Safety Precautions When Using Adjustable Wrenches – Why Non-Sparking Tools and Fixed Spanners Are Safer Choices

An adjustable wrench (often called a crescent spanner) is popular for its versatility,

as the movable jaw allows it to fit different sizes of nuts and bolts. A common misconception, however, is that an adjustable wrench can replace a fixed jaw spanner and withstand the same loads. This is far from the truth. Adjustable wrenches are designed for light-duty applications, while fixed spanners provide superior grip and torque strength for demanding tasks.

In this article, we explore the key differences between adjustable wrenches and fixed jaw spanners, highlight the risks of misusing adjustable wrenches, and outline where they should—and should not—be used. We also discuss additional precautions when working in flammable or explosive environments, where only Non-Sparking Adjustable Wrenches are safe.

Although convenient, adjustable wrenches come with risks. When misused, they can slip under load, damage equipment, or cause serious hand and finger injuries. In hazardous environments, their use in steel materials can create sparks, potentially triggering fires or explosions.

For these reasons, workers must follow strict safety guidelines, understand the limitations of adjustable wrenches, and always prioritize safety by using the correct tool for the job.

• Do Not Use Adjustable Wrenches as a Replacement for Fixed Spanners

  
  

  Adjustable wrenches are fundamentally different from fixed jaw spanners such as open-ended or ring spanners. Unlike fixed spanners, which are designed to withstand high loads and torque, adjustable wrenches rely on a movable jaw that is more prone to slipping under pressure. This makes them less reliable, especially in critical applications.

  
  

  Studies have shown that adjustable wrenches are more likely to damage fasteners, slip unexpectedly, and cause hand injuries. While they may appear versatile—able to “fit all”—they do not “secure all.” Under high torque, they can strip fasteners, injure workers, or damage sensitive machinery.

  
  

  For safe and reliable tightening or loosening, the correct size fixed spanner should always be the preferred choice. In hazardous environments, this becomes even more critical, where only Non-Sparking Tools should be used to eliminate spark-related risks.

• Limit Use to Light-Duty Applications Only

  
  

  Adjustable wrenches should be used only when absolutely necessary and strictly for light-duty applications. They are best suited for temporary tasks such as quick maintenance jobs or minor adjustments, where precision and high torque are not required.

  
  

  Overloading an adjustable wrench not only risks damaging the tool and fastener but also increases the chance of hand injuries. Industrial safety authorities, including the Hand Tool Institute (USA), strongly advise against their regular use in professional environments. These wrenches are not designed for continuous or heavy-duty industrial work, and misuse often leads to tool failure, equipment damage, and workplace accidents.

• Understand Torque Limitations

  
  

  According to IS 6149 standards for Single-Ended Open-Jaw Adjustable Wrenches, a 300 mm (12”) adjustable spanner is tested and rated to a torque capacity of 480 Nm. In comparison, a fixed open-ended spanner of 32 mm of the same size is tested at 643 Nm, and a ring/box spanner of 32 mm withstands up to 884 Nm. This significant difference clearly shows that adjustable wrenches are not engineered to handle the same load and torque as fixed jaw spanners.

  
  

  

  
  

  In real-world terms, this means that while an adjustable wrench may grip a fastener, it cannot deliver the same strength and stability without risk of slipping or failure. Under heavy torque, the movable jaw may shift, leading to damaged nuts and bolts, or worse, hand and finger injuries. For any critical application—especially in industries where safety is paramount—the correct size fixed spanner or non-sparking spanner should always be the first choice.

  
  

  Adjustable wrenches should remain limited to light, non-critical, and temporary tasks.

  
  

  Pahwa MetalTech ensures reliability by torque testing all its Non-Sparking Hand Tools to steel tool standards before dispatch. Explore our rigorous Torque Testing process for Hand Tools.

• Avoid in Flammable or Explosive Environments – Use only Non-Sparking Adjustable Wrench (if required)

  
  

  In industrial environments where flammable chemicals, vapors, gases, or explosive powders are present, the choice of hand tools directly impacts workplace safety. Conventional steel adjustable wrenches, although strong, pose a hidden danger. When steel surfaces strike, slip, or grind against other hard materials, they can generate sparks. Even a single spark in a hazardous zone can act as an ignition source, leading to catastrophic fires, explosions, or loss of life.

  
  

  This is why global safety standards strictly advise the use of Non-Sparking Hand Tools in such environments. Manufactured from specialized alloys such as Copper Titanium and Aluminum Bronze, these tools are specifically engineered to prevent spark generation. Unlike steel, they do not produce frictional sparks when in contact with other surfaces, making them the only safe alternative in high-risk industries.

  
  

  Industries such as oil & gas, petrochemicals, Chemical processing (Find out more about Non-Sparking Tools for Chemical Drums and Barrels), mining, refineries, and explosive manufacturing units rely on Non-Sparking Tools to maintain operational safety and regulatory compliance. Beyond preventing sparks, these tools also ensure long-term durability, corrosion resistance, and adherence to international safety standards.

  
  

  By choosing Pahwa MetalTech Non-Sparking Tools, you not only eliminate spark risks but also reinforce a culture of safety, reliability, and compliance in hazardous work environments.

• Follow Industry Safety Guidelines

  
  

  Safety organizations, Oil & Gas companies and Steel Mills worldwide, have banned or restricted the use of adjustable wrenches in their facilities due to frequent accidents and equipment damage. They recommend always using the correct size non-sparking spanner for safer and more reliable results and always follow site-specific tool safety policies.

• Protect Your Hands at All Costs

  
  

  Every year, more than 25,000 hand injuries are caused by the misuse of screwdrivers and adjustable wrenches. Slips or improper handling can lead to severe hand trauma, sometimes resulting in permanent impairment. One of the simplest ways to protect your hands is to use the right tool for the job—such as a fixed spanner instead of an adjustable wrench. Fixed spanners provide a more secure grip and reduce the risk of slips, keeping your hands safer during work.

•  General Safety Tips for Using Wrenches

  • Do’s

    • Use the right wrench for the job – pipe wrenches for pipes and plumbing fittings, general-use wrenches for nuts and bolts.

    • Inspect tools before use – discard damaged wrenches (spread jaws, broken box ends, worn ratchets).

    • Choose the correct jaw size to avoid slippage and accidents.

    • Wear proper PPE – safety glasses or a face shield in environments with flying particles or debris.

    • Maintain good body position – stand securely to prevent falls if the wrench slips or the bolt breaks.

    • Prefer box or socket wrenches with straight handles for better grip and torque.

    • Seat the wrench properly – ensure open-end jaws are fully flat on the nut/bolt before applying force.

    • Use adjustable wrenches correctly – always turn against the fixed (permanent) jaw.

    • Keep pipe wrenches sharp and clean – free of oil, dirt, and with sharp teeth for grip.

    • Check ratchets before applying force – apply light pressure to confirm the pawl and gear are engaged.

    • Support extensions – hold the ratchet head when using socket extensions.

    • Pull steadily, don’t jerk – use slow, firm pressure instead of sudden movements.

    • Stand aside for overhead work – avoid being directly beneath when using wrenches above head level.

    • Keep adjustable wrenches tight – ensure the jaws don’t slide open while in use.

    • Maintain tools regularly – clean, oil, and inspect them for safe operation.

    • Store tools properly – place them in a toolbox, rack, or belt after use.

      
      

  • Don’ts

    • Don’t push on a wrench – always pull to reduce risk if the tool slips.

    • Don’t use bent or damaged wrenches – replace them immediately.

    • Don’t use worn adjustable wrenches – check the knurl, jaw, and pin for wear.

    • Don’t pull with a loose adjustable wrench – always tighten it properly.

    • Don’t misuse pipe wrenches – never use them on nuts/bolts, or for bending or lifting pipes.

    • Don’t use wrenches on moving machinery.

    • Don’t substitute tools – never use pliers as a wrench, or a wrench as a hammer.

    • Don’t improvise – avoid make-shift wrenches or inserting shims for a better fit.

    • Don’t strike wrenches – unless they are specifically “strike-face” types designed for hammering..

• Conclusion

  
  

  Adjustable wrenches may seem handy, but they are not a safe substitute for fixed spanners. They should only be used in non-critical, light-duty applications. For industrial, hazardous, or flammable environments, Non-Sparking Tools—particularly fixed jaw spanners—are the correct and safe choice. Download our catalog with over 3500+ Non-Sparking Hand Tools. By following these precautions, companies can protect both workers and equipment while ensuring compliance with global safety standards. While adjustable wrenches are handy, they should be treated as temporary, light-duty tools. They are not safe replacements for fixed spanners and should never be used where precision, strength, or safety are critical. In hazardous industries, only Non-Sparking Tools should be deployed to prevent fire and explosion risks.

  
  

  By following the do’s and don’ts, understanding torque limitations, and using the right tool for the job, workers can avoid injuries, protect equipment, and maintain safe working conditions.

  
  

  Ensure safety, reduce risks, and improve efficiency. Contact us now to learn more about our Non-Sparking Hand Tools.