How to Use an Industrial Disc Sander
Industrial disc sanders are used in many different types of shops. Wood, plastics, and metals can all be shaped using this tool. Discs tend to be cheaper than belts. Straightening or flattening curves or warpage and sanding outside curves or convex radii are best done using a disc sander. It is essential to follow all safety recommendations and wear appropriate personal protective equipment when using an industrial disc sander.
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Things You'll Need
- Sander with old disc still attached
- Putty knife
- New sanding disc in correct grit
- NIOSH-approved respirator
- Long-sleeves, heavy leather gloves, and full, high-impact face shield
- Metal coffee can filled with water
- Paintbrush, rags, broom
- 5-gallon bucket of water, 5-gallon bucket of sand
- Large, fully charged ABC fire extinguisher
Instructions
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Make sure the sanding disc already on the sander is not worn out, and is the correct grit for the task you are about to perform. If it is worn or is the wrong grit, remove the old disc according to manufacturer's instructions. Some discs have a removable sanding surface held in place with an adhesive backing. Removing it may require using a putty knife if the adhesive on the disc has overheated.
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Warm the new disc to above 60 degrees F or cool it to under 100 degrees if the shop or the machine are colder than 60 degrees F or warmer than 100 degrees F. The adhesives that hold the disc onto the sander will not adhere well enough when the disc is cold. Poor adhesion can result in the disc flying off during use, which can cause severe injury or death.
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Peel away the protective backing and center the disc evenly on the head of the sander. Use firm, even pressure to make the disc stick. When installing the new disc, Makita recommends, "Mount the new pad onto the spindle. Fit the abrasive disc and countersunk washer on the pad and screw the clamp screw clockwise into the spindle. To tighten the clamp screw, grip the edge of the pad with your hand, then tighten the screw clockwise with a hex wrench securely. To remove the disc, follow the installation procedure in reverse."
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Don a NIOSH-approved respirator, long-sleeves, heavy leather gloves, and full, high-impact face shield. A sanding disc can cut deep and fast, like a saw blade, if it hits you on edge. There is always a risk of inhalation hazard when using a disc sander. Stand clear of the edge of the disc when starting the sander. Run the sander for a few seconds, and then turn it off. Check the disc once it has stopped spinning. Press firmly in all directions to make sure the adhesive is holding the disc in place.
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Adjust the the edge of the work rest on the sander so that there is only 1/8-inch of space between it and the piece you are sanding, cutting, grinding or polishing. According to 30-year home builder Jeff Ramold, who uses industrial disc sanders when making crown molding and wainscoting, "The biggest hazard with disc sanders is having the part you are working or a body part sucked into the space between the work and the disc."
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Use firm, even pressure and long strokes going away from your body. If cutting, grinding or polishing metal with an industrial disc sander, cool the metal with water as necessary to prevent heating the disc until it smokes. If cutting plastic or wood, stop working every few minutes for 30 to 60 seconds to prevent scorching or melting the material and to prevent overheating the disc. Grinding hot will make the disc very difficult to remove when it is time to replace it, and will reduce its usable life.
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Clean the machine using a paintbrush and rags to remove dust and debris. Use a broom to sweep the grinding area floor.
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Check for anything smoking or smoldering in your work area when finished. Use sand, water or an ABC fire extinguisher as needed. Wait 30 minutes, whether you find anything or not, and check again for anything smoking or smoldering before you leave your work station or close the shop.
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Tips & Warnings
If training a new employee or if you are a new disc sander operator, get a feel for the machine by grinding a few pieces of scrap to learn not to over-grind or grind at the wrong angle.
According to WMH Tool Group, "Abrasive sanding can be hazardous to operators and bystanders. Sanding sparks, chips and dust particles...can cause serious injury if contacted or inhaled. To avoid such injuries you must comply with the following safety requirements: Always wear protective eyewear when operating machinery. Eye wear shall be impact resistant, safety glasses with side shields which comply with ANSI Z87.1. Use of eye wear which does not comply with ANSI Z87.1 specifications could result in severe injury from the breakage of the eye protection."
WMH Tool Group continues, "Wear leather safety gloves, arm guards, leather aprons and safety shoes. A dust collection system is recommended. The operator should also wear a dust mask at all times."
Finally, they recommend, "Additional precautions may be necessary for sanding materials which are flammable or have other hazardous properties. You should always consult the manufacturer of such materials for instructions on sanding and handling (Reference 3)."
