08 Jul Portable Abrasive Saws & Grinders

Portable Abrasive Saws & Grinders

Portable abrasive saws and grinders are commonly used for cutting, grinding, shaping, and finishing metal, masonry, concrete, and other materials. These tools operate at very high speeds and can cause serious injuries if a wheel, blade, or disc breaks, the tool kicks back, or the operator contacts the rotating accessory.

Before operating an abrasive saw or grinder, employees must be trained in the safe use of the specific tool and understand the hazards associated with both the equipment and the material being cut or ground.

Pre-Use Inspection

Inspect the tool and accessories before each use. Check for:

• Damaged or missing guards.
• Cracked, chipped, warped, or otherwise damaged wheels, blades, or discs.
• Damaged electrical cords, plugs, switches, or housings.
• Loose or damaged handles.
• Improperly installed accessories.
• Damaged air or hydraulic hoses and connections.
• Evidence that the tool has been dropped or abused.

Remove damaged or defective equipment from service immediately.

Abrasive wheels requiring a ring test should be tested before mounting in accordance with the manufacturer’s instructions and applicable requirements.

Selecting and Mounting Abrasive Wheels

Always use a wheel, blade, or disc designed for the specific tool and application.

• Verify that the accessory is the correct type and size.
• Never exceed the maximum operating speed marked on the wheel, blade, or disc.
• The accessory’s rated speed must be at least equal to the maximum operating speed of the tool.
• Never force an accessory onto the spindle.
• Use only mounting hardware, flanges, and adapters approved for the tool and accessory.
• Never use a wheel, blade, or disc that has been dropped or damaged.
• Disconnect the tool from its energy source before changing accessories.
• Follow the manufacturer’s mounting and inspection instructions.

Never modify a wheel, blade, disc, guard, or tool to make incompatible components fit.

Guards

Never operate an abrasive saw or grinder without the required guard properly installed and positioned.

Guards help protect the operator from:

• Accidental contact with the rotating accessory.
• Sparks and flying particles.
• Fragments if a wheel or disc breaks.

Do not remove, bypass, modify, or secure a guard out of position for convenience.

Safe Operation

Before starting the tool:

• Make sure the workpiece is stable and properly secured.
• Keep coworkers clear of the work area.
• Position yourself out of the expected path of wheel fragments.
• Hold portable tools firmly using the handles provided.
• Ensure the accessory is clear of the workpiece before starting the tool.

During operation:

• Allow the tool to reach operating speed before contacting the workpiece.
• Apply steady, controlled pressure.
• Never force the tool.
• Do not twist, bind, pinch, or side-load a wheel unless it is specifically designed for that type of operation.
• Keep hands and body parts away from the rotating accessory.
• Maintain stable footing and body position.
• Be prepared for kickback or sudden tool movement.
• Do not set the tool down until the wheel or blade has stopped completely.

Never use a cutting wheel for side grinding unless the manufacturer specifically permits it.

Electrical, Pneumatic, and Hydraulic Tools

Electrical tools must be protected and used according to applicable electrical-safety requirements.

• Inspect cords and plugs before use.
• Use required ground-fault circuit interrupter (GFCI) protection or an applicable assured equipment grounding conductor program on construction sites.
• Keep electrical connections away from water.
• Do not use equipment in wet or damp conditions unless it is specifically designed and approved for that environment.

For pneumatic and hydraulic tools:

• Inspect hoses, fittings, and connections before use.
• Secure connections as required.
• Never exceed the manufacturer’s recommended operating pressure.
• Protect hoses from cuts, crushing, heat, and other damage.
• Never carry or lift a tool by its hose.

Gasoline-Powered Abrasive Saws

Gasoline-powered saws create additional hazards involving fuel, fire, and carbon monoxide.

• Never operate gasoline-powered equipment in an enclosed or poorly ventilated space where exhaust can accumulate.
• Shut the engine off and allow hot components to cool before refueling.
• Keep ignition sources away from fueling operations.
• Use approved fuel containers.
• Clean up spills promptly.
• Follow applicable flammable-liquid storage and handling requirements.

Carbon monoxide is colorless and odorless. Do not rely on smell to determine whether an area is safe.

Dust and Airborne Hazards

Cutting and grinding can generate hazardous dust, fumes, and particles depending on the material being worked.

Before beginning, identify the material and determine whether it may contain hazards such as:

• Respirable crystalline silica.
• Lead-containing coatings.
• Hexavalent chromium.
• Other metals or hazardous coatings.

Use required engineering controls, such as wet-cutting methods or local exhaust ventilation, whenever applicable.

Respiratory protection must be used when required and only in accordance with the company’s Respiratory Protection Program.

Sparks and Fire Hazards

Grinding and abrasive cutting can generate sparks capable of traveling significant distances and igniting combustible materials.

Before beginning:

• Remove or protect combustible and flammable materials.
• Check both sides of walls, floors, or other surfaces when sparks could travel through openings.
• Keep sparks away from compressed-gas cylinders, fuel containers, and flammable liquids.
• Follow the company’s hot-work procedures when the operation qualifies as hot work.
• Have appropriate fire-extinguishing equipment available when required.

Personal Protective Equipment

PPE must be selected based on the task and hazards and may include:

• Safety glasses with side protection.
• Goggles where additional particle or dust protection is required.
• A face shield worn over primary eye protection for severe flying-particle hazards.
• Hearing protection.
• Appropriate work gloves.
• Protective footwear.
• Protective clothing.
• Respiratory protection when required.

Avoid loose clothing, jewelry, or other items that could become caught in rotating equipment.

Remember

Portable abrasive saws and grinders operate at extremely high speeds. A damaged, incorrectly mounted, or improperly rated wheel can fail violently.

Inspect the tool and accessory before use, keep guards in place, verify the wheel or blade speed rating, control dust and sparks, wear the required PPE, and never force the tool.