ECIA UK & Global Safety Health & Environment Manual 2006

SECTION 34
ABRASIVE WHEELS

REQUIREMENTS
The material in this section is intended to provide a wide range of possibly relevant information and guidance. It must not
be assumed to be comprehensive. It is for the individual to determine what does or does not apply in given circumstances,
what other factors might apply, and what must be done, or must not be done, in order to satisfy all legal and other
requirements appertaining to any specific operation or location.

INTRODUCTION
The guidance given in this Section 34 remains based on the requirements of the revoked Abrasive Wheels Regulations, for it
remains relevant in meeting the requirements of the Provision and Use of Work Equipment Regulations 1998 and
sets down safe working practices.

GENERAL
The following UK publications, amongst others, contain useful information:
□ HSE: HS(G)17 Safety in the use of abrasive wheels
□ HSE: L22 Safe Use of Work Equipment: Approved Code of Practice and Guidance

ISOLATION
Before any wheel is removed or replaced it is essential that that it is isolated from its power source.
Electrically powered portable machines must be switched off and disconnected at the socket and pneumatically
powered portable machines must be disconnected from the hose.

GRINDING MACHINES
Foundations
Pedestal grinding machines must be heavily constructed and robust. They must be securely mounted on
sound foundations. Bench grinders must be anchored securely to a stout and robust bench.

Machine Bearings
machine Bearings must be kept in good condition, free of play and adequately lubricated to avoid out of
balance conditions producing vibration and possible risk of wheel shattering.

Speed Control
The speed marked on the machine must never be exceeded in any circumstances. Machines fitted with
governors must be serviced in strict accordance with the manufacturer’s procedures. Where an operator
detects, or suspects, any instability of speed, the machine must be immediately taken out of service as
this instability is frequently the first symptom of a governor defect.

Pneumatic driven grinders must be marked with the maximum permissible air pressure to help avoid the
possibility of over speeding.

Inspection Testing & Maintenance

Grinding machines must be regularly inspected by competent persons as part of a fixed maintenance
schedule that includes routine servicing. There is no fixed time period for this but it is generally accepted
that a period of six or nine months will suffice for machines not subjected to heavy use. However, in the
case of portable machines a period of three months would seem to be a maximum interval.

Section 34: Abrasive Wheels ECIA

ECIA UK & Global Safety Health & Environment Manual 2006

ADDITIONAL REQUIREMENTS FOR PNEUMATIC OPERATED MACHINES

Before connecting a pneumatic grinder to a compressed air source it is essential to check that the machine’s
maximum permissible air pressure cannot be exceeded by the compressed air source.

However, as an additional precaution, pneumatic machines must be protected by an air filter and regulator to
ensure that the machine’s design pressure is not exceeded.

The rotational speed of the machine must be checked with a calibrated tachometer when the machine is
commissioned and before the wheel is fitted to ensure that the design speed is not exceeded.

TRAINING AND APPOINTMENT OF PERSONS TO MOUNT WHEELS

No person may mount any class of abrasive wheel unless trained to do so and has been deemed competent to do so by his
employer. Such trained and approved person should be appointed in writing with details of the class or classes of abrasive wheel
noted.

The employer should keep a record of the appointments he makes and these records should specify the class or description
of the abrasive wheels which the appointed person may mount, and the person appointed should be provided with a copy of
the entry or certificate.

The employer may revoke an appointment at any time but should make a signed and dated entry in his records. The records
should be thus amended when an approved and appointed person leaves site or ceases employment.

SELECTION OF WHEELS
In selecting a wheel, due account must be taken of the factors which affect safety. Selecting the correct wheel for the job
is equally important for efficient production and for safety. As a rough and ready rule, soft wheels are more suitable for hard
material, and hard wheels for soft material.

With wheels of unsuitable structure for the job, loading may result, i.e. the abrasive wheel face becomes clogged with
particles of the material being ground. A wheel may also be too hard or too fine, resulting in `glazing'. The operator is then
tempted to press the workpiece too hard on the wheel, causing it to break. The best policy in selecting grinding plant is to
consult manufacturers of machines and abrasive wheels, and not to experiment without competent advice.

ABRASIVE WHEEL CHARACTERISTICS AND MARKING

In the process of manufacture of abrasive wheels, the abrasive and bonding materials are controlled to produce wheels of the
varying qualities required for an almost unlimited range of grinding conditions and requirements.

The following are the variable elements in abrasive wheel manufacture, and the standard symbols that are used to designate
them:
Abrasive means the abrasive used in the wheel construction. Aluminium Oxide is expressed as A, Silicon Carbide as C.

Grain Size means the size of abrasive grains used as cutting particles. The grains are classified according to the sieve
through which they have passed. The range is expressed by numbers (Coarse 8 to very fine 600).

Wheel Grade is generally considered as the tenacity with which the bonding materials hold the abrasive grains in a wheel.
Wheels are graded as `soft' or `hard' according to this degree of tenacity. The Grade scale is expressed in letters from A (soft)
to Z (hard).

Structure means the relationship of abrasive grain to bonding material, and the relationship of both to the spaces or voids
that separate them. The void or spaces in the structure assist in rapidly removing `chips' from the wheel face, thus eliminating
or choking of the abrasive surface.

Bond type means the bonding material used in the wheel construction, and is described by letters V (vitrified), B (resinoid),
etc.

Section 34: Abrasive Wheels ECIA

ECIA UK & Global Safety Health & Environment Manual 2006

Fig. 34.01 British Standard Marking System for Grinding Wheels

British Standard 4481 is generally adopted as a basis for the marking of abrasive wheels. This specification secures
uniformity, and completely identifies and describes a wheel. It also provides a general identification of the hardness and grain
size of any one wheel as compared with another. In view of the wide variation in grinding conditions, however, wheels of
similar marking, made by different manufacturers, may not necessarily give the same grinding action. The four principal
wheel characteristics are marked in the following order, and denoted by the appropriate symbols:
(a) Abrasive
(b) Grain (size of abrasive particles)
(c) Grade of hardness
(d) Bond type

The system is flexible and may in addition include the manufacturer's special symbol for exact abrasive type or, in the
final mark, the manufacturer's symbol (letters, numerals, or both), for any special identification of wheel type. A structure
symbol may also be used between the grade and bond type markings. The marking symbols are generally shown on the
abrasive wheels, on a tag attached to the wheel or on an accompanying label. Tags and labels should be carefully
preserved as they are essential information for exact duplication of a wheel.

It is essential that those persons who are trained for wheel mounting must be able to recognize the specification marked on
wheels.

Section 34: Abrasive Wheels ECIA

ECIA UK & Global Safety Health & Environment Manual 2006

MOUNTING OF WHEELS
Wheel speed
Before mounting the wheel, check that the speed of the spindle does not exceed the maximum permissible speed marked on
the wheel.

It must be remembered that centrifugal force (the ultimate cause of wheel bursts) increases, not directly with speed, but at
the square of the speed. The speed at which the grinding wheel revolves, is, therefore, extremely important. It cannot be
too strongly impressed that doubling the number of revolutions per minute of a wheel, increases four-fold its tendency to burst.
The peripheral speed is generally used for describing permissible wheel speeds.

Flanges
Every abrasive wheel must be mounted between suitable flanges, which should be not less than one third the diameter of the
wheel. The flanges must be recessed on the side next to the wheel, to ensure that clamping pressure is not exerted near
the hole.

Flanges for wheels with large holes must not be recessed, but the corners of the wheel seatings must be undercut, so that the
corners of the wheels will not be subjected to pressure. The inner (driving) flange must be keyed, screwed, shrunk, or
otherwise secured to the spindle, and the flange bearing surface must run true with the spindle.

Flanges must be of mild steel or other material of equal or greater strength and rigidity. Ordinary cast iron is not suitable.
Both flanges fitted to a particular wheel must be of the same diameter, and have equal bearing surface.

The flange bearing surfaces must be machined true, and there must be no exposed rough edges or surfaces. If the
bearing surfaces become damaged, they must be re-trued, and the recess re-cut, care being taken to maintain the
original diameter and depth of recess.

Washers
The purpose of washers is to distribute the clamping pressure evenly on the wheel. In addition to the prevention of slipping
with less clamping pressure, washers tend to reduce wear on the flanges.

Washers, or blotters, as they are sometimes called, must be made of compressible material not more than 1/16 of an
inch thick. They must be used between the wheel and the flanges whenever the clamping surfaces are flat, but not
otherwise, as in the instance of taper sided or dovetailed abrasive wheels. Washers must be an easy fit on the wheel
locating spigot, if any, and must not be larger in diameter than the wheel flange, if the flanges fit into a recess. On
straight wheels, the washers must be slightly larger than the flanges. Care must be taken to ensure that each washer is
free from crinkles. If the wheel has been used previously, any pieces of the old washer or loose grains of abrasive must be
carefully removed, otherwise high spots will occur, leading to severe local stresses when the wheel is clamped tight.

Securing the wheel

In the case of a single central spindle nut, tighten the nut only sufficiently to ensure that the flanges drive the wheel
and prevent slip. If the tightening torque recommended by the maker is known a torque wrench must be used. Otherwise
tighten by hand pressure on a spanner.

Excessive clamping pressure applied, for example, by using an extension to a spanner or by hammering, may damage
the wheel.

When the flanges are clamped by a series of screws take care to tighten them uniformly. First screw them home with the
fingers and then tighten in a diametrical sequence.

Starting new wheels

Before running the wheel make sure the guard is in proper adjustment.

If the machine is fitted with a work rest, adjust this as close as possible to the surface of the wheel; rotate the wheel
by hand to make sure it is clear all the way round.

New wheels must be run free at full operating speed for a short period before they are used; during the trial run
everyone must stand clear.

Section 34: Abrasive Wheels ECIA

ECIA UK & Global Safety Health & Environment Manual 2006

Plain (straight-sided) wheels with small holes

Figure 34.01 shows a wheel correctly mounted.

The wheel is gripped between flanges of equal diameter. The inner flange is keyed on the spindle and pressure is exerted on
the outer one by a nut on the threaded spindle. Each flange has an equal recess and the washers are slightly larger than
the flanges.

In contrast, the following unacceptable practices increase the liability of the wheel to fracture because they result in excessive
stress concentrated near the hole:
• paper washers not used between the wheel and the flanges;
• flanges not recessed;
• flanges unmatched in outside diameter and diameter of recess;
• one flange omitted and the nut tightened directly against the wheel;
• the use of an ordinary steel washer as a substitute for a properly recessed flange.

Fig. 34.01 A straight sided wheel with a small Fig. 34.02 A flange assembly for a wheel with a
hole, correctly mounted large hole. The corners of the wheel
seatings must be undercut as shown

Section 34: Abrasive Wheels ECIA

ECIA UK & Global Safety Health & Environment Manual 2006

Plain wheels with large holes

Figure 34.02 shows a plain wheel with a large hole, mounted correctly on adapter or hub type flanges. The corners of the
wheel seatings are undercut to prevent pressure being exerted on the corners of the wheel.

Tapered wheels
Tapered wheels must be mounted between protection flanges (Fig. 34.03 and 34.04). The taper of the flanges must be
exactly the same as that of the wheel with which they are used. Otherwise the general principles already outlined for straight
flanges apply equally to protection flanges, except that paper washers must not be used with protection flanges.

Fig. 34.03 Protection flanges used with a tapered wheel (small hole)

Fig. 34.04 Protection flanges used with a tapered wheel (large hole)

Section 34: Abrasive Wheels ECIA

ECIA UK & Global Safety Health & Environment Manual 2006

Bonded abrasive discs and cylinder wheels

Inserted nut mounting
In this method of mounting bonded abrasive discs and cylinder wheels, threaded nuts are anchored in the back of the wheels
by cementing, casting or moulding (Fig. 34.05). The screws must be long enough properly to engage the threads in the
inserted nuts, but not so long that they can be screwed into contact with the disc or wheel.

Cementing to a backplate
For this operation various cements are used, but the following precautions must be carefully observed when using a sulphur
type cement.

In this process a mixture of sulphur and beeswax is used to cement the wheel to a backplate. The wheel manufacturers'
instructions must be strictly observed, particular care being taken to clean the backplate thoroughly, and to heat the backplate,
cementing mixture and wheel only to the recommended temperature.

Chuck mounting
Where a cylinder wheel is mounted in a protection or safety chuck, the chuck must be adjusted to give the minimum
projection of the wheel beyond the chuck.

Fig. 34.05 Inserted nut mounting for an abrasive disc.

The screws must not come into contact with the abrasive material

Cup wheels
Fixed machines
Figure 34.06 shows how a cup wheel should be mounted on a fixed machine. The same principles apply as for the
mounting of plain wheels, but the diameter of the flange and paper washer inside the cup must be slightly smaller than the
internal diameter of the wheel to avoid any risk of radial pressure on the wheel.

Section 34: Abrasive Wheels ECIA

ECIA UK & Global Safety Health & Environment Manual 2006

Fig 34.06 Cup wheel mounting on a fixed machine

Unthreaded hole cup wheels

Wheels of this type, used on portable machines, are mounted by means of an adapter flange as shown in Figure 34.07.

To provide proper support for the wheel the back flange and adapter must be equally recessed as with plain wheels, and paper
washers must be used.

Fig. 34.07 The flanges are recessed to provide Fig. 34.08 A correctly mounted threaded hole wheel
uniform support on each side of the wheel

Section 34: Abrasive Wheels ECIA

ECIA UK & Global Safety Health & Environment Manual 2006

Threaded hole cup wheels

Threaded hole cup wheels for portable grinding machines are screwed on to the end of the machine spindle against the flange. The
flange must be flat and not recessed (Fig. 34.08); a recessed flange (Fig. 34.09) would tend to pull the threaded bush out of the
wheel. A paper washer is not required.

Fig. 34.09 An incorrectly mounted threaded hole Fig. 34.10 Correctly mounted cone wheel
wheel. The recessed flange does not
provide proper support

Cone wheels
When mounting a cone wheel (Fig. 34.10) make sure that the threaded hole is clean, and that the spindle is slightly shorter than the
hole, so that it will be long enough to give sufficient thread engagement to hold the cone but cannot press on the bottom of the hole.
The flange must not be recessed as this would tend to pull out the bush. A paper washed is. not required.

Depressed-centre wheels
Depressed-centre wheels must only be mounted with a flange assembly as shown in Figure 34.11. Two points should be
noted:
(a) When the adapter has been tightened there should be a slight clearance between the flange and the wheel at (A).
This ensures that clamping pressure is exerted only at the centre of the wheel;
(b) The outer part of the face of the flange adjacent to the wheel should be tapered as shown. This allows the full
width of the flange to support the wheel during the grinding operation.

Fig. 34.11 Flange assembly for a depressed-centre wheel

Section 34: Abrasive Wheels ECIA

ECIA UK & Global Safety Health & Environment Manual 2006

Cutting-off wheels
Cutting-off wheels should only be mounted on machines designed specially for their use. They must never be mounted on
makeshift machines such as woodworking circular saw benches. Never mount an un-reinforced cutting-off wheel on a
portable grinding machine. The wheel must be of the reinforced type.

Flanges must be as large as practicable and never less than one-third of the wheel diameter. It is most important that the
flanges must be of equal diameter; the use of unequal flanges is liable to cause distortion and breakage of a cutting-off
wheel.

SUMMARY OF MOUNTING PRECAUTIONS

Given proper equipment, safety largely depends on the few simply rules previously mentioned and summarized below:
• Before mounting, all wheels must again be closely inspected and `rung' to make sure that they have not been
mishandled in transit or storage.
• Wheel mounting may be carried out only by competent and authorized persons.
• The bush, if any, must not project beyond the side of the wheel.
• Care must be taken to ensure that all wheels, washers and flanges are free from foreign matter. Any burrs
must be taken off flanges.
• Washers of compressible material not over 1/16 of an inch thick, must be fitted between the wheel and its flanges where
the surfaces are flat.
• Wrinkles in washers must be avoided. Washers are not recommended for taper and dovetail wheels.
• When tightening nuts, care must be taken to tighten them only just enough to hold the wheel firmly. Excessive
clamping pressure is liable to damage the wheel The nuts must be tightened by hand pressure on a spanner and
never by a hammer and chisel or similar means.
• When the flanges are clamped by a series of bolts, care must be taken to screw up each bolt uniformly. All the bolts
must first be run up with the fingers and then tightened in pattern formation afterwards.

GUARDS
Guards must be securely attached to the body of the machine.

For straight-sided wheels, the maximum angular exposure of the abrasive periphery and sides must not exceed 180°.

Guards for straight grinding machines must be provided with a front curtain, which must be securely fastened to the
body of the machine.

For cup wheels, the back face and periphery must be enclosed, and the guard must be adjusted to compensate for the
wear of the wheel.

For depressed centre grinding wheels, the wheel must have a maximum angular exposure of 180° and the guard must be so
located as to be between the operator and the wheel during use. The clearance between the inside of the guard and the
periphery of the unused wheel, must not be greater than 5% of the nominal wheel diameter.

Guards have four main functions:

• To contain the wheel parts in the event of a burst
• To protect the wheel against inadvertent damage from shock, etc.
• To prevent, as far as possible, the operator coming into contact with the wheel.
• To prevent an over-size wheel being fitted.

CONTROLS
Machines in which abrasive wheels are used must be provided with efficient devices for starting and cutting off power, and
the controls of such devices must be readily and conveniently operated by the person using the machine.

Many clients insist that hand held machines be air driven and equipped with a “dead man’s” control.

Section 34: Abrasive Wheels ECIA

ECIA UK & Global Safety Health & Environment Manual 2006

RESTS FOR WHEELS

Where there is a rest for supporting the workpiece, it must at all times while the wheel is in motion, be properly secured and
adjusted so as to be as close as practicable (but in no instance in excess of 3 mm) to the exposed part of the abrasive
wheel. Adjustments must only be made when the machine is isolated from its power supply. Side rests must not be used
as they encourage the dangerous practice of side grinding and this causes grooves to be worn on the wheel and this leads
to the wheel bursting.

Every rest must be of substantial construction and properly maintained.

TRUING AND DRESSING

Incidents may be caused by the operator's fingers being trapped between the rest and the wheel; they may also be caused
if the work being applied is itself trapped in a similar way. Although such accidents are more frequently caused by bad rest
adjustment, their possibility is minimized by frequent truing to keep the wheel concentric on its spindle.

A wheel out of round will cause excessive vibration and periodic knocking of the work against the wheel. This will invariably
result in damage to the abrasive wheel or the spindle bearings.

Any condition of the wheel surface such as `loading' or `glazing' which reduces the cutting action, may induce the operator to
compensate by additional pressure of the work on the abrasive wheel. Dressing a wheel is therefore essential for
efficient production, and frequent light dressings are generally preferably to occasional deep dressings.

The following important precautions must be taken:

• Dressings tools must be rigidly mounted at the proper angle and direction, whether on the table or through the
hood. Hand dressers must be properly supported so that leverage may be applied without undue effort. With a dresser
of the revolving cutter type, the lugs provided as an anchor must always be employed;
• Haphazard methods of dressing such as the use of chipping hammer, or even striking the work against the wheel, must
be forbidden;
• Care must be taken to reduce the possibility of dressing tools jamming between the abrasive wheel and rest, or any fixed
part of the machine;
• Whilst truing or dressing the operator must be properly protected by hoods or screens;
• There are many types of abrasive wheel dressers and various methods by which these operations may be carried out.
If necessary, wheel and machine manufacturers should be consulted on the technical aspects of the subject.

WHEEL BALANCE
Abrasive wheels are balanced by the makers within normal limits. For some operations closer limits of balance are
required. This is obtained by various methods such as the insertion of lead, the use of heavy paint or by an arrangement of
sliding weights.

When a wheel has worn down, an appreciable amount of re-balancing may be necessary. Out of balance conditions
cause `chatter' with detriment to the work and if excessive, may result in dam-age to wheel and spindle. Generally, the
larger the wheel and the faster the speed, the greater the importance of correct balancing.

WHEEL STORAGE AND HANDLING

Abrasive wheels are relatively fragile and require careful handling and storage. They must not be dropped or bumped.

CONDITION OF FLOORS
The floor surrounding every fixed machine or area where portable tools are being used, must be maintained in good and
even condition. So as far as practicable it must be kept clear of loose material and prevented from becoming slippery.

CAUTIONARY NOTICE
A cautionary notice of the hazards arising from the use of abrasive wheels, should be affixed in every room where grinding
or cutting is carried out.

Section 34: Abrasive Wheels ECIA