1. PURPOSE
This Standard Operating Procedure establishes the minimum requirements for the safe setup, operation, blade changing, workpiece clamping, and chip/dust collection when using a standard mitre saw to cut aluminum at Rossen Glass & Mirror Ltd. job sites. Because cutting is typically performed in a client's garage or a new-build home, this SOP also covers portable table setup, ventilation, noise awareness in residential settings, and the protection and restoration of the client's space. Compliance protects operators, clients, and their property.
2. SCOPE
This SOP applies to all Rossen Glass & Mirror Ltd. employees who operate a standard (single-bevel) mitre saw at any job site, including new-build homes and existing client residences. It covers corded electric mitre saws set up on a portable table, used for cutting aluminum extrusions, angle, flat bar, and similar non-ferrous metal stock in connection with glass shower enclosure installation.
3. RESPONSIBILITIES
Operator
- Complete this SOP training and demonstrate safe operation before using the saw independently.
- Inspect the saw, blade, and guards before every use.
- Use only blades rated and approved for cutting aluminum/non-ferrous metal.
- Report defects, damaged guards, or incidents to a supervisor immediately.
Supervisor
- Ensure operators are trained, authorised, and using the correct blade for the material.
- Maintain an equipment log, blade inventory, and maintenance schedule.
- Remove defective saws from service and arrange repair or replacement.
4. HAZARDS & RISK SUMMARY
| Hazard | Potential Harm | Controls |
|---|
| Contact with rotating blade | Severe laceration, amputation | Guards in place; no-cut zone enforced; clamp workpiece |
| Flying metal chips / swarf | Eye injury, facial laceration | Face shield + safety glasses; chip deflector fitted |
| Hot chips / metal sparks | Burns to skin, eyes, or clothing | Face shield; no loose clothing; chip collection |
| Workpiece kick-back or movement | Hand/finger injury, blade contact | Clamp all workpieces; never hand-hold small pieces |
| Blade contact during change | Laceration | Disconnect power; blade fully stopped; cut-resistant gloves |
| Aluminum dust accumulation | Inhalation; slip hazard; fire risk | Dust mask; chip collector; regular cleanup |
| Noise | Hearing damage | Hearing protection for sustained cutting sessions |
| Unsecured saw movement | Loss of control, crush injury | Saw bolted or clamped to stable table before use |
| Reaching across blade path | Laceration | No-reach-across rule strictly enforced |
5. REQUIRED PERSONAL PROTECTIVE EQUIPMENT (PPE)
| PPE Item | Specification | Mandatory? |
|---|
| Full face shield | ANSI Z87.1; worn over safety glasses | YES — cutting operations |
| Safety glasses / goggles | ANSI Z87.1; worn under face shield | YES — at all times |
| Hearing protection | Foam earplugs or earmuffs; NRR 25+ | YES — sustained cutting |
| Cut-resistant gloves | ANSI A4 minimum; close-fitting | YES — blade changes only |
| Dust mask / respirator | N95 minimum for aluminum dust | YES — cutting aluminum |
| Steel-toed footwear | CSA Grade 1 or equivalent | YES |
| Secure clothing | No loose sleeves, gloves during cutting, ties, or jewellery | YES |
⚠ WARNING: Do NOT wear work gloves during cutting operations — gloves can catch the blade. Cut-resistant gloves are worn ONLY during blade changes, with the saw fully disconnected from power.
6. PRE-USE INSPECTION
Complete all checks before every use. Do NOT operate a saw that fails any item — tag it out of service and notify your supervisor.
1
Choose and prepare the setup locationSet up in the garage whenever possible. Open the garage door fully before starting — this is mandatory for ventilation of aluminum dust and noise management in the neighbourhood. If the garage door cannot be opened, do not cut until ventilation is arranged.
2
Set up the portable tablePlace the portable table on a flat, stable surface. Check all four legs are locked and even — the table must not rock. If the floor is uneven, use shims to level it before placing the saw. Do not set up on soft ground, gravel, or any surface that may shift under the weight of cutting.
3
Position the saw on the tablePlace the saw centred on the table and clamp or bolt it down if the table has mounting points. The saw must not slide or tip when the blade head is pushed down firmly. Ensure the table is positioned so the operator has clear access to both sides without reaching across the blade path.
4
Protect the client's floor and surroundingsLay a drop cloth or protective sheet on the garage floor and on any nearby surfaces before cutting begins. Aluminum swarf travels and can scratch finished floors or damage vehicles. This step is mandatory on all client visits, new build or existing home.
5
Upper blade guardConfirm the upper fixed guard is in place and undamaged, fully enclosing the top of the blade.
6
Lower / return guardConfirm the lower pivoting guard moves freely, springs back fully to cover the blade after each simulated cut, and is not bent or jammed.
7
Blade conditionInspect blade for missing, cracked, or damaged teeth. Confirm it is the correct type for aluminum/non-ferrous metal (non-ferrous TCT blade). Do not use a wood blade on metal.
8
Blade tightnessConfirm the blade arbour bolt is tight and the blade is correctly seated on the arbour flange.
9
Mitre angle lockSet and lock the mitre angle. Confirm the table rotates smoothly and the lock secures firmly at the required angle.
10
Fence integrityInspect both fence sections — they must be straight, undamaged, and flush with the table surface.
11
Clamp / hold-downConfirm the workpiece clamp (if fitted) is present and functions correctly. Have a separate clamp available if the saw has no built-in hold-down.
12
Power cord and outletNo cuts, fraying, or exposed wire. Plug into a GFCI-protected outlet only. Route the cord away from the cutting path and away from foot traffic areas. Do not use an extension cord that is not rated for the saw's amperage.
13
Chip collectionConfirm the chip/dust bag or vacuum hose is connected and the bag is not full. Clear any accumulated swarf from the table and base.
14
Work area and bystandersConfirm no homeowners, other trades, or bystanders are within the chip-ejection zone (minimum 3 metres / 10 feet to either side of the blade). If children or pets are present in or near the garage, cutting must not begin until they have been moved to a safe, supervised location well away from the work area. Politely but firmly communicate this to the client if needed.
7. NO-CUT ZONES & BLADE GUARD RULES
The following rules are absolute — they are never overridden for speed or convenience.
No-Cut Zone
- Keep both hands a minimum of 150 mm (6 inches) from the blade path at all times during cutting.
- The area directly in front of the blade — along the line of cut — is the no-cut zone. Hands must never enter this zone while the blade is in motion.
- Never reach across the blade or the cut line to hold, retrieve, or position a workpiece.
- Place offcuts to the side after the blade has fully stopped and the guard has returned.
Guard Rules
- NEVER remove, tie back, wedge open, or defeat any blade guard for any reason.
- If the lower guard does not return freely after a cut, stop immediately, disconnect power, and report the fault before continuing.
- Never use the saw with the upper guard removed or damaged.
- Do not use the saw to cut material so small that the guard cannot function correctly — cut from a longer piece and trim to length.
⚠ WARNING: Operating this saw with a guard removed or defeated is a serious safety violation and grounds for immediate removal from tool operating privileges.
8. WORKPIECE CLAMPING
Aluminum and metal stock can grab, rotate, or kick back violently if not properly secured. All workpieces must be clamped before every cut.
1
Position the workpiece against the fenceThe workpiece must be seated flat on the table and firmly against the fence before clamping. Never cut a workpiece that is not fully supported by the table and fence.
2
Apply the clampUse the saw's built-in hold-down clamp if fitted. If not, use a suitable C-clamp or quick-release clamp on the far side of the fence, clamping the workpiece to the fence or table. The clamp must be positioned well clear of the blade path.
3
Verify the clamp is tightAttempt to move the workpiece by hand before starting the saw. If it shifts, re-clamp.
4
Minimum workpiece lengthNever cut pieces shorter than 200 mm (8 inches) without first consulting your supervisor for a safe method. Very short pieces cannot be safely clamped and controlled.
5
Support long stockLong lengths of aluminum extrusion or bar must be supported on both sides of the cut using roller stands or a second table at the same height. Unsupported overhanging stock can tip, shift during the cut, or fall and injure the operator.
6
Never hand-hold a workpieceUnder no circumstances may the operator or any other person hold the workpiece by hand as a substitute for clamping. This applies to every cut, including short trim cuts.
9. CUTTING PROCEDURE
Step A — Setup
1
Don PPEPut on safety glasses, face shield, hearing protection, dust mask, and steel-toed footwear before starting the saw.
2
Confirm garage door is open and area is clearVerify the garage door is fully open for ventilation. Confirm no homeowners, children, pets, or other trades are within 3 metres of the saw. If the client approaches while cutting is in progress, pause between cuts to speak with them — never talk over a running saw.
3
Be mindful of noise in residential settingsA mitre saw cutting aluminum is loud. Limit cutting to reasonable hours and, where possible, batch cuts together to minimise the total duration of noise. If a neighbour or client expresses concern, acknowledge it respectfully and advise them of the expected remaining cut time.
4
Set the mitre angleLoosen the mitre lock, rotate the table to the required angle, and re-lock firmly. Confirm the angle on the scale before cutting.
5
Mark and position the workpieceMark the cut line clearly. Position the workpiece so the blade will cut on the waste side of the mark. Clamp as per Section 8.
6
Check the chip collectionConfirm the collection bag or vacuum is connected and clear. Position the chip deflector toward the collection port.
Step B — Making the Cut
1
Stand to the sidePosition yourself to one side of the blade — never directly in line with the blade path, which is the ejection zone for a kick-back.
2
Start the blade at full speed before contactSqueeze the trigger and allow the blade to reach full operating speed before lowering it to the workpiece. Never start the saw with the blade already in contact with the material.
3
Lower the blade smoothlyApply steady, even downward pressure — do not force or twist. Let the blade do the work. Forcing the cut overloads the motor and increases the chance of blade grab.
4
Complete the cut and hold downOnce the cut is complete, keep the trigger depressed and hold the blade head in the down position for 2–3 seconds to allow chips to clear before raising.
5
Raise the blade fully before releasing the triggerReturn the blade head fully to the rest position, then release the trigger. Wait for the blade to stop completely before reaching near the cut area.
6
Confirm the guard has returnedVisually confirm the lower guard has sprung back to fully cover the blade before removing the workpiece or adjusting anything.
7
Remove the workpiece and offcutOnce the blade has fully stopped and the guard is in place, unclamp and remove the workpiece and offcut from the table. Never remove pieces while the blade is coasting.
⚠ WARNING: NEVER lift the blade head while the blade is still spinning. NEVER place your hand near the blade until it has completely stopped and the guard is fully closed.
10. CHIP & DUST COLLECTION
Cutting aluminum produces fine metal swarf and dust that is a respiratory hazard, a slip hazard underfoot, and a fire risk if allowed to accumulate near electrical components. Chip collection is mandatory, not optional.
1
Connect collection before cuttingThe saw's chip collection bag or a shop vacuum hose must be connected to the saw's dust port before every cutting session. Do not operate the saw without a collection method in place.
2
Check bag / canister fill levelThe collection bag must not exceed 75% full before starting. A full bag restricts airflow, reduces collection efficiency, and can rupture. Empty it into a bag and set aside before beginning work.
3
Use a vacuum with a metal-rated filterWhen using a shop vacuum instead of the bag, ensure the filter is rated for fine metal dust. Standard paper filters can clog rapidly with aluminum swarf.
4
Keep the drop cloth in place throughoutThe drop cloth placed before cutting must remain in place for the entire cutting session. Do not remove it to check on chips mid-session — leave it down until all cutting is complete and the saw is powered off.
5
Clear the table between cutsUse a brush (never bare hands) to sweep accumulated chips off the table and fence between cuts. Brush chips onto the drop cloth, not the floor. Keep the table clear so workpieces seat flat.
6
Do not use compressed airNever use compressed air to blow chips — this disperses fine aluminum dust into the air and throughout the client's garage. Brush and vacuum only.
7
Full cleanup before leaving the client's propertyAt the end of every cutting session: disconnect power, then brush and vacuum all chips from the saw body, table, fence, guard pivot, and surrounding floor. Carefully fold the drop cloth inward to contain all swarf and remove it from the garage. Inspect the garage floor and any nearby surfaces for stray chips — remove every one. The client's space must be left in the same condition as it was found, or better.
8
Dispose of swarf safelyCollected aluminum swarf is transported off-site in a sealed bag and disposed of in the designated metal scrap bin at the shop. Do not leave swarf or offcuts at the client's property.
NOTE: Aluminum dust is combustible in sufficient concentration. Keep the work area clean, avoid open flames near cutting operations, and never allow dust to accumulate on light fixtures or electrical panels.
11. BLADE CHANGES
Blade changes must only be performed by trained, authorised operators. The correct blade for cutting aluminum at Rossen Glass & Mirror Ltd. is a TCT (tungsten carbide tipped) non-ferrous metal blade with a negative or low rake angle. Never use a wood-cutting or ferrous-metal blade on aluminum.
1
Disconnect from powerUnplug the saw from the outlet. Do not rely on the power switch alone — the saw must be physically disconnected before any blade work begins.
2
Allow the blade to come to a complete stopIf the saw was recently used, wait until the blade has stopped completely and confirm it is stationary before proceeding.
3
Don cut-resistant glovesPut on ANSI A4 or higher cut-resistant gloves before touching the blade. Even a stationary blade has sharp carbide teeth.
4
Raise and lock the blade headRaise the blade head to the full up position. If the saw has a head lock pin, engage it to hold the head securely while you work.
5
Remove the blade guard as minimally as neededSome saws require partial guard removal to access the arbour. Remove only what is necessary and set guards in a clean, visible place so they are not forgotten.
6
Loosen the arbour boltUse the correct wrench(es) for the saw. Note: many mitre saws have a left-hand thread on the arbour bolt — turn clockwise to loosen. Consult the manufacturer's manual if unsure. Use the spindle lock button to hold the blade while loosening.
7
Remove the old bladeRemove the arbour bolt, outer flange, and blade. Handle the blade by its plate, not the teeth. Place the old blade in the blade disposal sleeve or wrap in cardboard before discarding.
8
Inspect the arbour and flangesCheck the inner and outer flanges for damage or built-up aluminum residue. Clean if necessary. A dirty or damaged flange causes blade run-out and unsafe cuts.
9
Install the new bladeConfirm the new blade is the correct diameter, bore size, and tooth specification for this saw and for aluminum cutting. Install with the blade rotation arrow matching the arrow on the guard or blade head. Seat the blade flat on the inner flange.
10
Tighten the arbour bolt firmlyHand-tighten the outer flange and bolt, then snug with the wrench. Do not over-torque — tighten to the manufacturer's specification. Re-engage the spindle lock while tightening.
11
Reinstall all guardsReinstall any guards that were removed. Confirm the lower guard moves freely and springs back.
12
Test spin before cuttingReconnect power, stand clear, and run the saw for 5–10 seconds with no workpiece to confirm the blade runs true, with no vibration or unusual noise. If anything seems wrong, disconnect and investigate before proceeding.
13
Log the blade changeRecord the date, operator name, blade type/part number, and reason for change in the equipment maintenance log.
12. POST-USE PROCEDURE
1
Power downRelease the trigger and confirm the blade has fully stopped before doing anything else.
2
Disconnect powerUnplug the saw from the outlet before performing any cleanup near the blade.
3
Full chip cleanupBrush and vacuum all chips from the saw body, table, fence, guard, and base. Fold the drop cloth inward to contain swarf and remove it from the garage. Inspect the entire work area — floor, walls, and any nearby surfaces — for stray chips and remove them. Do not use compressed air.
4
Inspect the client's spaceWalk the garage and immediate surroundings to confirm no aluminum chips, offcuts, or debris have been left behind. The client's property must be returned to its original condition.
5
Inspect the blade and guardsQuickly inspect for damage. Note anything to report to the supervisor.
6
Empty the chip collection bagEmpty the collection bag, seal the swarf in a bag, and store in the van for disposal at the shop.
7
Return mitre angle to 0°Reset the mitre angle to 0° / square as the default park position for transport.
8
Lower and secure the blade headReturn the blade head to the rest/down position. Engage the transport lock if the saw has one.
9
Pack down the portable tableFold and secure the portable table for transport. Ensure all legs are fully folded and locked before loading.
10
Load equipment into the vanLoad the saw, table, clamps, and accessories securely in the van. Nothing should be loose in the cargo area during transit.
11
Complete the equipment logRecord date, job site, operator name, materials cut, and any observations or defects in the equipment log upon returning to the shop.
13. REFERENCES & RELATED DOCUMENTS
- Mitre Saw Manufacturer's Operator Manual (keep on file with equipment)
- Ontario Occupational Health and Safety Act (OHSA), R.S.O. 1990
- CSA Z432 — Safeguarding of Machinery
- Rossen Glass & Mirror Ltd. PPE Policy
- Equipment Maintenance & Blade Change Log
- Incident Reporting Procedure
14. ACKNOWLEDGEMENT & SIGN-OFF
By signing below, all parties confirm they have read, understood, and agree to comply with this Standard Operating Procedure.
| Role | Printed Name | Signature | Date |
|---|
| Operator | | | |
| Supervisor | | | |
| H&S Representative | | | |