Safe Operation of Abrasive Wheels / Power Tools For Cutting & Grinding

The purpose of this standard HSE procedure is to provide guidance on the safe operation and use of abrasive wheels used as high speed power tools for grinding and cutting operations on the construction sites or in the offices and house hold.

Project management including project manager, HSE manager and discipline engineers are responsible for the implementation of this standard procedure.

Any person using a high speed tool with abrasive wheel attached should be trained and assessed as competent prior to them actually using the tool on site.

Hazard Identification and Risk Assessment

When an abrasive wheel shatters, the results are often serious and sometimes fatal. Many of these incidents happen because the wheel is being operated at too high speed, or the wrong wheel for the task has been chosen.

It is essential therefore that all persons who fit or mount abrasive wheels are trained and competent, guards are fitted to the machines and eye protection worn by the operatives all the time.

List of Risks associated with abrasive wheel

a) Wheel bursting

b) Contact with wheel

c) Hit by flying materials

d) Entanglement

e) Exposure to noise

f) Exposure to dust

g) Exposure to fume (in confined or restricted space)

h) Improper storing of wheels / discs

Control Measures for Safe Operation

a) Once a trained person has been deemed competent their names will be entered into the site training register and appointed to use such tool.

b) Where the appointed person is found to have fitted a wheel incorrectly, the appointment can be revoked from the register and the person retrained before being permitted to use that equipment again.

c) The tool operator must ensure that only the correct wheel is used for the machine and material to be worked on.

d) The RPM should be marked on the wheel and the machine, the (RPM) of the machine should not exceed that of the wheel.

e) The machine spindle and flanges should be in good condition and the flanges of equal diameter, and not less than one third that of the wheel. The flanges should be recessed on the side next to the wheel and the drive flange keyed to stop any slipping.

f) The correct tool only should be used for changing wheels and care should be taken not to over tighten flanges. Ensure that the tool is disconnected from the power source whilst the blade is being changed.

g) Guards should be of good condition, properly adjusted and secured in position.

h) On bench mounted grinders the machine should be securely fixed, with all guards and rests properly adjusted and set at correct distance from wheel. (Rests should be no more than 3mm away – Working Gap).

i) Loose clothing, which could become entangled with the machine/wheel, should not be worn.

j) Eye protection and ear muffs/plugs should always be worn. Mandatory warning signs to be displayed in the area of noise.

k) Care should be taken when operating portable machines in enclosed areas, to ensure adequate ventilation is provided.

l) If dusts are being generated, then suitable respiratory protection should be worn.

m) Suitable protective footwear should always be worn when using this type of machinery.

Storage of Abrasive Wheels / Discs

Storing of the wheels is of great importance, stacking these wheels one on top of each other could lead to disastering outcomes due to the wheels not being able to breathe and collecting moisture.

When fitted to machines and suddenly turning at High RPM these wheels can fracture and shutter.

The wheels should be stored on a steel peg/pin vertically and spaced out.

To minimize deterioration, wheels must be stored in a room which is dry and not subject to extreme temperatures.

It is recommended that wheels should be marked with the date they are received from the supplier.

Older wheels should be issued before newer wheels and if there is any doubt, or if wheels have been in stock for more than three years, the manufacturer should be consulted about their suitability for use.

Suitable racks, bins or compartmented drawers should be provided to accommodate the various types of wheels used.

Most plain and tapered wheels are best supported on their edges or on a central support.

Related Records

Abrasive Wheels Safety Checklist

Abrasive Wheels Checklist
NO.	ITEM	YES	NO
Machinery:
1	In good condition, guard fitted, correctly adjusted?
2	Recent electrical inspection tag and up to date?
3	Are rests correct distance from wheel?
4	Maximum spindle speed clearly marked?
5	Are correct flanges fitted?
Abrasive Wheel:
6	Correct wheel type for the job being worked on?
7	Is the blade/disc free from cracks and excessive chips?
8	Is the RPM clearly marked on the wheel?
9	Does the RPM of the machine not exceed that of the wheel?
Operator:
10	Is he trained, competent, appointed and has his name entered into the register?
Tools:
11	Are they in good condition?
12	Are they the right type for the job?
13	Personal protective equipment being worn appropriately, eyes, ears, respiratory, clothing and footwear?
Notices:
14	If required, is area barricaded off?
15	If necessary, is a notice put up to warn personnel?