Abrasive & Cold Metal Chop Saws
Metal chop saws cut pipe, tube, angle, strut and rebar to length. Abrasive saws grind through steel with a thin wheel and throw a shower of sparks. Cold saws use a toothed blade at low speed. Each has its own hazards.
- Welders & fabricators
- Electricians
- Ironworkers
Photo: abrasive chop saw cutting steel tube clamped in the vise, with sparks directed away from the operator into a spark shield
Abrasive vs. cold saws
| Abrasive chop saw | Cold saw | |
|---|---|---|
| Cutting | Thin bonded abrasive wheel, high speed | Toothed carbide or high-speed steel blade, low speed |
| Sparks | Many; a fire hazard | Few; throws chips instead |
| Heat | Cut ends get very hot | Cut ends stay cooler |
| Biggest risk | Wheel breaking; sparks and fire | Hot, sharp chips; blade grab |
Abrasive wheels
- The wheel’s maximum RPM must be at least the saw’s speed.
- Check for cracks, chips and moisture damage. Don’t use a dropped wheel.
- Mount with the correct flanges, tightened as the maker says. Don’t force a wheel onto the arbor.
- Keep the guard in place and working.
- Stand to the side and let a new wheel run at full speed for a minute before cutting.
- Cut with the edge only. Never grind with the side of a cut-off wheel.
- Don’t cut wood, plastic or other materials the wheel isn’t made for.
Cutting safely
- Clamp the work in the vise. Hand-holding lets it spin or bind.
- Support long pieces on stands at the same height as the table.
- Let the wheel or blade reach full speed before cutting, and feed steadily without forcing.
- Let it stop before raising the head out of the cut or reaching in.
- Watch out for hot cut ends and sharp burrs. Use gloves to handle cut pieces, and deburr.
Sparks start fires. Abrasive saws throw sparks 30 feet or more. Aim the spark stream away from people and flammable materials, use a spark shield, keep an extinguisher handy, and get a hot work permit where your site requires one. See Hot Work Permits.
PPE
- Safety glasses plus a face shield
- Hearing protection (chop saws are often well over 100 dBA)
- Cotton or FR clothing, no synthetics that melt; sleeves down
- Leather gloves for handling metal, not near the wheel
- Safety-toe boots
Standards & references
- 29 CFR 1926.303: Abrasive wheels and tools
- 29 CFR 1910.215: Abrasive wheel machinery
- See also: Cut-Off Saws · Portable Band Saws · Welders & Fabricators
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