliable service.

Ideally the electrical power is always shutoff before commencing and repair or inspection project. For instances where this simply is not possible it is important to remember that insulated tools are an important link in the overall chain of safety. Other important safety items include the use of insulated gloves and boots and arc flash protection suits and clothing.