Eleonora Vilkancaite is a Digital Marketing Assistant at i2Comply. She has a University degree in Business Management and uses her knowledge to provide great content in our Social Media pages and to write informative articles on various Health and Safety and Regulatory Compliance topics.
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An abrasive wheel is a disposable tool made from an abrasive material or compound. These wheels are typically found on grinders, grinding machines, and metal cut-off saws. Abrasive wheels are a very versatile tool. They rotate at high speed and are capable of of cutting, shaping, smoothing and cleaning a wide variety of materials. So, engineers, builders, bricklayers, electricians, carpenters, fitters and welders widely use them at work.
However, since the the abrasive wheels rotate at high speed, they are capable of causing severe injuries. According to the Health and Safety Executive (HSE), almost half of all accidents that involve an abrasive wheel occur due to operator error or an unsafe work system. So, anyone whose work involves using or handling abrasive wheels, must be aware and follow strict health and safety practices to protect both themselves and anyone around them.
Through our knowledgeable manufacturing sector courses, we wanted to use this article to educate you on the safe use of abrasive wheels.
You are most likely to come across abrasive wheels in bench grinders, pedestal grinders and portable grinders.
Bench grinders permanently stay on a bench top. They are used in workshops for sharpening tools, rough shaping and removing burrs.
Pedestal grinders have a mounted wheel that sits within a pedestal. They are used to work on extremely hard materials and sharpen cutting tools.
Portable grinders are hand-held power tools, such as angle grinders. They are used for grinding, cutting and polishing. Portable grinders are common in metalworking and construction sites, as well as in the emergency rescues.
There are many different types of abrasive wheels, making them suitable for a wide variety of different tasks. Some examples include:
Straight wheels are basic grinding wheels often used in home workshops. They can be found on bench or pedestal grinders. Straight wheels are most commonly used for surface grinding and to sharpen tools, such as wood chisels and lawnmower blades.
Cup wheels can re-sharpen, finish or polish concrete and stone. However, with a small enough grit they can also remove adhesive and paint from materials.
Dish wheels look similar to cup wheels but are shallow and have a thinner edge. Their shape allows the tool to reach into narrow cracks and crevices that a cup wheel cannot access.
Cut-off wheels usually have a very narrow grinding surface. They make deep, narrow, precise cuts at 90-degree angles. They are used with both portable and stationary tools on numerous materials including aluminium, plastic, sheet metal and stainless steel.
Segmented wheels have segmented sections instead of a continuous rim. When used with cooling or lubricating fluids, these wheels remove large amounts of material rapidly without damaging its surface.
Plug and cone wheels can clean and remove excess metal from castings where other wheels cannot easily access.
Incorrect use of abrasive wheels can cause devastating injuries and even death. Almost half of all accidents that involve an abrasive wheel happen due to operator error or an unsafe work system. So, operators must follow instructions and adhere to strict health and safety requirements to reduce the risks of injury. The dangers of abrasive wheels include:
An abrasive wheel rotates at high speed and is capable of causing severe injuries if it comes into contact with any dangling items. For example, rags and waste can become entangled into the wheel when they come into contact, causing wheel breakage. Also, loose clothing, long hair or body parts can come into contact with the rotating wheel, may wrap around it and draw into the wheel. This can severely injure the operator.
Every wheel has the inherent risk of wheel breakage. If a wheel breaks while rotating at a high speed, it can eject particles at its rotation speed. This can cause serious wounds and can even be fatal.
When cutting and grinding materials, dangerous dusts, smokes and flying particles can spread into the air. It can cause coughing, sneezing, asthma attacks and develop into serious respiratory issues in the long term. For example, when cutting concrete, brick or stone, silica dust can spread into the air. When a person inhales silica dust, the particles scar lung tissue and can cause silicosis &#; incurable lung disease.
Working with abrasive wheels can produce an incredibly loud noise. Both short or prolonged exposure to loud noise can cause tinnitus and permanent hearing loss.
Operating vibrating machinery can cause hand arm vibration syndrome. This condition can lead to damage to the nerves, joints and muscles.
Grinding and cutting materials can cause sparks and start fire if the operator is carrying out work close to flammable materials.
There is a risk of electric shock if the operator cuts into cables or exposed live parts.
Grinding and cutting operations often involve the use of grinding fluids, lubricants and coolants. Workers are at risk of inhaling fluid mist and vapour, which can cause asthma, bronchitis, irritation of the respiratory tract and breathing difficulties. Also, the exposure may cause irritation to eyes, nose, throat and skin.
Tight, confined spaces can have high dust and fume concentration, which can cause harm to the operator&#;s health. It also poses a high risk of fire.
Most abrasive wheel injuries are due to operatives using the wrong type of wheel or using it in the wrong way or just not following the correct safety protocols.
Mainly these injuries are either caused by contact with the tool itself or by materials ejected during operation. Common injuries include: Cuts to skin, Finger amputation, Eye injuries, Head injuries and Foot injuries.
You can prevent most accidents that occur with abrasive wheels by ensuring, thorough training is delivered to operatives, appropriate PPE is always worn and by following the guidelines below.
To ensure you keep safe whilst using abrasive wheels, you should:
Abrasive wheels have specific markings that help users to select the correct wheel for the equipment and task they need to carry out. Knowing which wheel to use for each task and type of machinery is a vital skill. Using the incorrect wheel for a task can have serious consequences. There is a British standard for marking abrasive wheels.The wheel markings must follow Annex A of BS EN and BS ISO . Abrasive wheel markings must include the following information:
Trade mark &#; the wheel must have the manufacturer trade mark or brand.
Test record &#; it indicates that the wheel meets the required safety standards.
Restrictions &#; the label may include accompanying information for restrictions on use and will indicate if the wheel is suitable for a task. Also, the wheel markings may indicate PPE requirements and other safety precautions.
Expiry date &#; wheels have a marking of the expiry date. Operators should never use an abrasive wheel after the expiry date.
Dimensions &#; the wheel label provides wheel&#;s diameter, thickness and hole size in millimetres.
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Specification mark &#; it provides information on the composition and structure of the wheel. It indicates the abrasive material, grain size and bond.
Manufacturer&#;s code &#; this is a traceable number that indicates the source and manufacturing details of the wheel.
Maximum speed &#; all wheels over 80mm in diameter should have a marking of maximum permissible speed on the label. The users must never exceed the maximum permissible speed of the wheel.
High speed wheels (50 m/s or more) have a colour-coded stripe in the centre of the wheel that indicate the maximum operating speed.
Additional information on markings can be found within HSG17 on the HSE website.
Employers must ensure employee&#;s health and safety at work. The following regulations determine employers&#; and employees&#; legal duties that apply when using abrasive wheels at work.
The Health and Safety at Work Act (HASWA)
The Health and Safety at Work Act , also referred as HASWA, places a duty on employers or anyone who has control over a workplace to protect employees or anyone in the premises against health and safety risks. This includes the risks posed by the use of abrasive wheels at work.
The management of Health and Safety at Work Regulations
The management of Health and Safety at Work Regulations reinforce the HASWA by placing duties on employers, employees, contractors, designers and their clients to assess the health and safety risks to third parties and to take appropriate measures to protect them.
The provision and use of work equipment (PUWER)
The Provision and use of work equipment , also referred as PUWER, aims to keep workers safe while using equipment and machinery. PUWER requires employers to:
Personal protective equipment (PPE) at work regulations
PPE at work regulations oblige an employer to assess the risks and hazards in the workplace and provide suitable PPE to all workers. This includes employees, contractors, temporary workers and anyone else carrying out work in the workplace. The employer is also responsible for the maintenance, storage and replacement of the PPE.
The Control of Substances Hazardous to Health (COSHH) is relevant to the use of abrasive wheels as during cutting and grinding, hazardous substances such as dusts and fumes can spread into the air. You can learn more about COSHH here.
The Control of Noise at Work Regulations is relevant to work with abrasive wheels, because grinding and cutting machines produce loud noise that can permanently damage hearing. Therefore, employers must put hearing protection measures in place.
The Control of Vibration at Work Regulations apply to the use of abrasive wheels because it exposes workers to the health risks associated with the vibration from hand-held cutting and grinding machines.
The Supply of Machinery (Safety) Regulations require wheel manufacturers to take all precautions to reduce the risk of breakage and ensure that wheels meet required safety standards.
We offer the following RoSPA-assured and CPD-certified online Abrasive Wheels Training Course.
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In addition to the machine guards that protect the user against larger ejected pieces broken off from the wheel or the workpiece, it is necessary for users to wear eye protection as determined by a risk assessment. Eye protection complying with a relevant British Standard will protect against most of the smaller ejected particles such as dust.
Adequate and suitable respiratory protection should also be determined, based on a risk assessment including an evaluation of the level of exposure, occupational exposure limits, and on what the specific task and worker requirements are. The risk assessment should also take into account related processes which may include welding fume and/or gases used.
Dusts
There is a clear requirement under the Control of Substances Hazardous to Health Regulations (COSHH) for employers and the self-employed to assess and control the risks from dust exposure, and various workplace exposure limits exist. Often, natural ventilation is all that will be available to control exposure to dusts generated by abrasive wheels. If wet cutting is not possible, for example inside a building, then either fixed or on-tool extraction will be essential. There can be particular risks with concrete and masonry dusts, and consideration should be given to the possible need for the use of local exhaust ventilation or respiratory protective equipment (RPE). RPE should be used as a last resort. It is important that any local exhaust ventilation system is designed specifically for the task and the type of dust generated, that it is checked and serviced regularly, and that it undergoes statutory inspection/testing. Care also needs to be exercised if water is used as part of the process for dust dampening, to prevent slippery floors.
Noise
Regulations specify the level at which employers must enforce the use of hearing protection at 85dB, daily or weekly average exposure, and the level at which employers must assess the risk to workers&#; health and provide them with information and training at 80dB. There is also a legal exposure limit value of 87dB, taking account of any reduction in exposure provided by hearing protection, above which workers must not be exposed. Normally, site signage will indicate the hearing protection zones.
Depending on the specific operation, noise levels can range from moderate to very high, reaching up to 120dB. Grinding, for example, can result in noise levels in the range of 97&#;105dB. Repeated daily personal noise exposure above LEP,d 85dB can lead to permanent hearing loss and tinnitus. The LEP,d is a worker&#;s daily exposure to noise at work normalised to an 8-hour day, taking into account the average levels of noise and the time spent in each area. Almost anyone working in a metal fabrication environment is likely to be exposed to harmful noise levels. In addition to protecting against the harmful effects of noise, it is vital to maintain situational awareness so that important warning signals can be heard such as fire alarms and moving vehicles, for example.
Hand-arm vibration (HAV)
Employers must assess their employees&#; exposure to vibration and take steps as necessary to reduce exposure. The HSE&#;s vibration ready reckoner can be used to calculate how long it is permissible for an individual to operate each type of abrasive wheel or to carry out multiple operations that will expose them to the risk of Hand-Arm Vibration Syndrome (HAVS) within a defined period. Steps for reducing exposure to vibration include changing the equipment that is the source of the vibration, reducing the exposure time, and changing work methods. Health surveillance may be necessary. Anti-vibration mountings must be replaced at suitable periods not exceeding the manufacturer&#;s recommended intervals in order to reduce the risk of exposure to vibration. The risk of vibration-related injury is associated with tasks that require excessive bending of the wrists or time on tool. Prolonged exposure to vibration can cause damage to blood vessels, nerves and tendons in fingers, hands and wrists, leaving the sufferer with reduced sensitivity, strength and dexterity.
Fire or explosion
The choice of tool on which to mount an abrasive wheel should only be made after consideration of the environmental conditions of operation. Fire risk assessments take into account potential ignition sources, which would include sparks from ejected particles of steel potentially generated during the use of abrasive wheels, any fuels that might be present in the area where abrasive wheels are being used, for example packaging, and any high-risk sources of pure oxygen, for example oxyacetylene welding equipment. The risk is reduced by introducing prevention controls such as identifying a suitably inert area for abrasive wheel activity, and mitigation controls such as emergency procedures, firefighting equipment, and the provision of protected escape routes.
Where the risk is significant due to the presence of dangerous substances, for example flammable solvents or explosible dusts, Dangerous Substances and Explosive Atmospheres Regulations (DSEAR) assessments will have been completed to ensure the risk of fixed ignition sources, such as motors or lighting, are suitable. These assessments will also provide guidance for the conditions under which moveable ignition sources such as abrasive wheels can be used. Where the fire/explosion risk varies due to changes in the environment, employers may also need to implement the use of management procedures such as a hot work permit.
Electrical
Electrical risks to be considered arise from cutting power supplies or damage to machines which drive abrasive wheels. Tools which are part of the fixed installation will be inspected/tested during the periodic fixed electrical equipment to BS . Electrically powered hand tools must have portable appliance tests (PATs) which identify electrical safety faults. However, users should also be trained to carry out visual inspection of the equipment before each use. Air-powered tools will need hose checks and governor speed checks. Petrol-driven tools must have engine maintenance, filter changes, etc. Engineers should use these maintenance/inspection opportunities to double-check that guards are secure, the tool is operating safely and on/off switches are reliable.
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