Posted By holmezy Hi All, not something we normally do, however, we have a need to cut about 4" of each leg of a galvanised metal table with an angle grinder. I've provided dust masks,gloves, eye protection etc and the deed will be done outside. An employee has said that he is not happy doing this as the process produces cyanide gas and he will die!! A bit extreme I thought!! I know that when galvenised is welded, then it releases zinc, chromium and possibly lead fumes but am pretty sure that dry grinding using the stated PPE is minimal or zero risk from fumes etc. Can anyone advise? As an alternative method I have offered to provide him with a hacksaw. Thanks Holmezy

Posted By holmezy Seamus, the operator has had so much training and experience with abrasive wheels and grinders that he may as well have been born with one in his hand. Thats not the issue. Incidentally, the employee who said "cyanide" isn't the same one as the one with the angle grinder. I'm happy that there is no risk, but would be open to advise re the dust, fumes (or lack of....wont reach high enough temp to release zinc fumes) etc. Thanks

Posted By Mitch Grinding produces heat, heat on galvanising produces poisonous fumes, poisonous fumes casue flu like symptons for approximately 24 hours, unless large volumes are inhaled direclty and they will then result in more serious damage/death!!

Posted By holmezy Chaps, thanks for all the advice. Here is what I already know. Zinc vaporizes @ 1650 degrees F and melts at 900 degrees F. Lead which is present vapourizes at 3000+ degrees F. Zinc fumes mix with oxygen in the air to produce zinc oxide which is a white powder and not particularly harmful in small quantities. It is also the main ingredient of the stuff that people smear on their noses to prevent sunburn. I also know about metal fume fever, galvy flu, monday morning fever etc etc. Employee trained and suitably kitted up with PPE. Work to be done outside in what is at present a gentle breeze. Grinding dust to be ejected so breeze takes as much dust away from operator as possible. Total length of grinding will be about 8" of 1/4" material. Its a one off job, probably never have to grind galvenised material again. Fire hazard is negligible, but I do have a C02 extinguisher handy. Electrical supply is 110v through a transformer and a RCD at 240v socket. Manual handling training has been given so moving transformer is not a problem. First aider has fully stocked first aid box and is set to go. I've even got milk close at hand in the fridge just in case he develops a sore throat. What I don't know about is cyanide? And whether its given off during welding (which we are not doing) or dry grinding (which we are)? Think I'll just give him the hacksaw and let him get on with it....... ;) Holmezy

Posted By Peter MacDonald Elbow grease and hack saw. Probably a HAV issue with the saw as well as RSI or WRULD risks. As for the elbow grease, you'll need a COSHH. Pete

Posted By Paul Timms As someone who has experienced this form of poisoning I would say it is not to be taken lightly. As a young man (back in the days before H & S was invented) I cut a large amount of Galv pipe in an enclosed space without any resp. protection and was very severly affected. That said ( and back to the subject) I have cut it with a grinder and would say that the previous suggestions with masks and well ventilated areas are entirely appropriate. I was told to drink a pint of milk and line your stomach, this did seem to help a bit. This may have been a placebo but may also help if your employee is gullible.

Posted By Glen Coe If it is a one off job, I am sure you can be excused for not buying a Local Exhaust Ventilation and air fed hoods etc. etc. Do it outside, use a desk fan to blow the fumes away and give the guy a paper mask and tell him to keep his head upwind and not to breath the fumes. by the time the fumes have traveled 10 feet they will have dissipated to a tiny PPM and no longer an issue. That way he will do the job in just a few minutes, very unlikely to breath any fumes and all is well again... However, if this is a regular job then LEV and Air fed hoods is the right answer. Cheers GC

Posted By Crim Have you thought about applying water to the cutting area? This would prevent the dust problem and cool the metal as it is cut. If not an angle grinder with water applicator then a second man with a watering can, dressed in appropriate PPE can do the job just as well.

Posted By Glen Coe If the problem is this one guy, talk to him and discuss the job. Ask him how does he think the job can be done safely. I am sure you can achieve a common ground and maybe more respect for involving him. It has already be said, it was positive he raised the concern so maximise the engagement and get talking. If he sees it from both sides you could end up with a safety convert.

Posted By Crim I just took some advice from a grinding wheel supplier, Swift Abrasives, Yell.co.uk will give the number, who said water is OK to use with any grinding wheel, but not electric angle grinder.