Abbe Miller, Editor-in-Chief, FAB Shop Magazine Direct
Originally published in Modern Abrasives & Deburring, a special section of FAB Shop Magazine Direct.
Proper PPE is the first line of defense to protect employees from injuries when using abrasives, but there is more involved.
Of the many machines and tools in fab shops, workers instinctively know which ones are dangerous. Anyone near a saw blade, for example, knows to keep their distance and stay alert without needing to be told. That’s because humans are naturally wired to recognize that sharp or pointy objects could be potentially harmful. Thanks to evolution, the idea of steering clear of thorns, claws and fangs has been effectively ingrained into the human subconscious. Anyone that didn’t take heed became injured or died, making it less likely they’d pass on their genes.
That could explain why something like a grinding disc doesn’t seem to pose as much of a threat. When anyone sees a small, lightweight disc, the first thought is that it seems harmless. But, when applied with a power tool, that disc can pose several risks. Adam Bujnowski, senior product safety engineer at Norton | Saint-Gobain, says that abrasive products can only be considered safe when proper personal protective equipment (PPE) is in place and when they’re stored and used properly. To drive those ideas home, anyone using abrasives should be trained in those protocols.
Proper PPE
The majority of fabricators rely on abrasives for many operations in their shops, and typically, proper PPE is taken seriously. But, when new employees are onboarded or new workpieces and materials are introduced to the mix, it’s always a good idea to revisit safety protocols for abrasives.
Proper PPE is the first line of defense when it comes to protecting employees from injuries. For abrasive operations, that includes face shields, ANSI Z87-rated eye protection, gloves, safe shoes, arm guards, aprons, long pants and respiratory protection.
“It’s a given that you shouldn’t be walking around in your khaki shorts when grinding sparks and debris are flying around,” Bujnowski says. “But, an important piece of PPE that a lot of people don’t always consider is respiratory protection.
“With so many different materials today being engineered with new and different compositions to address application requirements, it’s another reminder on the importance of protecting operators when grinding these new materials,” he explains. “To protect the abrasives user, a safety data sheet provides recommendations for the correct face or dust mask that should be worn. Some of them only require something common like an N95 dust mask, but others require dust masks with cartridge filters.”
To keep everyone safe from the vapors, spark streams and debris potentially produced by abrasives work, operations should be carried out in a controlled area. But even when those areas are strictly designated, employees nearby should follow the same safety guidelines regarding PPE.
“For staff not directly involved in the abrasives work, but who are still in the surrounding area, it’s essential that they adhere to safety protocols such as maintaining a safe distance from the work area,” Bujnowski says. “Depending on the situation, you might have to use barriers or screens if you’re grinding something that has a lot of debris or scale that’s flying off the workpiece while also ensuring that people nearby are using proper PPE.”
Proper Training, Resources
To keep users safe, Norton and other responsible abrasives manufacturers provide safety literature in a variety of ways. It’s printed on the packaging and the product itself and is included separately in the box. Bujnowski says that by presenting the information multiple times in multiple ways, the goal is for users to not miss the basic PPE guidelines they should follow.
He’s been in the industry a long time, though, and recognizes the human tendency to throw packaging and materials away right after a new box is opened. That’s part of the reason that safety information is also printed directly on the abrasive product. And, instead of using verbiage to relay safety protocols, the industry has moved toward the use of icons.
“We’re displaying individual warnings as pictures or icons, which is great because they’re so much easier to understand,” Bujnowski says. “We’re in a diverse industry where people speak different languages. You only have so much real estate on that little 4.5-in. disc, but if you add a picture of a person wearing safety glasses, I think the message is going to resonate with a lot more people than if you print it in maybe just English or Spanish.”
For anyone that has any type of safety questions or concerns, however, Norton offers formal training from salespeople that have been deputized by Bujnowski and others in the product safety department. If there’s a customer with a need, they’re ready to step in and help.
“After Covid, the industry lost a lot of people to retirement, and with the plethora of new hires came a big need for training,” he explains. “In the past, senior employees would apprentice new employees to show them the ropes, but we lost a lot of that lineage, which resulted in a greater need for formalized safety training.”
To fill the gap, Norton salespeople will go to customer facilities to give safety talks and training on the abrasive products that are specifically being used on-site. The company also encourages customers to take advantage of its remote safety resources that can all be accessed through a dedicated page on its website. The resources page includes documentation for the full range of grinding applications and products, information for how to directly call or email Norton safety staff, as well as a collection of videos dedicated to user safety. Website visitors can also find a link to the United Abrasives Manufacturers Association, which offers a breakdown of the safety icons commonly found on abrasives.
Proper Application
Seemingly, an abrasive disc could be placed on any type of power tool or machine that accepts a round product, but Bujnowski says users shouldn’t be tempted to do that. Every single abrasive product Norton produces is machine-specific: The machines and tools they’re intended for are listed clearly on the product and packaging. If that information is ignored, users are putting themselves at risk.
“If someone places a 9-in. disc on a grinder that’s designed for 4-in. discs, they aren’t doing it with intentional malice, but they’re creating a potentially dangerous situation,” he says. “The problem is that the discs are round with a hole in the center, which means that, technically, they fit on a lot of stuff. We’ve heard of incidents where users put abrasive discs on weed whackers and lawnmowers, and while these are extreme examples, some of the results were catastrophic.”
Ultimately, these scenarios prove that safety guarding is paramount. When someone tries to match an abrasive product with the wrong power tool, oftentimes, they’ll remove the guarding to accommodate the disc. Bujnowski says the guarding is there for a very good reason – to protect users.
Every disc is marked with a speed rating, which indicates the maximum RPMs for operation. Likewise, all machines are marked with maximum operating RPMs. As an example, 7-in. and 9-in. grinders are typically rated for 7,000 RPM to 9,000 RPM while 4.5-in. discs are rated for 10,000 RPM to 12,000 RPM.
“If you try to run the 9,000 RPM-rated disc at 12,000 RPM, you’ll be running far over the recommended speed, which can result in some gruesome injuries,” Bujnowski says. “This type of mismatch is probably one of the most common things we see out in the field. Typically, people are just trying to save time and don’t want to go and get the other grinder for the larger disc.
“When someone sees that this little 4-in. disc spins at 12,000 RPM, they don’t really understand what that means,” he says. “They don’t realize that 12,000 RPM on a 4-in. disc is about 180 mph. I wouldn’t want to get hit by anything going 180 mph. Everybody has seen the consequences of speed in the context of car accidents, but people don’t associate RPMs with that.”
Application safety, however, isn’t limited to using the right product on the right tool or machine. Users must also make sure that they’re using the right product with the right material, which is part of the information included in and on the product packaging.
“Someone tried to cut vinyl siding with a metal cutting disc,” Bujnowski says. “The problem is that instead of cutting the vinyl, the disc melted it. Eventually, the melted vinyl built up on the disc, which caused the disc to expand with the heat and explode. It wound up injuring the operator.”
Proper Storage
Clearly, there are some aspects of safety that fly under abrasives users’ radars, but storage and handling might be among the most crucially overlooked. After all, it’s totally common for a user to leave a partially used disc on a grinder, wrap the cord around it, toss it in the toolbox in the back of a truck and let it bounce around on their way to their next stop.
“They’re very robust products, but they aren’t indestructible,” Bujnowski says. “You have to take care of your abrasives, and a big part of that is not exposing them to weather conditions. They need to be kept in a dry, temperature-controlled environment so they don’t get wet or overly hot. It’s best to keep them away from direct sunlight as UV light over time can break down some of the materials in the discs.”
When users throw their discs into a bin, the next person might randomly grab one, not knowing how long it’s been there or if it’s damaged, wet or otherwise unsafe to use. That’s why Norton recommends to rotate abrasive stock and have extra on hand.
“Exposure to elements over time can weaken the abrasive’s bond systems and cause very poor performance,” Bujnowski says. “While the safety of the disc might not always be impacted, it isn’t going to perform the way it should.”
Furthermore, as more abrasives are bought online and shipped to users, the potential for product damage increases. It’s recommended, therefore, to check newly delivered abrasives for damage before using them.
When it comes down to it, abrasive discs aren’t expensive. Using one that might be compromised or disregarding safety guidelines is never worth the injuries that could happen from ignoring them.
“If it’s damaged, if it’s wet, if something else has happened to it, if you have any doubt, just get a new disc,” Bujnowski says. “It’s best to stay on the safe side and not risk injury.”