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Wire Wheel Brush Hazards

Machine shop wire wheels and grinders have their permanent place in all facets of metal repair, crafting and maintenance. Wire wheels, used as attachments to floor-mounted grinding machines, bench grinding machines or hand-held tools, provide an easy way to remove or clean metal surfaces. Some wire wheels operate at speeds approaching 10,000 surface feet per minute. The hazards become obvious when considering that a human must be in proximity to such a device to perform work.

  1. Loose Clothing

    • When operating the bench, hand-held or floor-mount-style wire-wheel grinder, apparel considerations rank very high. Long, unbuttoned sleeves, loose or unbuttoned shirttails, and even long hair provide extreme hazards when such clothing (or hair) can become entangled in the wire and draw a person into direct contact with the spinning wheel. Fingers and hands can be maimed or severed. It takes only a second for a high-spinning wheel to catch a piece of clothing and draw the operator nto the wheel. Gloves should always be worn. No loose clothing should be allowed near the grinder.

    Threats to Vision

    • Wire wheels have a tendency to shed wire, throwing it off at tremendous speeds when a work piece makes contact with the wire strands. This happens due to friction. See-through safety guards come equipped with bench and floor-mount grinders that must be in place, adjusted correctly and tight in their swivel mounts. In addition, clear eye goggles should always be worn to protect the eyes from thrown wires. Serious eye injury and blindness can result without the proper protection.

    Projectile Hazards

    • The possibility of being struck by a broken or cast-off wire remain high, even when a person has the proper eye protection, gloves and suitable clothing. The velocities of thrown wire filaments can easily penetrate clothing. Deep penetration into the body cavity has been documented. Thick clothing, overalls or coveralls made from heavy materials should be worn at all times, including rigid work boots.

    Fire Hazards

    • Friction from the contact of a working piece against a wire wheel causes extreme heat. Sparks and glowing red wire and particles can be thrown for dozens of feet from the grinding station into flammable substances and materials, such as paper, cardboard, oily rags, gas spillage, open paint containers and other items. The wire particles contain enough residual heat to start instant fires wherever they make contact. All grinding stations or areas around grinding stations should be swept clean of debris and all fire hazards.

    Alcohol and Drugs

    • Under no circumstances should any operator of a grinding wheel be under the influence of drugs or alcohol. Any state of inebriation can cause a misstep, unintentional lunge or off-balance maneuver that can result in a serious accident with a grinder or wire wheel. People under the influence make bad decisions and misjudge distances. Wire-wheel grinding requires a sober, surefooted stance, in addition to a clear mind that has the task clearly in focus.

    Equipment Damage

    • Any grinding wire wheel should be inspected for cracks, loose mounting washers, frayed wiring or any other sign of inferior condition or operation. Wire wheels can break and explode off the hubs, due to stress cracks or manufacturer's defects. All grinding machinery should be inspected for integrity before every task.

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