Safety

Better Safety Equals Better Profitability: Masonry Saw Safety

23 Sep 2024

Paul Edwards, Product Engineer III, Norton | Saint-Gobain Abrasives

This article originally appeared in MASONRY magazine. Reproduced with permission.

In 2022, private industry reported 2.3 million cases of work-related injuries (Survey of Occupational Injuries and Illnesses, US Bureau of Labor Statistics, 2023). According to the National Safety Council, the total cost of those work-related injuries was a staggering $167 billion with an average medical cost of $40,000 per individual case (NSC Annual Research Report, 2023). The US Construction industry experienced 269,600 cases of OSHA-reportable events in 2022. Of these construction injuries, 71,700 cases included days away from work, totaling 136,470 days missed by the injured employees (US Bureau of Labor Statistics, 2023).

The cost begins to multiply when you factor in rising insurance costs to cover the increasing number of claims, contract deadlines missed and timeline bonuses lost, and the investment of training replacement workers. Neither companies nor employees can afford to ignore the value of safe work practices.

Man cutting a block with a Norton Clipper masonry saw

Creating a Safer Work Environment

The first masonry saw was invented in 1937 by Norton Clipper. Through years of development and innovation, the evolution of diamond saw blade technology has produced steel core segmented blades that can cut tough materials safely at very high speeds and under extremely harsh conditions. However, when improperly used, these blades can be damaged, resulting in wheel failure that can cause injury or death.

To reduce risk, companies and individuals must own their responsibility to make safety a priority. The first step is to understand and comply with the established regulations and guidelines for using a masonry saw. The most common sources of this safety information are:

Local, state, and federal safety requirements and industry standards such as ANSI B7.1, ANSI B7.5, OSHA
Manufacturer’s operator’s manual and instructional package inserts
Association of Equipment Manufacturers (AEM) RX for Diamond Blade Safety

Woman using a Norton Clipper masonry saw to cut a brick

Best Safety Practices for Masonry Saw Operation

If you understand and practice good safety principles, you can erase hazardous conditions, protect yourself and the people around you, and optimize cost efficiency.

Here are some basic rules to get you started.

Do	Don't
Follow the manufacturer's recommendations	Don't cut dry except with a blade manufacturer-designed for dry cutting
Make sure only properly trained operators are engaged in any cutting project	Don't force the blade onto the machine shaft, alter the size of the mounting hole, or tighten the mounting nut excessively
Inspect the blade before use to confirm no damage was incurred during shipment	Don't use bushings to reduce the arbor hole
Check for core flatness, fatigue cracks, segment damage, undercutting, and arbor hole damage	Don't exceed the maximum operating speed established for the diamond blade
Check mounting flanges to ensure they are of equal and correct diameter, do not exhibit excessive wear, and are not distorted	Never operate any saw without a blade guard
Ensure that the diamond blade is mounted on a correct diameter shaft and is securely hand-tightened	Don't stand in direct line with the blade during operation
Check for proper saw machine condition. Spindle bearings should be free of end and radial play	Don't cut or grind with sides of the diamond blade
Learn and follow the manufacturer's recommendation for operating speeds for specific blade diameters	Don't force the blades into the material; allow the blade to cut at its speed
Use proper protective gear including safety glasses, safety footwear, snug-fitting clothing, hearing protection, headgear, and respiratory devices	Don't use the blade to cut material other than that recommended by the manufacturer
Ensure all safety guards on the blades and belts are in place before operating the saw	Don't use the blade in a saw other than the one specified by the manufacturer

Consider Your Cutting Approach

There are different methods for cutting with a diamond blade saw.

Rip-Cutting

In rip-cutting (jam-cutting), the cutting head is locked in a fixed position and the material is pushed into the blade. This works well with wet diamond blades when cutting some soft materials. Rip-cutting provides greater efficiency than merely holding the head down. Lower the cutting head to the desired cutting depth and then lock the cutting head of the masonry saw into position so that it will not move. This will vary depending on the model of saw you are using. Ensure that the material is secured to the cutting table and then slowly move the material into the blade. Forcing the material into the blade or not properly securing may cause the blade to grab the object being cut.

Plunge-Cutting

Another commonly used cutting method is plunge-cutting (chop sawing). With plunge-cutting, the material is secured to the cutting table and positioned under the blade, then the blade is slowly lowered into the material. Care must be taken not to force the blade into the material or the blade may grab the object and pull it away with extreme force.

Step-Cutting

Step-cutting is generally optimal for most materials, especially when using dry diamond blades. Step cutting is a combination of rip-cutting and plunge-cutting. The material is secured to the cutting table, then moved under the blade. The blade is allowed to move freely up and down like with plunge-cutting. Next the blade is slowly lowered into the material until it lightly contacts the object and is allowed to go into the material approximately 1/8”. Now the blade is slowly passed through the material as in rip-cutting; once the blade has passed through the material, the process is repeated until the cut is completed. This method extends the life of your diamond blade as it applies less pressure to the blade, making a cut with each pass.

Regardless of which method you choose, clamp the material securely or hold it firmly against the conveyor cart backstop while cutting. Do not force the material or bump into the blade. When nearing completion of the cut, slow down and slightly hold back the conveyor cart. Following these steps exactly is essential to ensuring you do not inadvertently cause any damage to the material or the blade.

Put Safety First

Operating safely is the best path to the biggest rewards. Operators don’t get hurt, schedules stay on time, medical costs are reduced, equipment lasts longer, and jobs get done. For more safety resources, visit our product safety page and browse our safety articles.

Founded in Worcester, MA in 1885 by seven entrepreneurs, Norton grew into a global leader in the abrasives industry before being acquired by industrial giant Saint-Gobain in 1990. Norton offers the widest portfolio of grinding, cutting, blending, finishing, and polishing solutions for all markets, materials, and applications using the most advanced, affordable technology. You get powerful, precise, easy-to-use options designed and engineered for optimum performance, cost and safety. Constantly looking for ways to improve your working conditions and simplify the job by eliminating dust or noise, Norton delivers choices that matter to your workforce, the environment, and your bottom line.