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FRP) Crates Technology Assessment Summary Dewalt Reciprocating Saw- DW309 (Baseline Technology)

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FRP) Crates Technology Assessment Summary Dewalt Reciprocating Saw- DW309 (Baseline Technology) HCET-1996-D038-005-18 TECHNOLOGY ASSESSMENT PROGRAM (TAP) Glovebox Fiberglass Reinforced Plywood (FRP) Crates Technology Assessment Summary DeWalt Reciprocating Saw- DW309 (Baseline Technology) DEMONSTRATION OBJECTIVE LANL technicians and IT Corporation demonstrated the DeWalt reciprocating saw-DW309 at HCET during the Glovebox FRP Crate Size Reduction Assessment on August 13-16, 2001. The purpose of the demonstration was to evaluate the performance of the DeWalt reciprocating saw with respect to its ability to segment FRP crates following the HCET Test Plan especially designed for this purpose. TECHNOLOGY DESCRIPTION The DeWalt reciprocating saw, model DW309 (Figure 1), is a technology that uses an electrical power motor with a reciprocating system that forces a reciprocating saw blade to move up and down rapidly over a surface to be cut (FRP crate). Technical specs are 120-v; 50-60 Hz; 11.8 A; a load speed of 0-2,900 strokes per minute (spm); a speed range selector wheel, an adjustable shoe, a blade clamp release lever, and a speed trigger switch. The trigger switch or speed trigger adds versatility to the saw. The further the trigger is depressed, the higher the speed of the saw. To turn the tool off, the user only needs to release the trigger, and the saw automatically stops running after a few seconds. The speed range selector wheel controls the speed of the tool prior to use. The adjustable shoe adjusts to limit the depth of cut depending on blade length. The blade clamp release lever is a feature used to install and remove saw blades. Figure 1. DEWALT reciprocating saw (DW309). This unit has different material capabilities (wood and metal) depending upon the type of blade selected and the metal to be cut (nails). This tool is considered very light (6.9 lbs.) and small in size (1’ 9” L x 4” W x 7” H). Reciprocating Saw Blade Description Two different types of blades were used during the glovebox FRP crate size reduction: o DeWalt (DW4847) – This blade is classified as a bi-metal reciprocating saw blade for rough wood cutting. It is 6” long and has 5/8 teeth per inch (TPI) o Lenox (20573-S656R) – This blade is classified as a Figure 2. DEWALT Figure 3. DEWALT reciprocating saw blade for wood and nails. It is used for reciprocating saw during reciprocating saw used assessment. blades. general roughing-in work, nail-embedded wood, and fast cutting. It is 6” long and 5/8 teeth per inch (TPI) RESULTS The reciprocating saw was able to size reduce part of the glovebox FRP crate including nails but not the stainless steel plate (1/16” thick x 1” wide) inserted in the crate (Figure 2). The technology successfully demonstrated its ability to perform horizontal and vertical cuts on the assigned glovebox FRP crate. However, LANL technicians noted that this technology would be very useful as an auxiliary tool to cut difficult areas where circular saws cannot reach instead of as a main cutting tool for FRP crate size reduction. The DeWalt reciprocating saw blades tested worked properly on glovebox FRP crate size reduction activities. Several blades were bent or worn out rapidly while cutting. The Lenox blade cut smoothly and rapidly through the fiberglass, plywood, and nails. Figure 3 displays used reciprocating saw blades after the completed demonstration. Sawdust was generated during cutting activities (secondary waste). HCET-1996-D038-005-18 The technology has a number of advantages: (1) Production rate is considered medium -high. It is good to have this saw as a supplementary cutting tool instead of main cutting tool during glovebox FRP crate size reduction. (2) The reciprocating saw is lightweight, which minimizes worker exposure to ergonomic problems due to tool weight. Operator fatigue is also reduced. (3) The tool is easy to set up, operate, and handle, and blades can be changed easily and rapidly (quick-change blade clamp). (4) The DeWalt reciprocating saw is easy to clean, and it is an inexpensive tool. (5) The DeWalt reciprocating saw in combination with the Lenox blade was able to cut through combinations of fiberglass, resin, plywood, and nails simultaneously. (6) Cutting activities are relatively safe for saw operators and environment, e.g., minimal risk for injuries, low personnel dose, and convenient spread of contamination. However, the heat transfer from tool to crate and operator must be cautiously considered while cutting activities occur. (7) Secondary waste generation is mainly fiberglass and wood sawdust and worn out or bent blades. Some potential disadvantages follow: (1) The DeWalt reciprocating saw reaches high temperatures easily. Heat transfer from saw blade to tool and from tool to operator is high. Tool reached temperatures up to 114?F. Cutting activities were frequently stopped because LANL technicians had to let this saw cool down before continuing cutting activities. (2) The cutting tool is strong for small jobs but not recommended for total segmentation of FRP crates. (3) LANL technicians found it difficult to perform straight cuts with this tool. Drawing a cutting line is recommended to mitigate this problem. (4) The reciprocating saw produced noise up to 105 decibels (dBA), which represents a potential noise hazard for operators. (5) Vibration level for the DeWalt reciprocating saw, measured in terms of velocity at the rear handle, was 0.870 in/s ec. (6) Vibration levels fall into the dangerous level, which represents a risk for workers regarding Hand/Arm Vibration Syndrome (HAVS). Table 1 summarizes technical data collected during the DeWalt reciprocating saw demonstration. Table 1. Significant data collected during DeWalt reciprocating saw demonstration Aspect Results Comments Pre-demonstration 1hr. and 35 min. Safety orientation and formal briefing of EMS HCET policy for IT activities Corporation, LANL technicians, and IUOE representatives. Officials get familiar with the testing conditions under which the demonstration will proceed. Production Rate 0.40 ft/min Production rate reflects production time beginning immediately following equipment mobilization and ending at size reduction completion, just prior to equipment demobilization. Cutting Rate 2.20 ft/min Cutting rate includes data collection on the time the equipment is in operation. Cutting capability evaluates the ability of each technology to cut crates in different directions and the ability of each technology to dismantle crates to specification. Total Demo Time 2 hrs. and 40 min Gross time including production and cutting time. Total Cutting Time 29.37 min Only includes cutting time. Length Cut HC = 48 ft HC: Horizontal cuts; CTC: Crate top cuts; VC: Vertical cuts. CTC = 4 ft VC = 12.7 ft Total = 64.7 ft Surrogate Type Glovebox FRP Crate Glovebox FRP crate dimensions are 4’ H x 8’ L x 4’ W. A stainless steel piece of plate was placed on the front-internal side of the crate to observe tool kick-off performance. The plywood crate was reinforced with four (4) layers of fiberglass and resin up to ¼” thick. The plywood thickness is 5/8” for a total thickness of 7/8”. Crate corners and midsections have a reinforced wood frame of 2” x 2”. Blades Used 2 DeWalt reciprocating blades. Includes overall blades used during demonstration. 1 DeWalt bi-metal saw blade. 4 Lenox reciprocating saw blades. Waste Generated Crate Segments of 1’ x 2’. Primary waste includes FRP segments, and secondary waste Sawdust: 3.3 lbs. includes sawdust and used blades. Airborne Particulate Sampling: Air samples collected presented a unimodal distribution. An average weight of 0.1253 mg of respirable particulate (9.9 ?m to <0.051 ?m) was collected over a period of 20 minutes for the glovebox FRP crate size reduction assessment. It was found that the sample included overflow due to the large quantities of airborne generated during the DeWalt reciprocating saw demonstration. Respirable particulate is the fraction of the particle mass that may possibly be deposited in the different compartments of the respiratory tract. However, the harmful effects from the inhalation of particles are determined by the toxicity of the material (type of contaminant), air concentration, and particle size distribution. HCET-1996-D038-005-18 Figure 4 graphically shows production and cutting rate comparison for five cutting tools demonstrated during this overall tool assessment. Cutting Tools - Production Rates Cutting Tools - Cutting Rates 1.4 5 4.5 1.2 4 1 3.5 0.8 3 2.5 0.6 2 0.4 1.5 1 0.2 0.5 0 0 Dewalt (2.67) Milwaukee Porter-Cable Adamant Evolution 180 Evolution 180 Dewalt (0.57) Milwaukee Porter-Cable Adamant Evolution 180 Evolution 180 Production Rate (ft/min) (1.95) (2.05) (Plywood - (FRP - 0.65) (Metal - 0.18) Production Rate (ft/min) (0.59) (0.49) (Plywood - (FRP - 0.09) (Metal - 0.03) 1.38) 0.08) Cutting Tools & Total Demo Time (hr) Cutting Tools & Total Demo Time (hr) NOTE: DeWalt, Milwaukee, Porter-Cable, and Evolution 180 circular saws were tested on glovebox FREP crates. Adamant saw was tested on a plywood crate, and the Evolution 180 was also tested in metal. Figure 4. Comparison of production and cutting rates for all cutting tools evaluated during the assessment. HEALTH AND SAFETY FACTORS The noise level generated during the DeWalt reciprocating saw operation was above the OSHA action limit of 85 dBA (105 dBA). This represents a potential noise hazard for operators. Vibration level was measured at the rear handle of the tool and is reported in terms of velocity. Vibration frequency range is 10 Hz to 1 kHz; to a maximum of 2 in/sec. Vibration level for the DeWalt reciprocating saw was 0.870 in/sec. Vibration levels above 0.709 in/sec are rated as dangerous per Computational System Incorporated (CSI) Graph provided with a hand-held vibration meter used for this purpose.
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