Abrasive Wheels
by Callum Doolan-McCullough
What is an Abrasive Wheel?
The HSE defines an abrasive wheel as a “wheel consisting of abrasive particles bonded together with various substances”. However, despite the name, they don’t just come in ‘Wheel’ shape. They can also be manufactured as cups and cones. But, regardless of their shape or form, their main uses consist of cutting and grinding hard materials as well as polishing, sanding and deburring. Abrasive wheels are used in work places all over the world and in various industries and, although the hazards will vary from site to site and can’t all be listed, it’s important you’re aware of the most common dangers.
Hazards associated with Abrasive Wheels
Abrasive wheels are an essential part of many work places, but the potential for injury is high. According to HSE records, nearly 5,000 injuries are endured each year from angle grinders alone. Some of the most common hazards include:
Eye Injuries: Sparks and debris can cause severe and irreversible eye damage.
Contact Injuries: Rotating parts can cause cuts, abrasions and even amputations.
Dust and Particles: Inhalation of dust can lead to a range of respiratory issues.
Noise and Vibration: Prolonged exposure can cause hearing loss, musculoskeletal disorders and HAVs.
Wheel Breakage: Damaged wheels can break causing fragments to fly.
Incorrect Wheel Selection: Using the wrong wheel reduces efficiency and increases the likelihood of injury. 67% of accidents involving abrasive wheels are due to the wrong wheel being fitted.
Fire: If there are sparks, then there’s always a risk of something catching fire
What to look for
Every wheel must adhere to the British Standard (BS EN 12413 and BS ISO 525) marking system. Manufacturers mark all wheels with the type, size, specification, and maximum operating speed. This information should be easily identifiable and located on a circular label on the wheel itself. Below are the essential markings every wheel should have:
Trade Mark
Test Record
Restriction for Use
Expiry Date
Speed Stripe
Dimensions in mm
Specification Mark
Code Number
Maximum Operating Speed
ISO Type No. (shape)
Mounting Instruction
If you can’t see the markings, this usually indicates that the wheel hasn’t undergone any form of testing and will not meet safety standards. It’s likely they’ve been made cheaply or imported in order to keep costs down. Speak to your line manger and/or your safety representative if you have any concerns, but a good rule to stick to when it comes to the safety marking label is: “Can’t see it? Don’t use it!”.
Safety markings are essential, but they’re not the only thing that need to be taken in to consideration. When you’re using any kind of abrasive wheel, there needs to be ‘collective’ safety measures; Just because one thing looks in good order, it doesn’t mean the rest of it is. So other considerations should include:
1. Guards – Is there a guard on the machine and is it attached correctly?
2. Cables/Plugs – Are they in good condition? Are there any signs of wear & tear such as exposed wires, cuts or taped joints? If applicable, check to see that it has an in-date portable appliance test sticker.
3. Pedestals – If you’re using an abrasive wheel on a pedestal, is the machine secure and level?
4. Tool body – Is the tool itself in good condition? Check the body for any signs of damage. Is the handle in place and secured correctly? And don’t forget to check the vents. These need to be free from dust and debris.
Another check you can do is to carry out a ‘Ring Test’ on the wheel to ensure it doesn’t contain any hairline cracks or damage that can’t be easily spotted. To perform the ring test, the wheels/discs should be tapped gently with a light, non-metallic implement- such as the handle of a screw driver (or a wooden mallet for heavier wheels). If the wheel is undamaged, you should hear a clear ‘ring’ sound. If the wheel is cracked, then the it will produce a dull, flat sound that doesn’t resonate. Be aware though that this should be done BEFORE mounting the wheel, and the wheel should be dry and free from debris.
The list above isn’t exhaustive, but it’s good practice to take a few minutes to check the equipment over and look for any hazards before using it.
How can I keep safe?
· Use the correct disc for the job
· Ensure that you’ve received the correct training
· Check the tool and discs for wear and tear
· Look for the safety labels
· ALWAYS use PPE. It should be right for the job and fit for purpose (no baggy clothing)
· Practice good housekeeping by keeping your work area clear
· Adjust the guard to direct sparks away from you
· Carry out a ring test
Your safety is the most important thing, and protecting it is paramount. If you’re not completely satisfied that the equipment you’re using or the task you’re carrying out is totally safe, DON’T DO IT!
Think safety, act safely
These simple tips can help you in your toolbox talk delivery:
Practice makes perfect. Yes, it's a cliché - but it's true...
Stay on topic. Try not to get side-tracked by other subjects or topics...
Pace yourself...
Keep it simple...
Present positively...
Engage and involve...
Speak then listen...
Check everyone understands and record everyone involved to keep record of training.
We at KVF really believe that Toolbox Talks are ideal for raising awareness.
Please remember, task specific training should take place only once the basics of health and safety training have been issued to your teams. To get more information on our e-learning platform Intuity Training, including a 60 minute module on Abrasive Wheels, among many other topics, email: support@intuitytaining.co.uk
Look out for our regular blogs and if there are any subjects you want to see included, let us know at info@kvf-consultants.co.uk
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