Why are Non-sparking Sledge Hammers so expensive?

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Non-sparking sledge hammers are more expensive than their conventional counterparts due to the specialized materials and manufacturing processes involved in their production. The primary reasons for the higher cost include:

Specialized Materials:

Non-sparking tools are crafted from non-ferrous alloys, typically aluminum, bronze, or copper-beryllium. These materials are chosen for their non-sparking properties, as they do not generate sparks when striking against other metals. The selection of these alloys contributes to the tools&#; high cost compared to regular steel tools.

Complex Alloy Composition:

The alloys used in non-sparking tools are carefully engineered to meet specific safety standards. Achieving the right balance of hardness, durability, and non-sparking characteristics requires a complex composition of metals. The precision required in crafting these alloys contributes to the increased cost of manufacturing.

Strict Quality Standards:

Non-sparking tools are subject to stringent quality control measures to ensure their reliability in hazardous environments. Manufacturers adhere to strict industry standards and certifications, such as ATEX and FM (Factory Mutual), to guarantee the tools&#; safety and compliance. Meeting these standards involves additional testing and quality assurance processes, which contribute to the overall cost.

Specialized Manufacturing Techniques:

Crafting non-sparking tools involves specialized manufacturing techniques, such as precision casting or forging. These methods are more intricate and demanding than traditional tool production processes, requiring specialized equipment and skilled labor. The higher level of precision and attention to detail increases the overall manufacturing cost.

Limited Market Demand:

Non-sparking tools cater to specific industries where safety is paramount, such as oil and gas, chemical processing, and mining. The demand for these tools is relatively lower compared to general-purpose tools. The limited market size contributes to higher per-unit production costs, as manufacturers cannot achieve the economies of scale seen in mass-produced tools.

Regulatory Compliance:

Non-sparking hammers must comply with various safety regulations and guidelines to ensure their suitability for use in potentially explosive atmospheres. Meeting these regulatory requirements involves additional testing, certification, and documentation, adding to the overall cost of production.

Research and Development:

Developing non-sparking tools requires investment in research and development to continuously improve their design, materials, and performance. Innovations in non-sparking technology, aimed at enhancing safety and usability, contribute to the overall cost of bringing these specialized tools to market.

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Liability and Insurance Costs:

Manufacturers of non-sparking tools often face higher liability and insurance costs due to the critical nature of the industries they serve. These costs are factored into the overall pricing of non-sparking tools, further contributing to their higher price tag.

In summary, the higher cost of non-sparking sledge hammers is justified by the use of specialized materials, complex alloy compositions, stringent quality standards, specialized manufacturing techniques, limited market demand, regulatory compliance, research and development, and elevated liability and insurance costs. The safety and reliability provided by non-sparking tools in potentially explosive environments make them essential, justifying the investment for industries where the prevention of sparks is critical.

The following are some of the misconceptions about non-sparking tools that we have come across through interactions with industrial companies:

1. Non-sparking tools do not generate any spark

Non sparking tools are made of metal, and as a result, they do generate sparks. The difference between non-sparking tools and steel tools is the energy of the spark they generate.

The low energy of the sparks is the result of the special alloys in the composition of non-sparking tools.

2. Copper Beryllium (Cu-Be) tools are more expensive than Aluminum Bronze (Al-Bron) tools

Even if Cu-Be tools are around 30% more expensive than Al-Bron non-sparking tools, they are 40 to 50% harder. As a result, Al-Bron non-sparking tools may be a more expensive option over time considering you might need to replace them more often.

Depending on the frequency of use, using Cu-Be non-sparking tools may be a more economical option in the mid to long run.

3. Plastic coated tools are safe to be used in explosive work environments

Even if plastic coated tools are likely safer than steel tools, they can´t considered to be a safe option considering that it is not possible to coat all active parts of a tool.

 As a result, they are called spark reduction tools but not non-sparking tools. Their use is not recommended for the following reasons:

• They do not avoid the risk of explosion
• The plastic coating is susceptible to become damaged, further increasing the exposed areas
• The standard EN -1 prohibits the use of steel made tools in most zones and groups of gas.

4. Cu-Be non-sparking tools are carcinogenic and therefore represent a health hazard

We have found out that there is some confusion about the impact that Cu-Be non-sparking tools could have in the user´s health.

It is true that beryllium in the form of dust, inhaled continuously over long periods of time has been proven to be cause lung cancer (for example in foundries where this alloy is melted and appropriate safety measures are not in place).

However, there is no evidence or recorded cases about Cu-Be non-sparking tools causing any cancer. Main reasons are:

• Cu-Be has only 2% of beryllium in its composition.
• It is not in powder form, so you do not inhale it.
• The exposure is minimal.

It is for the above reasons that there is no country in the world that has banned the use of this alloy.

5. Cu-Be non-sparking tools are always the safest option

Even if Cu-Be non-sparking tools are generally the safest option, there is one exception: the presence of Acetylene gas.

Even if Acetylene is a gas in the IIC group (and therefore safe for Cu-Be non-sparking tools), the gas reacts with any alloy with a copper composition higher than 65%, creating a new highly explosive compound called copper acetylide.

As both Cu-Be alloys and Al-Bron contain more than 80% of copper, they must never be used in acetylene environments. In such environments, steel tools would likely be safer than Cu-Be non-sparking tools.

For such environments, EGA Master has developed an alloy called ACETILEX®, which have less than 65% of copper in their composition. As a result, ACETILEX® non-sparking tools are the only completely safe alternative on the market for working in environments with acetylene.

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