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Provision and use of Work Equipment
Regulations 1998 (PUWER 98)

To ensure work equipment, does not give risks to

Health and Safety regardless of:-

• Age
• Condition
• Origin

Revoked Abrasive Wheels Regulations 1970

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This course will give advice on the
prevention of accidents when using
Abrasive Wheels, in particular:-

• Injury from breakage

• Injury from contact

The impact of Noise, Vibration and

Dust will also be discussed.

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The Risk of Breakage is inherent in every Abrasive Wheel

It is prevented by:-

• Care exercised in design, manufacture and testing

• Safe measures by users.

• Injury statistics show that nearly half of accidents are

due to an unsafe system of work or operator error.
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Course Content Course Duration - 4hrs

• Hazards and risks arising from use of Abrasive

Wheels and the Control Measures.
• Methods of Marking
• Storage and Transport
• Inspection and Test
• Functions of Components - flanges, blotters etc.
• Proper method of dressing and adjusting work rest
• Proper PPE
• Health Risks - Noise Dust Vibration

• TEST PAPER AT END OF COURSE

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Abrasive Wheel Classifications

An Abrasive Wheel is a wheel consisting

of Abrasive particles bonded together with
various substances:-

• Organic

• Inorganic

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Inorganic Bonded Wheels

• Vitrified
• Fired in Furnace to give, hard
strong, but brittle structure
• Used for precision grinding
• Used on Pedestal Grinder
• Requires Dressing
G

Type 1

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Organic Bonded Wheels

• Cured at low temperature

• Bonds are:-
Resinoid (B)
Rubber (R)
Shellac (E)
• Tough, shock resistant non- dressing G

• Metal preparation (fettling), cutting

Type 41
G

Type 42
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Organic Bonded Mounted Wheels G

• Special Precautions
• Speed Match Important
Type 17

Type 18

G
G = grinding surface

Type 16
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Organic Bonded Mounted Points

• Have spindle built in 22x63x36mm

19,800 rpm
• Safe speeds vary enormously
• Must be matched with machine
• 13mm maximum overhang between
machine chuck and back of stone
• All type 52
25x25x38mm
34,500 rpm

6mm
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Characteristics of Abrasive Wheels Cut Grind

Abrasive - A - Aluminium A A
Grain size - 08 - 24, coarse 24 30
30 - 60, medium
70 -180, fine
220 - 600, v.fine
Grade - A(Soft), L(Medium), Z(Hard) U P
Structure - (Porosity) - 0 (Open) 9 8
14 (Compact)
Bond - BF - Resinoid BF BF

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 TRADE MARK

EN 12413 TEST RECORD

RESTRICTIONS
NOT PERMITTED FOR
HAND HELD CUTTING
OFF MACHINES EXPIRY DATE
04/2004

SPEED BAND

100 x 2 x 16 DIMENSIONS (MM)

WA 603 K6V SPECIFICATION MARK

M768453 CODE NUMBER

MOS 50M/S 1600rpm MAXIMUM SPEED

ISO TYPE 1 ISO TYPE (SHAPE)

MOUNTING MARK

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 T

Not permitted for Not permitted for Not permitted for

hand-held and manually face grinding wet grinding
guided grinding

Restrictions of use (RE)

50
125

63
Maximum
operating 140
80
speed (m/s)
16013
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SAFETY - Wheel Breakage

Abrasive Wheel Manufacturers

carry out tests and inspection to
ensure the integrity of their wheels.

They will also reinforce wheels.

Resin coated glass fibre mats are

used in organic wheels to help
withstand high stresses and to
contain fragments
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SAFETY - Wheel Breakage

Breakage may occur in service due to:-

• Bad storage
• Incorrect selection of wheel
• Improper mounting
• Excessive imbalance
• Excessive speed
• Grinding machine defects
• Malpractice
Two or more factors may act together.

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Examination of Wheels
• Visual check
• “Ring Test” will only work
with vitrified wheels
• Check classification for
suitability
• Ensure suitability for
grinder - depressed centre?
• Ensure suitability for task
grinding or cutting?
• Check rpm of wheel, especially
with points and cones.
• If in doubt consult manuals
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STA TRAINING BAKU-TBILISI-CEYHAN CRUDE 17
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HAZARDS
• Noise
• Dust and Fume
• Vibration
• Contact with Wheel
• Wheel Breaking
• Risk to others
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 Noise
• Depends on workplace
• Depends on material
• use protection
• think of others
• manage ppe

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Dust and Fume
• depends on environment
• depends on material - paint
chemicals, temperature
• wear ppe

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 Vibration
• use low vibration tools
• keep hands warm
• take breaks
• don’t grip too hard
• maintain circulation
• report problems

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Contact with Wheel
• plan the job
• get in a good position
• don’t overeach
• don’t use unsuitable hop ups

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Wheel Breaking
• right wheel
• don’t bend or stress
• compatible with grinder
• correctly fitted
• wear ppe

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Risk to others
• plan the job
• consider barriers
• comply with permit
• use sheeting if possible

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THE GRINDING MACHINE
• Wheels mounted on compatible machines

• No home-made efforts!!

• Spindles with sufficient thread to ensure nut

and flange can be mounted

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SPINDLE SPEED
• Speed marked on spindle so it
can be compared with speed on wheel.

• Peripheral speed on a fixed speed spindle

will decrease as diameter of wheel shrinks.

• Tendency to use more force - may cause

breakage

SPEED REDUCES

TEND TO USE PRESSURE

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FLANGES
Stresses on an Abrasive Wheel
are greater nearer the hole.
STRESS
INCREASES
Hence flanges are fitted.

Flanges should be at least one

third diameter of wheel.

Pedestal Grinders - Inorganic

Exceptions next

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Reinforced resin bonded wheels

Cutting or Grinding

Flat or depressed centre

Up to 230mm diameter
G
Portable Machines
Type 41
G
May have smaller flanges

Type 42
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BLOTTERS
• Should be used between wheels and flanges
• Between 0.2mm and 1.0mm compressible material
• Distribute clamping force of flanges, prevent slipping
and wear on flanges
• Blotter - wrinkle free - remove old material
Blotter may be a label - but label not a blotter

NOT NORMALLY
USE ON PORTABLE
MACHINES

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Securing the Wheel

Fit freely but not loosely - if tight, spindle

could expand and crack wheel.
After mounting
check speed
Central nut fixing - only tight enough to
marked on wheel
prevent wheel slipping
or blotter is not
exceeded by
that marked on
WHEEL spindle.
KEYS

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Summary of Wheel Mounting Procedures

• Trained Person
• Compatible Machine
• Inspect for damage
• Speed marked on machine
should not exceed that of Wheel
• Flanges correct for wheel
• No wrinkles in blotters
• Wheels, blotters and flanges free from
foreign matter

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GUARDS - two main functions

1. To contain wheel if it bursts

2. To prevent operator coming in
contact with wheel.

Also protects wheel from damage

and prevents fitting of oversize
wheel.

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Guards - for portable machines

Enclosure 1750

Front Lip 5mm

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 PORTABLE AND
HAND HELD GRINDING
MACHINES

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PORTABLE AND HAND HELD GRINDERS

• Only organic bonded wheels to be used.

• Cutting wheels should have fibreglass reinforcement
• Machine guards securely in place
• Guard between user and rotating wheel
• Serious often fatal incidents, when guard removed
to allow larger wheel to be fitted

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ELECTRIC GRINDERS
• Machines after 1/1/97 - CE mark
• Voltage 110v
• Class 1 tools accessible metal work earthed
• Class 2 tools marked double insulated
• Cables with abrasion resistant sheath
• Plug and sockets compatible
• Regular Inspections by competent electrician
• Always inspect before use
AS WELL
AS GRINDER
SAFETY

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COMPRESSED AIR GRINDERS

• Whip lines or pins on hoses

• Hoses protected from mechanical damage
• Compressor exhaust fumes?
• Overhead hoses supported with messenger line

AS WELL
AS GRINDER
SAFETY

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 PERIPHERAL SPEED

The speed at
Spindle Speed
which a point
marked on machine
on the
measured in ACME
circumference
revolutions per
travels in meters
minute (rpm)
per second (m/s)

PERIPHERAL SPEED CALCULATED FROM SPINDLE SPEED AND DIAMETER OF WHEEL

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 CALCULATION

{RPM X (2piD) }
PERIPHERAL SPEED (m/s) = 1000
{ 60 }

SPINDLE RPM = 2OOO

WHEEL DIAMETER = 175mm

PERIPHERAL SPEED (m/s) = { 2000 X (2pi175) }

1000 = 39(m/s
{ 60 }

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PEDESTAL GRINDERS - maximum peripheral speed

VITRIFIED BOND - 35 m/s

Type 1

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 CHOP SAW - maximum peripheral speed

Type 41 ACME

REINFORCED ORGANIC
BOND - 100 m/s
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PORTABLE RIGHT ANGLE GRINDER-
maximum peripheral speed

GRINDING AND CUTTING

REINFORCED ORGANIC BOND
80 (m/s) G

Type 41
G

Type 42

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SUMMARY OF PRECAUTIONS

• Training
• Housekeeping
• Mounting of Wheels
• Speed
• Guards
• Rests
• Lubrication
• New Wheels
• Stopping Wheels
• Overhang on Mounted Wheels
{RPM X (2piD) }
{ 60 }

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