This document is provided as general guidance only and does not constitute legal, safety, or compliance advice. See the Important Notice at the end of this document.

This document provides guidance on pre-use and end-use checks for breakers and demolition hammers used in construction, civils, groundworks and engineering maintenance: electric machines (including 110V site supply and battery models), petrol breakers, and air-powered breakers run from a compressor. It covers equipment checks, operator safety considerations, and hand-arm vibration (HAV) obligations, which matter more for this category than for almost any other tool on site.

For consistency, this document uses breaker to refer to each individual machine, and steel for the inserted tool: the point, chisel, or asphalt cutter the breaker drives. Checks described here are visual and operational only and do not replace inspection, servicing, or repair by a competent person. Where a defect involves the tool retention, a power cord, an air hose, or any safety-critical component, the breaker should be assessed by a competent person before it is returned to service. If there is any doubt about a breaker's safety at any point during a check, take it out of service until that assessment has happened. This guidance should be used alongside your organisation's site-specific risk assessments and safe working procedures. It does not cover breaking technique, permits to break ground, buried service avoidance, or structural demolition sequencing, all of which require their own procedures beyond the scope of an equipment check document.

Hand-Arm Vibration: Why Breakers and Demolition Hammers Matter

Breakers sit at the top of the hand-arm vibration league table. The HSE's exposure calculator lists vibration-reduced breakers at 7 to 18 m/s² with a recommended value of 14, and demolition and rotary hammers at 10 to 21, and the real figure on any given day depends on the machine's condition, the steel's condition, the material being broken, and how the tool is used.

The arithmetic is worth spelling out, because it surprises people. Using the HSE exposure points system, a breaker at the HSE's recommended 14 m/s² accrues roughly 390 points per hour of trigger time: the 100-point exposure action value arrives in about 15 minutes, and the 400-point limit value in around an hour. On a breaker, daily exposure is not managed across a shift; it is managed across minutes of actual trigger time. That is also why honest timing matters so much: operators genuinely on the trigger for 40 minutes are often assumed, on paper, to have been breaking all day, and vice versa.

The Control of Vibration at Work Regulations 2005 requires employers to manage HAV exposure and keep daily exposure below defined thresholds.

Exposure Action Value (EAV)

Daily exposure: 2.5 m/s²
At this level employers should take action to reduce exposure
Health surveillance should be introduced
Operators should be informed of the risks

Exposure Limit Value (ELV)

Daily exposure: 5 m/s²
This level should not be exceeded
Exceeding this value is a breach of the Regulations
Immediate action to reduce exposure is required

Tracking HAV exposure with Toolminder. Toolminder tracks hand-arm vibration exposure in real time as each breaker is used, converting actual trigger time into exposure points against that machine's vibration magnitude and flagging with amber and red indicators as the EAV and ELV approach. On a tool where the ELV can arrive inside an hour, live tracking is the difference between managing exposure and discovering it afterwards.

Vibration data: do not rely on manufacturer figures. The HSE advise that manufacturer quoted vibration values are typically measured under controlled conditions and are often not representative of real-world use. A breaker's true magnitude changes with the condition of its damping system, its steels, and the material being broken. For accurate exposure calculations, vibration testing should be carried out on the actual machines in use. Earlsmere offer on-site vibration testing. Contact Earlsmere for further information.

Pre-Use Check

A pre-use check should be completed each time a breaker is brought into use. Where vibration exposure is tracked in Toolminder, the pre-use check is presented automatically before timing begins, so it is completed as part of starting work with the machine. Checks are typically completed in 2-3 minutes where no issues are found.

PPE Requirements

Head protection: an industrial safety helmet to EN 397, as required on site and because breaking throws fragments upward as well as outward
Eye protection: impact-rated eye protection to EN 166 is essential; breaking concrete and masonry produces high-velocity fragments. Standard safety glasses typically carry only the low-energy F impact grade, so goggles or a face shield rated to the medium-energy B grade are appropriate for heavier breaking, per your organisation's risk assessment
Hearing protection: hearing protection to EN 352 is essential; breakers operate well above the levels at which it becomes mandatory under the Control of Noise at Work Regulations 2005, and operators should be aware that noise exposure is cumulative across the day. The noise Regulations guide covers the thresholds
Respiratory protection: breaking concrete, mortar, or stone releases respirable crystalline silica, which causes irreversible lung disease at exposures far below visible dust levels. RPE per your organisation's COSHH assessment should be worn, with an FFP3 respirator the common minimum for concrete breaking, alongside water suppression or extraction where the assessment requires it. Tight-fitting RPE such as an FFP3 mask only protects a wearer who has been face-fit tested for that specific model. Dust control is a health control of the same seriousness as vibration management
Foot protection: safety boots to EN ISO 20345 with toe and midsole protection; dropped breakers and steels, and the rubble underfoot, are both realistic hazards
Gloves: good-grip gloves in good condition. Anti-vibration gloves should not be relied upon as a control measure for HAV exposure: the HSE advise that their effectiveness against the vibration frequencies produced by this category of equipment is limited, and relying on them risks a false sense of protection. Reducing trigger time and maintaining equipment in good condition are the effective controls. Warm, dry gloves do, however, matter: cold hands are more vulnerable to vibration injury

Do not use a breaker with a safety-critical defect. Any breaker with a damaged power cord or plug, a tool retention that does not hold the steel positively, a cracked casing, a damaged or bulging air hose, missing hose restraints, faulty controls, or any fault that could affect operator safety or increase vibration output should be taken out of service and assessed by a competent person before further use.

Isolation Before Hands-On Checks

Several of the checks that follow involve handling the steel and the tool holder. Before any manual inspection, steel change, cleaning, or adjustment, the breaker must be made incapable of operating.

On mains-electric breakers, unplugged from the supply before any work on or around the tool holder. Switching off at the trigger is not isolation
On battery breakers, the battery physically removed before any manual inspection, steel change, or cleaning. With the pack seated, a bumped trigger is all it takes
On petrol breakers, the engine stopped and, for any work at the tool holder, the spark plug lead disconnected in line with the manufacturer's handbook
On air breakers, the air supply isolated at the compressor or manifold and the hose vented of pressure before uncoupling or any work at the tool holder. A pressurised hose whipping free is a serious injury mechanism in its own right
Gloves worn when handling steels: a recently used steel can be hot enough to burn
Breakers taken out of service due to a safety-critical defect should be tagged or labelled clearly to prevent use by another operator, and physically separated from serviceable machines where possible, with a service job raised in Toolminder so the fault is formally recorded and tracked

Steels & Tool Retention

Steel condition is to a breaker what chain sharpness is to a chainsaw: the single most operator-controllable factor in both performance and vibration exposure.

Correct steel for the task and the machine, with the correct shank type and size for the tool holder (for example SDS-max or hex). A wrong or worn shank hammers loose in the holder, damaging both
Point or chisel edge in good condition. A blunt steel does not break material; it transmits energy back into the machine and the operator's hands, increasing both vibration and the trigger time needed for the same work
No mushrooming on any part of the steel. A mushroomed striking end sheds metal fragments at speed and is a defect, not a cosmetic issue: the steel should be dressed or replaced before use
No cracks, chips, or excessive wear along the steel, and no bent steels in use or in the kit
Shank cleaned and lubricated per the manufacturer's handbook before fitting
Tool retention latch or sleeve operating correctly and holding the steel positively: fit the steel, lock the retention, and confirm by hand that the steel cannot be unintentionally withdrawn. Some holders allow the steel a deliberate degree of axial movement; the check is that it is retained, not that it is rigid. A retention that does not lock takes the breaker out of service
Excessive play between shank and holder noted and reported. A worn holder increases vibration and accelerates steel wear, and it will eventually fail to retain

Body, Casings & Handles

Body and casings free of cracks and impact damage, with all fasteners present and tight. Breakers live a hard life and shed loose bolts quickly
Handles secure, with no excessive play against the body. On machines with vibration-damped handles or a sprung damping system, the damping elements visually checked for cracking, perishing, or collapse, and any noticeable increase in vibration at the handles compared to the machine's normal feel treated as a fault and investigated, not worked through. A collapsed damping system can multiply the vibration reaching the operator at any given trigger time
Side handle, where fitted, secure and correctly positioned for the work
Trigger and any lock-on or lock-off mechanism moving freely and returning positively when released

Power Source Checks

Mains-Electric Breakers

Supply is the site-standard reduced low voltage (typically 110V centre-tapped in the UK) or protected per your organisation's arrangements
Cord in good condition along its full length: no cuts, abrasion, crushing, or taped repairs, with the cord anchorage at the machine intact and the plug undamaged with no bent or missing pins
Portable appliance testing or formal inspection in date per your organisation's regime, with the label legible. Toolminder can hold each machine's test records against the asset
Vents clear of packed dust, and the machine running without sparking from the vents, burning smells, or intermittent cutting out, any of which is a fault
Cord routed to avoid water, sharp edges, and the work area itself, and never used to drag or lower the machine

Battery Breakers

Battery charged and correctly seated and latched before work, with the casing free of cracks, swelling, or signs of water ingress and the terminals clean
Battery physically removed, not just switched off, before any hands-on work, as covered under Isolation Before Hands-On Checks
Spare batteries carried and stored per the manufacturer's guidance, protected from contact with metal objects and from extremes of temperature

Petrol Breakers

No fuel leaks, with the fuel cap secure and its seal intact; check around the cap, tank seams, and beneath the machine
Correct fuel or fuel mix per the manufacturer's handbook, from fresh fuel
Air filter clean and correctly seated; a blocked filter increases engine load and worsens running
Exhaust secure and undamaged, and directed away from the operator's working position
Refuelling carried out with the engine off and cooled, away from ignition sources, with no smoking, on ground where spillage can be contained, and the machine moved away from the refuelling point before starting

Air Breakers

Hoses free of cuts, bulges, soft spots, and abraded reinforcement along their full length
Couplings secure and correctly mated, with safety clips or pins fitted and whip-check restraints fitted across every connection, and no coupling ever broken while the hose is under pressure
Operating pressure per the manufacturer's handbook, and the compressor's own daily checks completed per its procedures
In-line lubricator, where fitted, serviced and topped up; a dry air tool wears fast and vibrates more
Hoses routed to avoid traffic, sharp edges, and standing water, with couplings kept out of the mud

Operational Check

Machine starts and runs per the handbook, strikes cleanly when loaded against material, and stops promptly when the trigger is released
No abnormal vibration, rattles, or noises compared to the machine's normal character. Any change should prompt investigation before work begins
Breakers are percussive tools designed to strike against resistance: avoid sustained free-running off the work where the handbook advises against it, as idle blows hammer the machine and the operator's hands for no output
Any failed task should prompt a reason for failure and supporting photos. Raise a service job immediately within the app
Use the observations field to note early signs of wear, unusual vibration, or running issues. Proactive reporting prevents unplanned downtime and protects operator health

Work Area & Planning

Buried and embedded services addressed before breaking starts, under your organisation's procedures: scanning, service drawings, and permits where required. Striking a live cable or gas main with a breaker is a fatality mechanism, and embedded rebar or post-tensioned elements carry their own risks. This document does not cover those procedures; confirm they have been followed before the first blow
Silica dust controls in place per the COSHH assessment: water suppression or on-tool extraction where required, RPE worn, and other trades kept clear of the dust zone
Exclusion arranged around the work: breaking throws fragments, and bystanders should not be within the range your risk assessment sets
Manual handling planned: full-size breakers commonly weigh 15 to 30 kg or more. Getting the machine to the work, and up from the ground, is a two-person lift or a mechanical-aid task where your assessment says so, and awkward postures holding a breaker horizontally or overhead both raise the effort involved and change what reaches the operator's hands
Footing and body position stable, with the work at a height and angle the operator can control; breaking above shoulder height needs specific justification and kit
Cold weather planned for: cold hands are more vulnerable to vibration injury, so warm dry gloves and shorter trigger-time sessions matter in winter
Trigger-time rotation planned across the team before work starts, using each operator's remaining daily exposure, not guesswork at the end

End-Use Check

An end-use check should be completed each time a breaker is finished with and returned to storage. Where exposure is tracked in Toolminder, an end-use check can be configured to run automatically when the machine is stopped. Completing it closes the operator's usage record for that session, which is important for accurate HAV exposure tracking on the highest-exposure tool most organisations own.

Cleaning & Condition

Machine isolated before cleaning begins: unplugged, battery removed, engine stopped, or air supply isolated and vented, as applicable
Dust and debris removed from the body, vents, and tool holder. Avoid dry sweeping or blowing silica-laden dust with compressed air; wipe down or use extraction in line with your dust control arrangements
Steels removed, inspected, and stored properly: edges and points assessed honestly, mushrooming dressed or the steel replaced, and shanks cleaned and lightly lubricated per the handbook so the next pre-use check does not begin with a fault
On electric machines, the cord inspected as it is coiled, which is when damage from the day gets found, and coiled loosely without tight kinks
On air machines, hoses drained, coupled ends protected from mud, and coiled without kinks

Wear & Damage Review

Damping elements and handles re-checked after the day's use, especially if the operator noticed any change in vibration during the session
Tool holder and retention re-checked for play and positive locking
Any new damage, leaks, or running issues recorded with notes and photos before the machine is returned to storage. Raise a service job if a fault requires attention before next use

Storage & Transport

Machine stored dry and secure, out of reach of unauthorised users, with batteries and fuel managed per the manufacturer's guidance for the expected storage period
For transport, the machine secured against movement, steels carried so their edges are protected and cannot fly free, and fuel carried only in approved containers
Check saved to the asset history, with operator usage time recorded and visible to supervisors for HAV exposure monitoring

HAV Exposure: Operator Responsibilities

Operators using breakers should be aware of their cumulative daily vibration exposure and should report any symptoms of hand-arm vibration syndrome (HAVS), including tingling, numbness, or whitening of the fingers, to their supervisor immediately. Early reporting is important as HAVS is a progressive condition and symptoms can become permanent if exposure continues without intervention. The guide to HAVS symptoms and employer responsibilities covers what to look for and what should happen next.

Operators should also be aware that vibration exposure on a given day is cumulative across all equipment used, not just the breaker. A morning on a grinder or a drill draws from the same daily budget, and on a tool this far up the vibration scale, the remaining trigger time available may be far shorter than the work plan assumes.

A blunt steel is an exposure problem, not just a consumable. A blunt or wrong steel increases the vibration transmitted to the hands and increases the trigger time needed for the same output, so it raises exposure twice over. Sharp, correct, undamaged steels are one of the most effective HAV controls available on a breaker and should be treated with the same seriousness as any other safety measure.

Common Situations

All tasks pass

Mark each task as Pass, add any observations if relevant, and the check is complete. The breaker is confirmed in good condition and ready for use. Plan the session's trigger time against the operator's remaining daily exposure budget before starting work: on a breaker, that budget is measured in minutes, not hours.

Blunt or mushroomed steel identified

Mark the relevant task as Fail and document the condition. Replace or dress the steel before use: a blunt steel raises vibration exposure and trigger time, and a mushroomed striking end sheds metal fragments at speed. Record the change in Toolminder so steel consumption per machine is visible over time; a machine eating steels is telling you something about its condition or its use.

Steel too hot to change

After sustained breaking, the steel can be too hot to handle. Allow it to cool naturally or use suitable gloves and handling methods to remove it, and do not quench a hot steel in water unless the manufacturer permits it: rapid cooling can affect the steel's properties. Record the change as normal so steel condition stays visible in the asset history.

Increased vibration noted during use

If the operator notices vibration levels are higher than the machine's normal feel, stop and inspect. Common causes include a blunting steel, a worn tool holder, loose fasteners, or a failing damping system. Record the observation, raise a service job in Toolminder, and do not continue use until the cause has been identified. On a breaker, "working through it" converts directly into operator harm.

Damaged cord, failed retention, or damaged air hose

A breaker with a damaged power cord or plug, a tool retention that will not hold the steel positively, or a cut, bulging, or unrestrained air hose must be taken out of service immediately. These are safety-critical faults. Tag or physically separate the machine so it cannot be picked up in error, record the fault in Toolminder, and raise an urgent service job for assessment by a competent person.

Operator approaching daily HAV exposure limit

If an operator's cumulative HAV exposure for the day is approaching the EAV or ELV, breaking work should be stopped or handed to another trained operator with budget remaining. Record the session end in Toolminder so the exposure record is accurate. Supervisors can review live sessions and operator records across all assets to rotate the work before limits arrive, which on breakers is the difference between planning and breach.

Configuring Breakers in Toolminder

Toolminder can be configured with your organisation's breakers and demolition hammers as individual assets, each with their own pre-use and end-use check templates covering the checks in this document. HAV exposure is tracked in real time as operators use each machine, with Toolminder calculating cumulative daily exposure automatically across every tool used that day and alerting as the EAV and ELV approach. Accurate vibration data matters more on breakers than on any other category, and magnitudes change meaningfully with steel, holder, and damping condition. Earlsmere offer on-site vibration testing to ensure figures reflect real-world conditions rather than manufacturer quoted values. Contact your Toolminder representative to discuss configuration and vibration testing for your fleet.

Important Notice

This document is intended as general guidance only and does not constitute legal, safety, or compliance advice. It does not replace any statutory obligations, manufacturer instructions, or the requirements of relevant legislation including PUWER, the Control of Vibration at Work Regulations 2005, the Control of Substances Hazardous to Health Regulations 2002, or HSE guidance on hand-arm vibration and construction dust where applicable. Organisations are responsible for determining appropriate inspection intervals, exposure limits, training requirements, and procedures for their own equipment and circumstances. Earlsmere Limited accepts no liability for any loss or damage arising from reliance on this document.

All resources