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Kelly tool
Kelly tool
Kelly tool
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A Kelly Tool in the NYC Fire Museum (2nd from left)

The Kelly tool is a tool used in fire and rescue service for forcible entry and other prying and striking tasks. The predecessor of the Halligan bar, it has largely been superseded by the latter, but still sees some use.

Design and uses

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The Kelly tool is named after its designer, Captain John F. Kelly of H&L Company 163 (FDNY). It consists of a straight steel bar, generally about 28 inches long.[1] One end is formed into a chisel; the opposite end has a 90 degree adze. The primary advantage over the claw tool it replaced is that the striking end (the adze) is in a straight line with the rest of the tool; on the claw tool the corresponding end was curved into a hook with no flat surfaces.

The Kelly tool was intended specifically for opening doors and other barriers. Modern versions often are modified along the lines of the Halligan bar, especially at the chisel end. Originally the chisel blade was flat and straight; more recently it has tended to take on a curved and forked form, similar to the claw of a carpenter's hammer. There are similar tools referred to generically as "Kelly tools", but in general they are variations on the original form.

References

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Kelly tool

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from Grokipedia
The Kelly tool is a specialized forcible entry implement used by firefighters and rescue personnel for tasks such as prying open doors and windows, striking obstacles, and breaching structures during emergency operations. Developed in the early 20th century by Captain of Ladder Company 163 in the (FDNY), it represents an evolution from earlier tools like the claw tool and serves as a direct predecessor to the modern . Originally measuring approximately 24 inches in length and constructed from welded , the tool features a flat end for aligned striking and a end for leverage, weighing significantly more than later designs and sometimes contributing to user injuries from its heft. The Kelly tool emerged in the years following the introduction of the claw tool in the early , which had been inspired by a burglar's implement discovered during the response to a in the and adopted by the FDNY for its versatility in entry operations. Captain Kelly's innovation addressed key flaws in the claw tool, such as its off-center striking surface and curved that made it cumbersome and less safe for repeated impacts; by straightening the and replacing the claw with a more efficient end, the Kelly tool improved balance, reduced the risk of glancing blows, and allowed for dual striking points, leading to its rapid adoption within the FDNY. This design shift marked a pivotal advancement in equipment, emphasizing and durability in high-stakes environments, though some firefighters retained the claw tool for its unique prying capabilities on certain materials. In terms of functionality, the Kelly tool excels in scenarios requiring precise leverage and impact, such as forcing interior doors, removing frames, or extracting debris, with its robust construction enabling it to withstand extreme forces without deforming. Modern iterations, often produced by specialized manufacturers like Fire Hooks Unlimited and Council Tool, extend the original 24-inch length to 30 inches for greater reach, incorporate drop-forged 4140 for enhanced toughness, and add features like Celtex grips for better handling and a flattened surface to minimize slippage during strikes. These updates maintain the tool's core purpose while adapting it to contemporary demands, including compatibility with hydraulic systems or integration into kits. The Kelly tool's legacy is evident in its influence on the Halligan bar, invented in 1948 by FDNY Deputy Chief Hugh Halligan, who sought to rectify the Kelly's excessive weight and injury risks by lightening the design to about 8.5 pounds while retaining the and adding a pike for versatility. Today, while the dominates standard issue in fire services worldwide, the Kelly tool persists in specialized applications, particularly where a pike-free profile aids in tight spaces or reduces snag hazards, underscoring its enduring role in the progression of emergency entry tools.

History

Origins and Development

The Kelly tool emerged in the early as a key advancement in forcible entry equipment for the (FDNY), designed to overcome the limitations of prior tools like the Claw tool, which had been adapted from a burglar's implement and proved cumbersome for rapid urban fire operations. Captain of FDNY Ladder Company 163 developed the tool in the 1910s to 1920s, focusing on creating a more balanced and efficient pry bar to facilitate quicker access to burning structures amid the dense, wooden-framed buildings common in at the time. His design replaced the Claw tool's awkward fork and hook configuration with a straight shaft featuring a end and an , allowing for safer, more precise strikes and better leverage during high-stakes entries. Prototypes were iteratively tested within Ladder Company 163, where refinements emphasized enhanced durability through welded steel construction—approximately 24 inches long and weighing around 10 pounds—to withstand repeated heavy use while maintaining versatility for both prying and striking. These efforts addressed critical inefficiencies in existing equipment, such as off-center that risked to firefighters under time . By the 1920s, the Kelly tool had been adopted across FDNY units as a standard component of "the irons," proving its value through practical demonstrations of superior over ad-hoc alternatives like axes or improvised bars. This evolution laid the groundwork for further innovations, including the in the 1940s.

Designer and Early Adoption

Captain John F. Kelly served as a captain in the New York City Fire Department (FDNY)'s Hook and Ladder Company 163 during the early 20th century, where he encountered persistent challenges in forcible entry operations. Drawing from his frontline experience, Kelly observed the shortcomings of existing tools, particularly the Claw tool's awkward prying angles, off-center striking, and vulnerability to failure under intense pressure during emergency responses. These limitations, which often delayed access to fire scenes and endangered lives, inspired him to innovate a more reliable alternative. To address these issues, Kelly developed a custom-forged prototype of what became known as the Kelly tool, featuring a straight design that improved leverage and transmission for prying and striking tasks. The tool was initially produced by local blacksmiths using heavy , resulting in a durable implement approximately 24 inches long and weighing around 10 pounds. This hands-on fabrication process reflected the era's reliance on skilled craftsmanship for equipment, allowing for rapid iteration based on practical needs. The FDNY approved the Kelly tool for departmental use following successful field evaluations, marking a significant step in its early adoption as a standard forcible entry aid. It quickly replaced or complemented the Claw tool in operations, with initial production scaled through blacksmith workshops to equip and companies across the . The tool's integration demonstrated Kelly's personal innovation in enhancing operational efficiency, as it was later recognized as a foundational advancement in FDNY tool . This efficiency gain proved crucial in high-stakes scenarios, solidifying its role in FDNY protocols and paving the way for further evolutions in forcible entry technology.

Design

Physical Specifications

The original Kelly tool features welded , which undergoes heat-treated tempering to enhance its resistance to bending and deformation under significant force. This material choice ensures durability in demanding environments while maintaining structural integrity. The standard design measures approximately 24 inches (61 cm) in overall length, providing an optimal balance between reach and maneuverability for the user. This dimension allows the tool to be effectively wielded in confined spaces without excessive bulk. Weighing around 12 pounds (5.4 kg), the tool was relatively heavy, contributing to its robust performance but also posing risks during prolonged use. At one end, the tool incorporates a straight tip optimized for inserting into gaps and applying prying leverage. The opposing end consists of a 90-degree blade equipped with a flattened striking surface to accommodate impacts from hammers or axes while enabling cutting and chopping functions. The handle portion offers a smooth, tapered grip without electrical insulation, consistent with the tool's pre-modern design era prior to widespread adoption of safety standards for live electrical hazards.

Key Features and Improvements

The Kelly tool's straight bar design facilitates superior leverage in confined spaces, addressing the limitations of curved predecessors like the claw tool, which had an off-center striking surface that hindered control and increased risk during use. The end, oriented at a 90-degree to the bar, enables precise hammer-like striking with a flattened surface that minimizes slippage and delivers cleaner, more controllable impacts compared to the awkward geometry of earlier tools. At the opposite end, the chisel features a flat blade optimized for insertion into door seams or window frames, generating enhanced prying torque for efficient forcible entry without the forked design's reduced effectiveness. These design elements collectively improve durability through welded steel construction, allowing the tool to endure repeated high-impact strikes without deformation, a significant advancement over the claw tool's vulnerabilities. Ergonomically, the Kelly tool's balanced weight distribution and centered alignment reduce firefighter fatigue and injury risk during extended operations, as validated in early testing by the New York City Fire Department.

Applications

Forcible Entry Techniques

The Kelly tool facilitates forcible entry in fire rescue operations primarily through its chisel and adze ends, which allow for precise insertion and leveraged prying to breach secured doors and windows. For door breaching, firefighters insert the chisel end into the door jamb, typically 6 inches above or below the lock assembly, to create an initial gap; the adze end is then struck with a flat-head axe or sledgehammer to drive the tool deeper, followed by twisting motions to spread the frame and disengage the lock or hinges. This method exploits the tool's 90-degree adze configuration for enhanced leverage on inward-swinging doors, enabling controlled force application without excessive battering. In window access scenarios, the is wedged under the window or frame to gain purchase, while the serves as a fulcrum for prying actions that pop locks or lift sashes outward. The "adze-up" technique positions the tool with the adze facing upward during overhead strikes, minimizing back strain and improving strike accuracy by aligning the adze's flat surface inline with the shaft for better impact transmission. Integration with traditional irons sets, such as pairing the Kelly tool with the tool, allows for combined operations where the Claw hooks and pulls while the Kelly drives and pries, optimizing efficiency in multi-lock or reinforced barriers. Safety protocols emphasize coordinated , with operators working in pairs to manage heavy doors and maintain tool control during strikes. Firefighters must position themselves offset from the breach point to avoid flying or rebound, and regular tool maintenance—such as filing the and edges without over-sharpening—is critical to prevent slippage or breakage under load. These practices, rooted in early 20th-century FDNY adoption, underscore the tool's role in rapid, low-risk entries during rescues. The Kelly tool's techniques influenced subsequent designs like the , which refined similar breaching methods for broader application.

Striking and Prying Tasks

For hybrid operations during the overhaul phase, the Kelly tool is frequently paired with axes to expose and extinguish hidden fire pockets after initial suppression. This combination facilitates the systematic removal of charred and insulation, preventing rekindle while supporting thorough scene assessment. Such versatility stems from the tool's balanced design, which complements the cutting action of axes for efficient material breakdown. FDNY training materials highlight the adze end's flat striking surface, which aligns directly with the tool's shaft to enable controlled impacts on metal barriers, reducing the risk of glancing blows and enhancing operator safety during precision tasks.

Comparisons and Evolution

Relation to the Halligan Bar

The Halligan bar was developed in by FDNY Deputy Chief Hugh Halligan as an improvement on the Kelly tool, incorporating its core -chisel concept while introducing key enhancements for greater versatility in forcible entry operations. Building directly on the Kelly's design, which featured an for striking and a end for prying, Halligan replaced the chisel with a forked end to facilitate better removal of pins and other hardware, allowing for more efficient prying and leverage in tight applications. This adaptation, combined with the addition of a pike (or ) at the opposite end, enabled pulling actions and multi-purpose use that were absent in the Kelly tool, transforming it into a more comprehensive assault tool. While the Kelly tool was approximately 24 inches long and constructed from welded steel components, the was 30 inches long and utilized drop-forged construction from a single piece of No. 4140 steel, resulting in a lighter yet stronger tool weighing around 8.5 pounds. Halligan also refined the taper and balance inherited from the Kelly, improving striking efficiency and overall handling for prolonged use in demanding scenarios. Due to potential conflicts of interest, the FDNY did not initially purchase Halligan bars directly from the inventor but allowed individual firefighters and units to acquire them; following the patent's expiration, the department adopted comparable versions from other manufacturers, leading to the gradual phase-out of the Kelly tool in favor of the Halligan's proven superiority in field tests and operations. The Kelly tool's influence endures in the Halligan bar's design, particularly its inline striking surface and balanced proportions, which enhanced the safety and precision of forcible entry tasks. Although largely superseded, the Kelly tool retains a niche legacy, with some fire departments continuing to use it for specialized applications where its compact profile offers advantages over the longer . As of 2025, manufacturers like Council Tool have introduced updated Kelly tools with enhancements such as a tuned for better performance, optional 24- or 30-inch lengths, and durable finishes.

Differences from the Claw Tool

The claw tool, originating in the early as one of the earliest forcible entry implements in formalized , featured a curved end designed for pulling nails and prying, paired with a forked opposite end, but its off-center striking surface made it heavy, difficult to handle, and prone to unreliable engagement during operations. In contrast, the Kelly tool, developed by FDNY Captain in the early , introduced key innovations by replacing the claw tool's curved claw with a straight end aligned for more reliable and centered striking, while enhancing the end for greater robustness compared to the claw's hook, allowing for safer and more effective prying and leverage in tight urban environments. These design changes addressed the claw tool's performance limitations, providing the Kelly tool with cleaner, more controllable strikes, improved leverage for forcible entry tasks, and reduced to the user from slippage or awkward handling, as the all-steel welded construction—typically around 24 inches long—enabled better force transmission without the vulnerabilities of earlier designs. The Kelly tool's superiority led to a rapid shift in adoption within departments like the FDNY, where it largely supplanted the claw tool by the mid-20th century for its hybrid capabilities in both prying and striking, particularly suited to dense urban scenarios requiring versatile, compact tools. Today, the claw tool sees rare use, mostly in historical or specialized contexts, while Kelly tool variants continue to be carried in some legacy fire departments for tasks demanding a non-spiked, dual-purpose entry option, though it has further evolved into tools like the .
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