Portable Cutoff Wheel Safety - Do's, Don'ts, and Safe ...

Contact us to discuss your requirements of Non-Sparking Cutting Tools. Our experienced sales team can help you identify the options that best suit your needs.

Cut-off wheels are an incredibly useful tool for quickly cutting different materials, but when used incorrectly, can be extremely dangerous. Safe use of a cutoff disc includes wearing the right safety gear, inspecting the wheels before use, and making sure you are using the cutting discs as intended. Please take these "do&#;s and don&#;ts" safety tips into consideration before operating any tools with a portable cutoff wheel.

Cutting Wheel Safety Always DOs:

• Always wear proper safety equipment. Personal protective equipment is extremely important. This includes wearing safety glasses, along with goggles, and/or a face shield. We also recommend wearing other protective equipment, as needed, such as dust masks and gloves.
• Always do a safety check of each cut-off wheel before usage. Check for cracks or any damage. This will prevent flying bits around the shop or a broken disc from shattering during use.
• Prior to use, check the maximum operating speed marked on the wheel and compare it against the machine&#;s speed. BHA&#;s can be found on any product description page or on the front of the cutting disc.
• Check to make sure that your disc is the right size for your angle grinder or other power tool you plan on using it with. Using one too small or too large can be dangerous.
• Do ensure the cut-off wheel is meant for the material you are using it on. This also prevents contamination and waste of materials and wheels. This step can save you quite a bit of overhead cost.
• Do make sure your portable cut-off wheels are mounted on grinders that have proper guards and proper flanges.
• Do position the wheel guard so that it is properly in place between the operator and the cut-off wheel.
• Always do a one-minute test run of your wheel in a protected area before cutting. This allows for you to ensure the wheel will be safe to use before cutting your workpiece.
• Always do a check to ensure that the workpiece is secure at both ends before cutting. The slightest movement or sliding of the piece can be a major hazard.
• Do ensure that the portable cut-off wheel is only used for cutting metal. Never use it for a task it isn&#;t intended for like grinding or deburring.
• Always maintain a 90-degree angle for the cut-off wheel to the workpiece.
• Always stop cutting when you hear or feel any unusual vibrations, sounds, or if something doesn&#;t feel right. Inspect the wheel before continuing on.
• Always do your best to prevent impacts to the cut-off wheel. If an impact happens stop cutting and inspect the wheel for damage -- change your wheel if damage is seen.
• Do use a moderate and consistent rate of feeding to the wheel.
• Do keep all clothing and body parts clear of the cut-off wheel, especially while it is in motion. This also includes your protective wear.
• Always be aware of your surroundings and the spark stream to protect both yourself and bystanders.
• Do ensure your work area is clear of flammable materials.
• Always replace wheel guards that show any sign of damage.
• Always handle and store your portable cut-off wheels carefully and safely.
• Do check your wheel for all warnings and follow all of them.
• Always review safety data sheets for your wheel and the material your wheel shall be cutting prior to use.
• Always reach out to us regarding any additional safety information or concerns regarding your BHA cut-off wheels. Your safety is our number one priority.
• Always ensure you are complying with not just OSHA and ANSI B7.1, but also thoroughly read and review your machines guidelines, warning, and safety paperwork. It is your responsibility to ensure not just your safety but everyone in the surrounding vicinity safety when you are operating your machine.

Cutting Wheel Safety DON&#;Ts: 

• Don&#;t ever use a different size cut-off wheel than what your machine takes.
• Never remove or alter any wheel guards on your machine.
• Never use a wheel that has been damaged, cracked, or dropped.
• Don&#;t use arbor bushings other than those supplied by the wheel manufacturer.
• Don&#;t use your wheels to cut any material that they are not specifically designed for.
• Never use your cut-off wheel to cut wood.
• Don&#;t use the side of the cut-off wheel or operate it in a manner it is not intended for.
• Don&#;t use excessive or abrupt pressure while operating the cut-off wheel.
• Never allow the wheel to twist, turn, or bend during cutting.
• Don&#;t use the cut-off wheel if you notice it is bent or twisted, even the slighted bit.
• Never use the machine or the cut-off wheels before having reviewed all the safety materials for both the machine and the specific cut-off wheel you are going to us.
• Never put your grinder down with it leaning on the wheel.
• Never leave flammable materials in your work area, especially within the spark stream.
• Don&#;t use the wheel prior to letting it run for 60 seconds.
• Don&#;t forget that your safety and those around you should be the most important thing. Don&#;t take shortcuts or use these tools and abrasives outside of their intended use. 

When to Replace a Cut Off Wheel

There are several instances when you should definitely replace a cutoff wheel:

• Always replace a cutting disc if it shows any signs of damage. This includes, but is not limited to visible cracks and chips or any signs of bending or twists to the wheel.
• Cut off wheels should be replaced when they hit their expiration date. This can be found imprinted on the metal center of the disc. Time, UV light, changes in temperature, humidity, and other storing conditions cause the bonding agents that keep the disc together to break down.
• If you have any reservations about the safety of your disc, you should probably replace it. Don&#;t take a risk because you think that &#;maybe&#; it is good to use.

Having respect for both your tools and the abrasive materials that go with them is paramount to preventing unnecessary accidents or even deaths. While Black Hawk Abrasives/BHA makes an excellent product it is important to inspect your cut-off wheels upon receipt to ensure there was no damage during shipping.

At EmpireAbrasives.com, we do everything we can to ensure the safe arrival of safe-to-use products. However, damages during shipping can happen. It is important that you also never forget to inspect the wheel once more prior to use. Damage can happen accidentally while operating, transporting, or even during storage.

Always remember to use the appropriate wheels for your machine. Whether you use a depressed or flat center, Black Hawk Abrasives does offer quite the selection of top quality cut-off wheels for angle grinders, chop saws, die grinders, and other power tools in varying materials and various sizes. 

Not Sure Which Cut-Off Wheel to Get?

If you are unsure which cut-off wheel is right for you, please do not hesitate to reach out to us. We know how difficult it can be when a few products may work for you and we&#;re here to help guide you as best we can. Please feel free to reach out to one of our experts at Empire Abrasives, 1-800-816-. Whether you are experienced or a novice -- we are always happy to lend a helping hand.

Non-sparking tools are made from materials that do not contain iron (non-ferrous metals), thus reducing the risk of sparks when using the tools. Non-sparking tools prevent fires and explosions in environments that may contain flammable liquids, vapors, dust or residues. Non-sparking tools are best used when working in confined spaces and in areas where flammable gases or dusts are present.

Common materials used for non-sparking tools include brass, bronze, copper-nickel alloys, copper-aluminum alloys, or copper-beryllium alloys. Beryllium alloys are less popular due to the potential toxicity of beryllium dust. Non-metals such as wood, leather and plastic can also be used to make non-sparking tools.

Some common tools available in non-sparking options include hammers, axes, pry bars, chisels, hobby knives, mallets, pliers, screwdrivers, sockets, and wrenches. Non-sparking polypropylene shovels are commonly used for hazardous material spill cleanup.

Because non-sparking tools are non-ferrous, they are softer than standard tools usually made of high-strength alloy steel. This can cause non-sparking tools to wear out faster than steel tools.

Regulations and Compliance

The Occupational Safety and Health Administration's (OSHA) standard for hand and portable power tools and equipment [29 Code of Federal Regulations (CFR) .242(a)] states that "Each employer is responsible for the safe condition of tools and equipment used by employees, including those that may be provided by employees." Keeping non-sparking tools in a safe condition is critical.

Botou Safety Tools, a leading manufacturer of non-sparking tools, provides common sense guidelines for the proper use and maintenance of non-sparking tools.

Keep non-sparking tools clean and free of iron or other contaminants, which can impair non-sparking characteristics.

Do not use non-sparking hand tools in direct contact with acetylene as explosive acetylene compounds may form, especially in the presence of moisture.

During normal use, all hammers and chisels will gradually cause some damage to the striking surface of the hammer or the cutting edge and striking end of the chisel. As part of normal operating and safety procedures, these tools should be returned to the shop for surface and head repair in the same manner as steel tools. This is essential to prevent eye damage from chips falling off the item during use.

Do not store hammers and other hand tools with wooden handles where the handles may dry out and shrink. This will increase the risk of handle breakage or head loosening.

Avoid excessive hammering, which can cause shaft damage. Replacement handles are usually available from the manufacturer and should be installed by a qualified operator using approved installation methods, with special attention to wedge installation.

Fiberglass handles offer advantages over wooden handles in terms of fracture stress and resistance to adverse environmental conditions. Fiberglass shafts fail gradually, rather than catastrophically, reducing the risk of sudden failure, injury or damage.

When selecting a wrench, the jaw opening should fit tightly and snugly over the head of the nut or bolt to which it is applied. This is especially true for non-sparking tools, as they are usually not as hard as steel tools.

Tools are designed for specific uses. As with any tool, additional torque should not be applied through the use of a "cheat bar". In addition to the potential for damage to the tool, this is a dangerous practice for the safety of the operator. A wrench should not be used as a lever; a screwdriver is not as good as a chisel, etc.

In addition to any specific recommendations generated by the alloy used, non-sparking hand tools must also use accepted safety and maintenance standards for common steel hand tools.

When sharpening non-sparking safety tools, follow normal safety procedures, such as providing eye and face protection, adequate extraction and dust removal facilities.

Selecting non-sparking tools

In general, non-sparking tools should be used in any environment where an ignition source is present. Applications include, but are not limited to

Maintenance and repair operations in environments that may contain flammable liquids, vapors or combustible dusts or residues

Collection, storage and transfer of flammable liquids

Hot work

Working in confined spaces

Transportation (airports, railroads, tankers, shipyards)

Chemical, petrochemical and natural gas operations

City, state and federal government (utilities, waste management, hazardous materials response, weapons of mass destruction)

Selecting the right tool for the task is critical. Tools must be used only for the purpose for which they were designed. The Hand Tool Institute (HTI) offers many safety education materials to help with proper tool selection on their Safety Education Program webpage.

Frequently Asked Questions

What is a "non-sparking" tool?

"Non-sparking", "spark reduction", "fire resistant" or "fireproof" tools are the names of tools made of brass, bronze The name for tools made from metals such as brass, monel metal (copper-nickel alloy), copper-aluminum alloy (aluminum bronze), or copper-beryllium alloy (beryllium bronze).

Commonly used hand tools are usually made of steel alloys. Preferred "non-sparking" metals have lower tensile strengths than the steel typically used to make tools. The lower tensile strength means that the metal has less strength or tear resistance when stretched under test conditions. This also means that these tools are softer, wear faster, and must be trimmed more frequently than ordinary steel tools.

What is the most important thing to understand about "non-sparking" tools?

Non-sparking tools also produce sparks, sometimes called "cold sparks". These cold sparks are so low in heat that they do not ignite carbon disulfide, the lowest ignition point of any substance known to man. Therefore, while "non-sparking" tools may reduce the risk of sparking, they do not eliminate the possibility of sparking. The name "non-sparking" is misleading because these tools can produce sparks: the term "spark reduction tools" better describes these tools.

Non-metals such as wood, leather and plastic are suitable for tools such as shovels, scrapers or spatulas and do not pose a frictional spark hazard.

The company is the world’s best Non-Sparking Tightening Tools supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.

Non-sparking tools prevent fires and explosions in environments where sparks are a concern for igniting flammable solvents, vapors, liquids, dust or residues.

Note: It is important to carefully evaluate each situation and use the appropriate tool for the hazard present. In some cases, "non-sparking" tools may still be able to produce sparks. Contact the tool manufacturer and the manufacturer of the flammable material (for example) for advice and more information.

Note: It is also important to consider the metals used in the tools themselves. For example, beryllium has been linked to a variety of health problems, including cancer. While the potential for exposure to beryllium dust is very low with the general use of non-sparking tools, the grinding or polishing tool itself may need to be considered.

What are the hazards of "sparking" and "non-sparking" tools?

Both "sparking" and "non-sparking" materials can cause ignition. Two types of hazards are associated with tools made of either material.

Frictional ignition, collision with each other or with other materials such as steel or concrete, where "ordinary" (mechanical or frictional) sparks are produced. All tools can ignite flammable mixtures through sparks generated by friction or impact. However, this is only true if the spark produced is combustible: this means that the spark must have sufficient heat content (i.e., sufficient mass and high enough temperature) and must last long enough to heat the combustible air-vapor mixture above its temperature. ignition temperature. This is more likely to occur in the case of sparks forming when using a metal grinder, where sparks are generated when a hammer strikes certain metals.

Ignition by chemically generated sparks, caused by the collision between certain metals and certain oxygen-containing substances such as rust, i.e. iron oxide.

How should you use and maintain "non-sparking" tools?

Ensure that all "non-sparking" tools are kept clean and free of iron or other contaminants that could interfere with the non-sparking characteristics.

Choose the right size tool for the task (e.g., a wrench to open a nut). Proper fit will help prevent tool slippage and thus reduce the chance of sparking.

Do not use non-sparking hand tools that are in direct contact with acetylene, which can form explosive acetylenes, especially in wet conditions.

Use local or mechanical ventilation systems as appropriate to remove hazardous materials, dust and vapors from the workplace.

Non-sparking tools will require more frequent restoration. Follow normal safety procedures when sharpening non-sparking tools, such as providing eye and face protection, adequate extraction and dust removal facilities.

What is the best protection against accidental explosions?

Follow safe work procedures. Always evaluate the work to be done in any hazardous environment. Use appropriate tools and equipment to eliminate ignition, such as motors that can be certified as "explosion-proof" for use in most hazardous workplaces, or non-sparking tools that are properly used and maintained. Remember, there is no such thing as a truly spark-free tool. In any work where flames are used or sparks are generated, make sure that an explosive atmosphere is not created. This atmosphere includes flammable vapor-air mixtures and organic dust clouds, such as flour or coal dust. Isolation, ventilation and decontamination are ways to ensure a safe working environment. Explosion meters are used in the workplace to protect personnel working in hazardous environments.

Where is Non Sparking Safety Tools used?

Having a comprehensive, proactive safety and health management system, especially in industries with a high risk of explosion or fire, is one of the most important factors in reducing workplace hazards and injuries caused primarily by unsafe acts or conditions. Choosing the right spark-free tools will minimize the risk of explosions in these potentially explosive areas or "ATmosphere EXplosible" ATEX areas. 

Botou Safety Tools has the expertise to manufacture the best and highest quality non-sparking, non-magnetic tools on the market, offering the widest range of safety hand tools that are unique in their unmatched strength and durability. Our catalog includes non-sparking wrenches, ratchets and sockets, hammers and axes, screwdrivers, pliers, and more.

Non-sparking tools are what we call safety tools for minimizing the risk of explosions in silos while working in ATEX areas such as refineries, offshore oil rigs, chemical industries, paint warehouses, spray booths, coal mines and grain. 

What are the most important features to consider when choosing an explosion-proof tool?

After defining the area and environment in which we will use explosion-proof tools, one of the most important features to consider when selecting the right tool is the right material, depending on the type of tool and its use. Many materials can be non-sparking, but what the tools are looking for is fairly good resistance that allows them to be used in good conditions.

It is important to select and use the right tool for a given task so that employees can complete it in less time and move on to a new task. Choosing the right non-sparking tools not only helps prevent accidents, but also prevents high costs to the company, such as damaged infrastructure, materials that need to be repaired, and even costs caused by accidents.

The most common materials used to manufacture these explosion-proof tools are usually alloys of non-ferrous materials. botou Safety Tools gives preference to two materials for a more rugged and durable tool: aluminum bronze and beryllium copper.

Beryllium copper has a high hardness, from 280 to 350 Brinell, and it is specifically used for tools with cutting surfaces, such as saw blades and cutting pliers, or small surfaces that require hardness, such as screwdriver bits.

Aluminum bronze has a higher energy absorption capacity and higher impact resistance due to its flexibility. This material is the right choice for tools that are more prone to wear, such as striking wrenches or hammers. 

To produce high-performance aluminum bronze and special copper alloy tools, Botou Safety Tools offers better uniformity through fine and uniform grain size, resulting in improved wear resistance.

Does the maintenance and storage of non-sparking tools require special attention?

It is important to remember that non-sparking tools are not as strong as steel tools. For this reason, they wear out more quickly, depending on the working environment and the precautions taken to maintain them. Thorough maintenance of your tools is highly recommended to prolong their life. Consider the following recommendations. 

- Choose the right size for the right task to prevent the tool from falling off.

- Avoid contact with corrosive products, such as iron or other contaminants that may affect the non-sparking characteristics. 

- Clean non-sparking tools after use to avoid deterioration.

- Never use non-sparking tools in an environment where acetylene is present, as it can cause explosive acetylene compounds.

-Non-sparking tools that may wear out, such as hammers or wrenches, should be inspected frequently.

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