Machine Guarding Requirements

Machine Guards for Abrasive Wheels

Machine guards are one of the most critical safety features on any equipment that uses abrasive wheels. They protect users from direct contact with the wheel, flying particles, and debris if a wheel fails or bursts. For this reason, guards must always be fitted, correctly adjusted, and never removed or bypassed.

Why Guards Are Essential

The primary purpose of a guard is to contain wheel fragments in the event of a failure and to shield the operator from sparks and flying material. Because abrasive wheels operate at very high speeds, guards provide protection against hazards that occur too quickly for human reaction.

General Guarding Requirements

Every abrasive wheel machine must be fitted with a guard suitable for the type of wheel in use. The guard should:

• Cover as much of the wheel as is reasonably practicable
• Allow safe operation of the machine
• Remain securely fixed at all times

Guards on Bench and Pedestal Grinders

Bench grinders and pedestal grinders are typically fitted with several guarding components, including:

• A fixed wheel casing
• Adjustable tool rests
• Spark deflectors
• Eye shields

All of these must be correctly adjusted before use. The tool rest should be positioned no more than 3 mm from the wheel to prevent workpieces becoming trapped. The spark deflector should be set close to the wheel surface to help control the direction of sparks.

Guards on Angle Grinders and Handheld Tools

Angle grinders and other handheld abrasive tools rely on robust, adjustable guards. These guards are designed to:

• Sit between the user and the wheel
• Direct sparks away from the operator
• Provide protection if the disc shatters

The guard must be securely attached and positioned correctly. An angle grinder must never be used without a guard fitted.

Guards on Chop Saws and Cut-Off Saws

Chop saws and cut-off saws are fitted with automatic or fixed guards that cover the wheel when it is raised. As the saw is lowered, the guard retracts to expose the wheel only during the cutting action.

Before use, always check that the guard:

• Moves freely
• Is not damaged or jammed
• Returns fully to the protective position when released

Maintaining Guards in Safe Condition

Guards must be kept clean, secure, and free from damage. Cracked, loose, or modified guards are unsafe and must be repaired or replaced before use.

Regularly check that guards are not obstructed by dust build-up or debris, as this can affect both movement and effectiveness.

Never Modify or Remove Guards

Guards must never be altered to make a task easier. Actions such as removing guards, enlarging openings, or wedging guards out of the way are extremely dangerous.

Such actions are a direct breach of PUWER regulations and manufacturer’s instructions.

Key Safety Message

Always remember that a guard is designed to protect you from hazards that occur too quickly to avoid. Abrasive wheels rotate far too fast for anyone to move clear if something goes wrong. The guard is your first and most important line of defence.