Abrasive Wheels Regulations – Everything You Need to Know

An abrasive wheel usually consists of abrasive particles bonded together with various substances.
Abrasive wheels can be bonded using inorganic or organic substances.

Inorganic bonding materials are usually the result of firing the wheel in a furnace to give it a strong and hard form. This also adds brittleness to the overall structure. These are known as vitrified inorganic abrasive wheels and are usually used for precision grinding work.

Organic bonds do not use the firing method but are made using bonding agents such as resinoid, rubber and shellac. These abrasive wheels are tough and shock resistant, but still require careful handling to prevent damage. They are most commonly used in cutting work that does not require a degree of precision.

Depending on their type and specification, abrasive products are used for grinding, cutting, sanding and polishing materials such as wood, tile, concrete and metal. Bonded abrasive wheels can take the form of a wheel, cone or cup, with abrasive particles held together by a bond. Grinding and cutting wheels are fitted to machines such as grinders. This article focuses on bonded abrasive wheels.

Unsafe systems of work and operator errors can contribute to accidents involving abrasive wheels, as explained in HSE guidance.

Due to the high speed of the spinning wheel, abrasive wheels are hazardous to both operators and people in the near vicinity.

Operators and others nearby may be injured through contact with the abrasive wheel or workpiece, or by flying fragments and other debris. Abrasive wheels can break, ejecting fragments at high speeds.

Common causes of abrasive wheel breakages are:

• Improper storage methods
• Wrong wheel selection
• Incorrect mounting
• Extreme out-of-balance conditions
• Excessive speed
• Equipment defects
• Incorrect grinding or cutting procedures

More than one of these factors can occur at the same time to cause wheel breakage.

Abrasive wheel operators are also exposed to the hazard of vibration, which can lead to hand-arm vibration syndrome (HAVS). HAVS can be permanently debilitating.

There are also risks associated with being in the vicinity of someone using abrasive wheels. High noise levels from abrasive wheel work can cause damage to hearing. The dust given off by working with abrasive wheels can cause lung damage.

Cutting concrete, stone and similar materials can generate respirable crystalline silica dust. The work should be planned to avoid or reduce cutting where possible, with suitable dust controls such as water suppression, on-tool extraction, and using equipment designed for the chosen method. HSE guidance on cutting paving materials specifies suitable respiratory protective equipment (RPE) as well as dust controls, with face fit testing for tight-fitting masks.

Sparks and hot fragments can ignite combustible materials or flammable substances. Fire and explosion risks must be assessed and controlled, including removing or protecting combustible materials and preventing ignition where dangerous substances are present.

Employers must assess these risks and put suitable controls in place, supported by adequate training, maintenance and supervision.

The following legislation helps to control these risks.

The use of abrasive wheels in Scotland, England and Wales is regulated by the Provision and Use of Work Equipment Regulations 1998 (PUWER). These regulations replaced PUWER 1992 and revoked the remaining provisions of the Abrasive Wheels Regulations 1970. PUWER is enforced by HSE or the relevant local authority, depending on the premises and work activity.

PUWER requires that employers supply only work equipment, such as abrasive wheels, that is suitable and fit for purpose. All tools and machinery must also be correctly installed, maintained in efficient working order and kept in good repair.

Equipment should be checked before use and inspected at suitable intervals where deterioration could create danger. Inspections must also be carried out after installation where safety depends on installation conditions and after exceptional events that could affect safety. Inspection scope and frequency should reflect the risks and manufacturer’s instructions.

Inspections must be carried out by someone with sufficient knowledge and experience. Records of inspections required by PUWER regulation 6 must be retained until the next inspection; simple pre-use checks do not normally need individual records.

PUWER requires adequate training for people who use work equipment and for employees who supervise or manage its use. Equipment must have suitable safeguards, including guarding, safe controls, clear markings and means of isolation from energy sources. Emergency stop controls must be provided where appropriate to the equipment and risks.

In Northern Ireland, the corresponding duties are set out in the Provision and Use of Work Equipment Regulations (Northern Ireland) 1999. The Health and Safety at Work (Northern Ireland) Order 1978 provides the main legal framework.

In the Republic of Ireland, separate abrasive wheel provisions form part of the Safety, Health and Welfare at Work (General Application) Regulations 2007, as amended by S.I. No. 36 of 2016. These provisions do not apply in Northern Ireland.

PUWER operates alongside other legislation covering risk assessment, hazardous substances, noise, vibration and personal protective equipment (PPE). Employers must comply with all the requirements applicable to their work. In Great Britain, this legislation includes:

• Health and Safety at Work etc. Act 1974 – This is the main piece of legislation that covers health and safety at work in Great Britain. It includes employers’ duties to protect employees and others affected by their work, so far as is reasonably practicable.
• Personal Protective Equipment at Work Regulations 1992, as amended – Employers must provide suitable PPE free of charge where required. The 2022 amendments extended duties to limb (b) workers, including some casual workers. PPE must be maintained, stored and used correctly.
• Control of Substances Hazardous to Health Regulations 2002 (COSHH), as amended – COSHH regulations outline what employers must do to control substances that are hazardous to health.
• Control of Noise at Work Regulations 2005 – This legislation is designed to ensure that workers’ hearing is protected from high levels of noise in the workplace.
• Control of Vibration at Work Regulations 2005 – Employers must assess and control risks from vibration exposure, including hand-arm vibration from powered tools.
• Management of Health and Safety at Work Regulations 1999 – Employers must carry out suitable and sufficient risk assessments and make arrangements to manage health and safety.
• Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR) – Employers must assess and control fire and explosion risks arising from dangerous substances at work.

PPE should supplement measures that prevent or control exposure at source. Noise and vibration risks should be assessed and reduced through suitable equipment, maintenance and working methods, with health surveillance provided where required by the relevant regulations.

Those who manufacture or supply abrasive wheels also have legal duties under section 6 of the Health and Safety at Work etc. Act 1974. They must ensure, so far as is reasonably practicable, that articles for use at work are safe and without risks to health when being used, set, cleaned or maintained at work, and provide adequate safety information. Any examination and testing necessary to meet those duties must also be carried out or arranged.

The Supply of Machinery (Safety) Regulations 2008 apply to machinery such as grinding and cutting machines. Machinery within scope must meet the relevant conformity requirements and be supplied with appropriate conformity marking, a declaration of conformity and instructions. In Great Britain, CE marking continues to be recognised alongside UKCA marking. Ordinary replacement abrasive wheels are tools and do not require machinery conformity marking or a machinery declaration of conformity merely because they are fitted to a grinder.

Depending on the wheel design, manufacturers may use the following safety features:

• Fibre reinforcement – Some organic wheels are reinforced with a woven, resin-coated mat made of glass-fibres. This helps the wheel withstand high-stress work and helps retain fragments if breakage occurs.
• Steel rings – These rings may be moulded into an abrasive wheel near the bore. They can help prevent excessive wear and retain fragments if breakage occurs when the wheel is close to its discard size.
• Safety inserts – Threaded nuts with locking teeth form part of a plate that strengthens the base of a cup wheel used for portable grinding work. Safety inserts are an additional measure. They do not replace the need for a safety guard.
• Tape winding – Glass-fibre, adhesive tape or metallic wire can be used to provide extra strength to thin-walled cylinder and cup abrasive wheels.
• Fine grit centres – Fine grit centres are placed around the bore of a vitrified wheel to increase its strength.

A key risk control for manufacturers is the provision of information about how their equipment should be used and the conditions in which it can be operated safely. Relevant standards for bonded abrasive products include BS EN 12413:2019 and BS ISO 525:2020. These standards do not cover coated abrasive or superabrasive products. Standards provide technical benchmarks for safety and are distinct from the legal duties placed on manufacturers and employers.

Depending on the product and applicable standard, safety information may appear on the wheel, its label, packaging or accompanying instructions. Users should check the relevant information, including:

• The maximum operating speed in rpm and metres per second
• The restrictions of use
• The expiry date, where applicable
• Traceable manufacturing or batch numbers
• The dimensions of the wheel
• The manufacturer’s trademark
• The ISO type number indicating the wheel’s shape
• Mounting instructions

Follow the manufacturer’s storage instructions and do not use damaged, expired or otherwise suspect wheels.

In order to meet their legal duty to provide safe and suitable work equipment, employers must ensure that the wheels they provide are suitable for the machine, material and intended operation and are supplied with adequate safety information.

Employers must also ensure that the wheels are only used within the design specifications of the equipment and only used for the purposes for which they were intended.

The machine’s spindle speed must not exceed the wheel’s maximum permitted rpm. The correct guard must be fitted and securely positioned. For wheel changes and routine maintenance, stop and isolate the equipment from its energy sources and make any stored energy safe.

But this alone is not enough. Employers must also conduct a risk assessment to ensure the work environment and work being done will be conducted safely. Any hazards identified must be suitably controlled.

Any employees using abrasive wheels must be provided with sufficient training to help ensure they are competent to do their jobs safely.

Mounting, adjustment and maintenance must only be undertaken by people with the training and competence needed for those tasks. Employers should assess practical skills and provide appropriate supervision.

To quote the HSE: “There is no substitute for thorough practical training in all aspects of the mounting and use of abrasive wheels”. Abrasive wheels training should provide trainees with information on the risks of using abrasive wheels, what PPE should be worn and the safe working practices relevant to their tasks.

HSE guidance recommends that abrasive wheels training covers how to read the markings on abrasive wheels and how to handle, store and transport them. Participants should understand the functions of the components relevant to their equipment, such as nuts, bushes, flanges and blotters. Where their role includes mounting wheels, trainees also need practical instruction in correct assembly and inspection for damage. Training should also cover dressing wheels and adjusting work rests where those tasks are relevant.

Human Focus provides online abrasive wheel training that introduces the risks and general principles of safe abrasive wheel use. Training can be taken in online bite-size sessions. The course includes an online knowledge assessment and a certificate of completion. It supports awareness and knowledge development, but does not replace equipment-specific practical training, supervision or the employer’s assessment of competence.