Cutting Materials using Saws and Abrasive Discs

1. Cutting Materials using Saws and Abrasive Discs Unit Number: L/504/9219 Part of: EAL Level 2 in Fabrication and Welding Engineering (QCF)

2. Session Aims: • Understand health and safety roles and responsibilities • Understand the application of health and safety in the engineering environment • Understand how to use Abrasive Wheels and Cutting Equipment Safely • Understand relevant Health and Safety Legislation in the workplace

3. Safety (1) • Risk assessment procedures • A risk assessment is simply a careful examination of what, in your work, could cause harm to people, so that you can weigh up whether you have taken enough precautions or should do more to prevent harm. Workers and others have a right to be protected from harm caused by a failure to take reasonable control measures. • HASAWA • The Health and Safety at Work etc Act 1974  (also referred to as HSWA, the HSW Act, the 1974 Act or HASAWA) is the primary piece of legislation covering occupational health and safety in Great Britain. The Health and Safety Executive, with local authorities (and other enforcing authorities) is responsible for enforcing the Act and a number of other Acts and Statutory Instruments relevant to the working environment.

4. Safety (2) COSHH (Control Of Substances Hazardous to Health) COSHH is the law that requires employers to control substances that are hazardous to health. You can prevent or reduce workers exposure to hazardous substances by: • finding out what the health hazards are; • deciding how to prevent harm to health (risk assessment) • providing control measures to reduce harm to health; • making sure they are used ; • keeping all control measures in good working order; • providing information, instruction and training for employees and others; • providing monitoring and health surveillance in appropriate cases; • planning for emergencies. Most businesses use substances, or products that are mixtures of substances. Some processes create substances. These could cause harm to employees, contractors and other people. Sometimes substances are easily recognised as harmful. Common substances such as paint, bleach or dust from natural materials may also be harmful.

5. Safety (3) Work Equipment Regulations Provision and Use of Work Equipment Regulations 1998 (PUWER) These Regulations, often abbreviated to PUWER, place duties on people and companies who own, operate or have control over work equipment. PUWER also places responsibilities on businesses and organisations whose employees use work equipment, whether owned by them or not. PUWER requires that equipment provided for use at work is: • suitable for the intended use • safe for use, maintained in a safe condition and inspected to ensure it is correctly installed and does not subsequently deteriorate • used only by people who have received adequate information, instruction and training • accompanied by suitable health and safety measures, such as protective devices and controls. These will normally include emergency stop devices, adequate means of isolation from sources of energy, clearly visible markings and warning devices • used in accordance with specific requirements, for mobile work equipment and power presses

6. Waste Disposal Safe disposal of waste materials There is other legislation governing the proper disposal of waste, ranging from low risk waste through to hazardous waste. These laws are enforced by the Environment Agency and Local Authorities. When waste is disposed, certain types of waste may require waste tracking notes or may need to disposed of by specialists. Particularly if its hazardous.

7. Appropriate Personal Protective Equipment (PPE) – (1) • Flame retardant overalls (Pro-ban Overalls) • Welding gauntlets • Safety boots (Leather Steel Toe Capped Boots) • Safety glasses • Welding Mask

8. Appropriate Personal Protective Equipment (PPE) – (2) • Welding hat • Ear plugs • Leather apron • Leather sleeve • Grinding mask

9. Safe Working Practices • Be aware of other operatives / visitors in your work area • Follow all safety instructions • Always employ guards where required • Have understanding of emergency stops • Be trained in the use of the machinery

10. Moving Materials • When moving / lifting heavy plate or rolled sections, there are various methods including: • Use of cranes, jib or gantry • Use of slings, chains, bespoke lifting equipment • Use of magnetic lifting equipment • Use of plate clamps

11. Hazards • Hazards faced in fabrication and cutting operations are: • Use of dangerous or badly maintained tools and equipment • Sharp moving machine parts • Airborne particles • Hot metal • Burrs and sharp edges

12. Work Instructions (1) • Work instructions come in various forms like Engineering drawings and Standard operating procedures. • Standard operating procedures, are used as a training aide giving full instruction on the task, these would normally be accompanied by engineering drawings • Engineering drawings can be obtained from the design department. • Engineering drawings give you a visual of the component, the dimensions related to the component and the weld detail.

13. Work Instructions (2) Here are some examples of work instructions that may be used in welding and/or fabrication:

14. Work Instructions (3) - Standards • The two standards are ISO (world standard) and ANSI/ASME Y14 (American)

15. Machine Saws (1) • Power Hacksaws • Band Saws • Circular Saws

16. Machine Saws (2) • Bench Saws • Hand Held Cutting Equipment e.g. Grinder with Slitting/Cutting Disc Attached

17. Use of Cutting Discs • Cutting Discs vary in diameter and thickness • The location hole can vary in size • Information can be found on the disc, such as: diameter, thickness, size of location hole, maximum rotation speed and what type of material it is designed to cut. • The side of the disc showing the information is the rear of the disc and this should be noted at point of fit. (Other makes of cutting disc available) Selecting the correct disc would be based on factors such as: • Material to be cut • Machine type • Machine size

18. Relevant Legislation The Approved Code of Practice and Guidance to the Regulations (L22) contains the following advice, specific to the use of abrasive wheels: • To minimise the risk of bursting, abrasive wheels should always be run within the specified maximum rotation speed. (b) If they are large enough, this will be marked on the wheel (a requirement of regulation 23) (c) Smaller wheels should have a notice fixed in the workroom, giving the individual or class maximum permissible rotation speed. (d) The power driven spindle should be governed so that its rotation speed does not exceed this. (e) Guarding must be provided to contain fragments of the wheel that might fly off if it did burst, to prevent them from injuring anyone in the workplace. The guarding has an additional role in helping to meet the requirements of regulation 11; it should be designed, constructed and maintained to fulfil both functions. (f) Providing information and training of workers in the correct handling and mounting of abrasive wheels (including pre-mounting and storing procedures) is also necessary to prevent the risk of bursting.

19. Cutting Characteristics Material cutting characteristics: • Different materials have different cutting characteristics, for instance when cutting or grinding mild steel sparks are clearly evident , but when cutting or grinding aluminium no sparks are evident though in both cases airborne particles are present and a real hazard. • Material thickness as an effect on the cutting process, thinner materials flex easier and can grab the cutting discs. • When preparing for a cutting process, you must consider clamping methods and how secure the parts are prior to cutting. Also consider the off cut and whether it will be secure after cutting. Equipment care Always ensure that the equipment you are about to use is fit for purpose • Check; Disc condition, Saw blade condition, Power cables, Plugs and sockets and All protective guards.

20. Safety Screens Fixed grinding /cutting machinery • Safety screens are needed to protect the operator and other operatives. • Most cutting / grinding machinery has built in screening, some are completely enclosed and cannot be operated with the with the screening open. • The purpose of the guarding is to protect the operator and others from moving mechanical parts and from airborne particles. Hand held equipment • When using hand held cutting / grinding equipment, it is very important that you consider the safety of other operatives. • Always try to grind into a safe area • Try not to grind upwards • Use safety guards to protect others if required

21. Power Saws Setting Power Saws • When using power saws there are variables that can adjusted / set: • Saw cut speed – Adjust blade speed to suit material being cut • Saw fall rate – Adjust fall rate to suit material being cut • Saw angle – Adjust either the blade angle or the bed angle to achieve the required angle cut

22. Tool Safety Important rules • Follow all safety procedures • Select the correct tool/ piece of equipment for the task • Use the correct blade for the material being cut • Use the correct cutting disc for material being cut • Use the correct grinding disc for the material being ground • Never grind with cutting discs • Wear all required PPE • Store hand tools properly when not in use • Isolate the power to machinery when not in use

23. Possible Problems PROBLEM: Wrong dimension achieved • Check twice before cutting • Check blade condition • Check back stop PROBLEM: Wrong angle achieved • Check machine set up • Check blade condition PROBLEM: Part not cut square • Check blade condition • Check fall speed

24. Quality and Measuring Quality Quality checking equipment: • Rulers / tapes • Micrometres • Squares • Set squares • Vernier gauge • Faro arm It is important to check all dimensions against the drawing to see if parts are within tolerance.

25. Reporting Procedures • The operator role is to carry out the daily tasks asked of him / her, that he / she is trained to do. • When problems arise in those daily tasks that the operator is not trained to resolve, the operator should report the issue to his / her team leader / supervisor. • The team leader / supervisor, may choose to elevate the issue to the quality department or the engineering department for help. • If the operator is unsure of the correct path to take, he / she should always use the reporting procedure.

26. Thanks for taking part – do you have any questions before we finish?