Guidance Note 4-13

ABRASIVE WHEELS

Introduction
An abrasive wheel is a cutting tool made of abrasive particles bonded together by various adhesive
substances. They are made in different shapes and sizes and are used for the grinding, cutting, sanding,
deburring and polishing of hard materials.
In use they rotate at very high speeds and create a significant risk of injury should they fail in use or if
the correct control measures are not put into place and enforced. Issues that require consideration by
employers are correct the installation and fitting of abrasive wheels, their maintenance, the way the
equipment is used and the training and competence of employees using them.

Associated Hazards
The use of abrasive wheels gives rise to risks of ill-health as well as risk of injury. There is a risk of
injury caused by an abrasive wheel bursting (breaking up whilst in use), contact with the moving wheel,
including entanglement, and ejected particles that cause eye damage. The health hazards associated with
the use of abrasive wheels include exposure to dust, noise, vibration etc., each of which are covered in
other Guidance Notes.
Please refer to:
 Guidance Note 1-7 Occupational Health and Health Surveillance for advice and information on
potential health hazards and the controls required.
 Guidance Note 5-21 – Local Exhaust Ventilation systems for information and guidance on
controlling dust emissions.
 Guidance Note 5-1 for information and advice on the control of hand arm vibration.
 Guidance Note 5-17 for information and advice on controlling noise at work.

Legal Duties
Health and safety legislation requires machinery and equipment to be properly designed, used and
maintained so as not to give rise to health and safety hazards. The supply of machinery legislation
requires essential health and safety information to be provided by the manufacturers and suppliers. It is a
mandatory requirement to train employees and ensure that they are competent to mount or replace
abrasive wheels.
Where you use resin bonded abrasive wheels for precision manufacturing you should also ensure that
you have a competent person to regularly monitor the condition of the abrasive wheels and ensure that
they are maintained in good order.

Recognised Control Measures

Before purchasing any abrasive wheels and associated equipment that you have identified and trained a
competent person to maintain it correctly. Many technical colleges and employers’ associations are able
to offer short formal training courses.
The training should include:
 The safe use or mounting of abrasive wheels.
 Identification of the hazards and risks associated with the equipment’s use.
 The methods of marking abrasive wheels with type, size and maximum speeds.
 Abrasive wheel storage, transport and handling.
 Inspection and testing.
 Methods of dressing abrasive wheels.

Guidance Note 4-13. Abrasive Wheels

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  Adjusting the work rest.
 The use of suitable guards.
 The use of personal protective equipment.

Training records can be kept either in personnel files or with safety management papers.
Abrasive wheels should be securely mounted and maintained in accordance with manufacturers’
instructions. All wheels should be examined prior to use. When in storage they should be protected to
prevent damage and should be handled carefully to prevent dropping or bumping; rolling should be
avoided as far as is practicable.
When mounted, wheels should be marked with their maximum safe operational speed, restrictions of use,
the shelf life and a traceable number. The maximum speed can be marked in peripheral speed in metres
per second and rotational speed in revolutions per minute (rpm). Wheels larger than 80mm in diameter
will be marked with their maximum speed: for smaller wheels the maximum speed should be posted on a
notice in a position where it can be easily read. Abrasive wheels should never be operated in excess of
the identified rotational speed.
Abrasive wheel equipment should be fitted with clearly visible and accessible start and stop controls and
appropriate guards to prevent the operator coming into contact with the wheel or injury from flying
fragments in the event of a wheel burst.
Regular inspections and preventative maintenance should be carried out in accordance with
manufacturers’ instructions. These records should be kept with your safety management files.
Employees who use abrasive wheels must be trained to recognise the hazards and how to minimise risk
when using them. Be sure to record the training given and the date. Use regular toolbox talks to reinforce
the training message.
Appropriate protective equipment, as identified in your risk assessments, should be worn when using
abrasive wheels to protect against such risks as eye injury from debris and metallic particles, inhalation
of dust, physical injury from flying wheel fragments, noise, vibration, head, foot or hand injury.
To prevent entanglement, loose clothing and any other items such as rags should be secured, when using
abrasive wheels. Arrangements should be made for the protection of persons within the working area and
demarcation lines and warning signs should be positioned to warn of the hazards present.
Abrasive wheels used in circumstances where they generate significant amounts of harmful or respirable
dust will need to be fitted with suitable dust control measures. See Guidance Note 1-7 – Occupational
Health and Health Surveillance for advice and information on potential health hazards and the controls
required. Guidance Note 5-21 – Local Exhaust Ventilation systems provides information and guidance
on controlling dust emissions.
Further advice and guidance on the storage and use of abrasive wheels or any of the issues contained in
this guidance note is available from our 24 Hour Advice Service.
 In Great Britain call 0844 892 2785;
 In Northern Ireland call 0844 892 2786 option 2; or
 In the Republic of Ireland call 01 855 5050 option 2.

Guidance Notes are regularly revised and updated to reflect current best practice, standards or legislation. The latest version
of every Guidance Note is always available in your online system.

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