Cut-off saw kickbacks are a serious safety risk, occurring when the blade pinches or stalls in the material being cut. The force generated by the blade can cause the saw to be thrown out of the cut, sometimes even back at the operator. Understanding how to use your cut-off saw properly can help you avoid kickbacks, increase productivity, and confidently tackle even the toughest cuts.

1. Let Your Saw Do the Work

Excessive pressure can lead to issues with your saw blade, including uneven or inconsistent wear patterns. When the width of the segments is smaller than the width of the steel core, the blade becomes more susceptible to pinching in the material, which increases the risk of a kickback. Let the saw do the work by applying only the necessary pressure for efficient cuts.

2. Avoid Using a Worn or Damaged Blade

A worn-out or damaged blade is not only inefficient, but it also increases the likelihood of kickbacks. If you notice chips, cracks, or missing segments on your blade, stop using it immediately. Discard the damaged blade to prevent accidents. Always ensure you’re using the correct blade for the material you're cutting by following these 5 Steps When Selecting Your Diamond Blade

Top Blade: Worn Segments... Bottom Blade: New Segments

3. Support the Material Properly

To avoid a pinch during cutting, it's crucial to support the material properly. Make sure the cut remains open throughout the process. Support both sides of the material to prevent it from shifting, pinching, or binding the wheel. If necessary, use a wedge to keep the material open. Always work on a level surface. When cutting pipe, cut 90 degrees around the pipe, and repeat the process until the pipe is fully cut.

If you're cutting in a trench, support the pipe’s bottom with bricks, wood blocks, or even a tie to an excavator or another machine for additional support.

Illustration from STIHL TS 410, 420 Instruction Manual, Page 13, Copyright Andreas Stihl AG

4. Maintain a Safe Cutting Stance and Grip

Your safety is paramount when operating a cut-off saw.

• Ensure proper footing and balance throughout the cutting process.

• Position the machine so your body remains clear of the cutting attachments.

• Never stand directly over the material or lean too far over the saw.

• Lock your left elbow while operating, and grip the handles firmly with both hands, ensuring your thumbs are wrapped around them for added control.

• Always cut with two hands: place your left hand on the front handle and your right hand on the rear handle, near the throttle trigger.

• Avoid turning the wheel at an angle or pushing the wheel into the cut when reentering, as this can lead to a pinch.

5. Cut with the Lower Quadrant of the Blade

For maximum control and safety, always cut with the lower quadrant of the blade. In a pinch situation, this allows the saw to pull away from you, reducing the risk of kickback. Never cut with the upper quadrant of the blade, and never adjust the wheel guard past the designated stop. When introducing the cutting wheel into the material, do so with extreme caution—never twist or push the blade into the cut.

Illustration from STIHL TS 410, 420 Instruction Manual, Page 13, Copyright Andreas Stihl AG

6. Use the Proper Personal Protective Equipment (PPE)

The Occupational Safety and Health Administration (OSHA) mandates the use of specific personal protective equipment (PPE) when operating a cut-off saw. This includes a hard hat, safety glasses, hearing protection, respiratory protection, long sleeves and pants, and durable boots.

Wearing the appropriate PPE not only protects you from immediate dangers but also helps minimize long-term health risks related to concrete dust exposure and excessive noise.

A key piece of PPE is the New Husqvarna SmartGuard Safety Helmet, designed to enhance operator safety. Part of the SmartGuard™ family of protective equipment, this helmet features a chin guard that can reduce the severity of injuries from blade contact in the event of a kickback.

Lightweight, well-ventilated, and comfortable, the helmet provides a universal fit with easy size adjustment using a wheel ratchet. Additionally, it includes earmuffs and a visor for added protection.