ISSUES:
- Cuts and Amputations – Cutoff saws have different types of cutting or abrasive blades designed to cut through materials such as wood, metal, and concrete. Blades are typically diamond-tipped, carbide-tipped, or abrasive disks. They are very sharp.
- Improper Training or Use – One primary safety hazards with these saws arise when the rotating blade is suddenly slowed or stopped due to pinching or binding in the material being cut. This can trigger powerful reactive forces, increasing the risk of serious injury.
- Silica Inhalation – Concrete cutting with hand-held saws can produce elevated concentrations of respirable dust, a portion of which is composed of respirable crystalline silica (RCS). Repeatedly breathing too much of this dust can eventually lead to silicosis, lung cancer, chronic obstructive lung disease (COPD), and decreased lung function.
- Carbon Monoxide (CO) – Handheld gas-powered cut-off saws produce high levels of CO, a poisonous gas that is colorless, odorless, and tasteless. It can accumulate if the saw is being used in work areas such as basements, precast concrete pipes, and vaults. OSHA sets limits on permissible CO levels and NIOSH has recommendations to decrease exposure to CO. Prevention actions include switching from gas-powered saws to electrically or pneumatic/compressed air-powered saws, proper saw maintenance, and effective ventilation.
- Fire – The main fire risk related to cut-off saws comes from sparks produced by the blade or wheel making contact with the material. This can ignite nearby materials, so it is important to clear the work area of debris or combustible material before cutting. Additional risks include faulty equipment or improper use of the blade guard.
- 6. Struck-by hazards – A risk of workers being hit by flying particles and debris from the material being cut is real. Be sure to properly support all materials while cutting. Clear the nearby area and/or make sure adjacent workers are protected with PPE.
- Noise – handheld cut-off saws produce high levels of noise. Prolonged exposure to loud noises can produce irreversible hearing loss. OSHA sets limits on permissible noise levels and NIOSH has recommended exposure limits for occupational noise exposure. It is important to invest in noise reduction measures such as the use of quieter tools and routine equipment maintenance. Hearing protection devices may also be needed to decrease workers’ noise exposure.
SOURCES OF HAZARDS:
- Employees ignore inspection, SOP ‘s, manufacturer requirements for use, and regulations.
- Employees do not recognize defective tools.
- Employees do not establish a safe operating area.
- Employees have not been properly trained.
REGULATIONS:
HAND-POWERED CUT-OFF TOOLS & AUXILIARY HAZARDS:
1926.300(a) Condition of tools. All hand and power tools and similar equipment, whether furnished by the employer or the employee, shall be maintained in a safe condition.
1926.300(b)(4)(ii) The point of operation of machines whose operation exposes an employee to injury, shall be guarded. The guarding device shall be in conformity with any appropriate standards therefore, or, in the absence of applicable specific standards, shall be so designed and constructed as to prevent the operator from having any part of his body in the danger zone during the operating cycle.
1926.300(d)(3) All hand-held powered tools, such as circular saws, chain saws, and percussion tools without positive accessory holding means, shall be equipped with a constant pressure switch that will shut off the power when the pressure is released.
1926.302(c)(1) All fuel-powered tools shall be stopped while being refueled, serviced, or maintained, and fuel shall be transported, handled, and stored in accordance with subpart F of this part.
1926.302(c)(2) When fuel-powered tools are used in enclosed spaces, the applicable requirements for concentrations of toxic gases and use of personal protective equipment, as outlined in subparts D and E of this part, shall apply.
1926.302(a)(1) Electric power-operated tools shall either be of the approved double-insulated type or grounded in accordance with subpart K of this part.
1926.303(d) All employees using abrasive wheels shall be protected by eye protection equipment in accordance with the requirements of subpart E of this part, except when adequate eye protection is afforded by eye shields that are permanently attached to the bench or floor stand.
1926.28(a) The employer is responsible for requiring the wearing of appropriate personal protective equipment in all operations where there is an exposure to hazardous conditions or where this part indicates the need for using such equipment to reduce the hazards to the employees.
1926.28(a) Training. Standards in this part requiring training on hazards and related matters, such as standards requiring that employees receive training or that the employer train employees, provide training to employees, or institute or implement a training program, impose a separate compliance duty with respect to each employee covered by the requirement. The employer must train each affected employee in the manner required by the standard, and each failure to train an employee may be considered a separate violation.
EXAMPLE INCIDENTS:
In May 2020, an employee was using a cutting saw to cut a section of concrete. The saw hit a rebar rod and kicked back landing on the foot of the employee causing a laceration (cut) on the top of his foot. The employee received medical treatment but was not hospitalized.
In October 2023, an employee was working for a water/sewer installation contractor. The employee was using a cut-off saw to cut pipe and when the employee’s shirt got caught in the blade the employee was pulled into the rotating saw. The blade struck the employee in the chest killing the employee.
PREPARE FOR SAFETY:
- Select or purchase equipment with prevention through design features, such as anti-kickback devices.
- Review the manufacturer’s operator’s manual (instructions and safety precautions) for all tools that may be used and make them available to staff.
- Make sure tools are equipped with appropriate engineering controls (e.g., dust collection systems and integrated water delivery systems for wet cutting).
- Plan to control Silica Dust while cutting. Silica-containing materials produce respirable crystalline silica dust, a hazardous airborne contaminant. Prolonged exposure can lead to silicosis, an irreversible and potentially fatal lung disease.
- Perform job activity-level hazard analyses prior to beginning work tasks to identify potential hazards and ensure proper control measures.
- Include considerations for the protection of employees who work near equipment, but do not directly operate the equipment.
- Use the hierarchy of controls as the basis for selecting controls for identified hazards.
- Have relevant safety devices available for use if needed. For example, a clamp, or other safety device can help restrain the working surface or limit movement of the blade in only one direction. Some manufacturers have introduced new technologies designed to enhance safety by stopping the rotation of the cutting wheel in fractions of a second if kickback occurs.
- Plan to have the personal protective equipment needed for the job tasks.
- Remember the saw’s high-speed rotation creates multiple reactive forces, increasing the risk of sudden kickback, blade pinching, or material ejection. If the tool is used improperly, the saw itself, or the material being cut, can become a deadly projectile.
- Review the OSHA Silica Standard for Construction Table 1 provides engineering and work practice control methods: these include integrated water delivery or dust collection systems for cut-off saws and a variety of other tools along with requirements for respiratory protection in different situations.
- If elevated cutting is required, make arrangements for safe operation using a scissor lift, scaffolding, or suitable elevated work platform.
WHAT YOU NEED TO KNOW ABOUT HANDHELD CUT-OFF SAWS:
HERE ARE IMPORTANT DO’S TO KEEP IN MIND ABOUT HANDHELD CUTOFF SAWS:
- Do train all workers on safe work practices (see below) in the language(s) they understand.
- Do remember – remind others that many saws leave much of the blade exposed.
- Do understand each saw is different.
- Do ensure proper blade usage. Manufacturers make different saw blades for different materials.
- Do inspect all equipment.
- Do ensure that saws cannot be started unintentionally. Unplug cord-based saws and retain control of the cord.
- Do protect against inhalation and other hazards by implementing engineering and other controls as appropriate.
- Do prevent the blade from overheating.
- Do keep all body parts away from the blade while it’s running.
- Do support and secure concrete, asphalt, structural steel, and other materials being cut so they do not fall, pinch the blade, or crush workers.
- Do ensure there are no gas or electric utility lines embedded within cutting zones.
HERE ARE IMPORTANT DON’TS TO KEEP IN MIND ABOUT HANDHELD CUTOFF SAWS:
- Don’t cut in the vicinity of anything flammable – most cutting procedures produce sparks.
- Don’t cut on material that is or may become unstable.
- Don’t Use the saw without the blade guard in place.
- Don’t exceed the maximum operating speed marked on the blade.
- Don’t jam or wedge the blade into a cut.
- Don’t use the saw overhead or on a ladder.
- Don’t wear loose clothing which could become caught in the cut-off saw blade.
- Don’t forget to wear PPE. PPE often includes head protection (i.e., hard hat or helmet); safety shoes, steel-toed, and/or waterproof boots; aprons; safety glasses, goggles or face shields; hearing protection; cut-resistant gloves; and respiratory protection.
- Don’t use power tools that need repair.
