Avoid Unsafe Practices When Using Abrasive Products

By Tony Hufford,Category Manager, Metal Fabrication, Weiler Abrasives

Safety is everyone’s responsibility. All day. Every day.

In a manufacturing environment, safety isn’t covered by a one-time seminar or meeting. It’s an ongoing task involving management and operators.

Making safety a priority can add upfront costs to an operation — time and money spent on training or the proper products, for example. But an investment in safety pays off in the long run, resulting in more productive workers who lose less time to accidents and injuries.

Learn more about some tips for safe use of abrasive products and why safety is critical for operator wellbeing and productivity.

The cost of unsafe practices

Unsafe practices happen in many shop environments. While an operator may not be injured every time an unsafe practice occurs, the potential for injury is always there.

Some unsafe practices pose a greater risk of injury than others. An operator using a grinding wheel while wearing gloves and short sleeves has the potential to be hit with sparks on bare skin. While this situation isn’t recommended, it’s not likely to cause serious harm or injury. Compare that to incorrect product usage that causes the product to come apart and send debris flying. That unsafe practice has the potential for serious injury to the operator and others.

When abrasive products are used unsafely or improperly, it can result in several negative consequences:

• Personal injury: Operators or others in the work area can be seriously injured if a product breaks and causes high-energy debris.
• Increased costs: Operations may have to deal with the cost of worker’s compensation when someone is injured on the job. Companies may also see a loss of revenue if the injury results in downtime or slowdown. This is true even for minor injuries that cause an operator to leave their work area for a short time.
• Reduced productivity: The injury of one worker can have a ripple effect that decreases productivity in the entire operation. This can have an impact on throughput goals or the ability to complete jobs on time. Even if an operator isn’t injured, but they change the way they use an abrasive product because they are not wearing the proper personal protective equipment (PPE) for example, this can affect productivity. If it takes twice as long to grind a weld due to the angle of approach, it costs money.

Common safety mistakes with abrasives

Among the most frequently used types of abrasives, there are several common mistakes that can result in an unsafe environment.

• Cutting wheels: Many operators don’t realize that the type of tool guard they should use differs depending on the type of cutting wheel being used. When using a Type 1 (or flat) cutting wheel, ANSI specifies that the guard should come over the top of the wheel covering 180 degrees of the abrasive wheel periphery and both sides of the wheel. This is referred to as a half-moon guard. Often these guards must be purchased separately from the tool, since Type 27 guards are typically the standard provided with purchase.
• Combination wheels: Not every 1/8-inch combination wheel on the market is the same. Some 1/8-inch combo wheels have two layers of fiberglass reinforcement holding them together. These are designed for vertical cutting and notching only. Other wheels have three layers of fiberglass reinforcement and can be used for cutting, notching, facing and grinding thanks to that extra layer of support. Grinding at an angle with a 1/8-inch wheel that is only designed for cutting or notching (vertical use) can cause the wheel to come apart — resulting in a highly unsafe situation.  Always review the proper use diagram on the 1/8-inch combo wheel blotter. If it does not have one, assume it is only to be used vertically.
• Flap discs: One of the most common safety mistakes with flap discs is when operators try to use these products on their underside or grind on their edges. This can rip the flap from the backside of the disc. Never use a flap disc on its edge unless the product is specifically designed for that application.
• Wire brushes: Operators will often position a knot wire brush like they do a grinding wheel, using the brush on its edge. But wire brushes aren’t designed to be used this way, so they won’t work effectively, leading to wire breakage. Instead, orient the brush so the tips of the wires are striking the metal and doing the work. Also, don’t push down too hard with a wire brush, which can bend the wires and cause long-wire breakage.

Tips to improve safety when using abrasives

In many cases, safe use of abrasives involves common sense and being aware of one’s surroundings. There are also some best practices that can help reduce safety risks. Consider these tips for safe abrasive use:

1. Always use the proper PPE

Safety gear goes a long way toward protecting the operator if an unsafe situation does arise. Check out the sidebar below on PPE recommendations. Operators should also avoid wearing loose-fitting clothing and tuck their shirt in to prevent problems when working near hot workpieces or spinning tools.

2. Pay attention to speed and size

Always match the speed and size of the abrasive to the speed and size of the tool. Even though an abrasive may fit a specific tool, that doesn’t mean it’s designed to be safely used on it. Be sure the rpm rating of the abrasive meets or exceeds the rpm rating of the tool and that the product fits under the tool guard. When the tool has a higher rpm rating than the abrasive being used, it can result in product failure and potential injury.

3. Mount products correctly

Pay attention to how wheels and discs are mounted on the tool spindle. Mount them flush rather than at an angle. Using an angled mount or incorrectly sized adapters can cause a wheel imbalance and excessive vibration, which may result in product failure. In addition, be sure to always unplug the tool before installing or changing over an abrasive product.

4. Jog the tool

Jog the tool (run at free spin for 30 seconds) before contacting the workpiece to make sure the product is running properly. Attempting to start a grinding or cutting tool while it’s touching the work surface can cause the wheel to bind or break and result in significant kick back.

5. Watch the edges

Several product types, including wire brushes and cup brushes, work very well on flat surfaces. But these brushes can catch on the workpiece edge and create safety issues. Pay close attention to the workpiece edges when using any type of wire brush.

6. Pull, don’t push

When starting to grind, use a pull motion rather than a push motion. A pulling motion is flatter and provides more operator control.

7. Inspect the product

Any time an abrasive product or tool is dropped or left in harsh conditions, inspect the abrasive for visible cracks or damage. Also check wire brushes occasionally for rust, which can weaken the metal wires and create long-wire breakage.

Reducing safety hazards when using abrasives 

Safety in a manufacturing environment is a group effort that goes beyond the regular daily safety meeting. Training operators to use abrasive products safely is step one. Companies must also provide employees with the right tools and equipment to carry out safe practices — and follow up by monitoring safety and making it a priority. Taking the time and making an investment in safety can deliver significant productivity and competitive benefits in the long run.

Republished from Welding Journal (August 2022) with permission from the American Welding Society (AWS). Click here to view the original article.

Tony Hufford, Category Manager, Metal Fabrication

Need Support? Contact Us.

Use the Proper Protective Equipment

An operator’s first line of defense when working with abrasive products is wearing the appropriate protective gear. The recommended PPE can vary depending on the work being done. Consider these common categories when choosing PPE:

• Safety goggles/face shield: Safety goggles or full-face shields worn over safety glasses with side shields should be worn by all operators and others in the area of brush and abrasive operations to comply with the requirements of ANSI Z87.1.
• Protective clothing: Appropriate protective clothing, such as jackets, must be used where there is a possibility of injury that can be prevented by such clothing.
• Hearing protection: Use of abrasive products may create elevated sound levels. Hearing protection must be worn where required.
• Safety gloves: Grinding applications are conducted in harsh environments. The use of safety gloves is recommended.
• Respiratory protection: Wear respiratory protection against dust and fumes (see ANSI Z88.2).