Rail Cutting and Drilling

Rail cutting and drilling are carried out during track renewal, S&C work, and maintenance possessions.
Rail saws, disc cutters, and abrasive wheels generate extreme noise levels typically exceeding 100 dB(A).
Metal fragments and sparks from cutting and drilling are ejected at high speed, causing eye and burn injuries.
Vibration exposure from rail cutting and drilling equipment contributes to HAVS in regular operators.
All rail cutting work must take place during confirmed possessions with a safe system of work on track.
Rail drill rigs clamp onto the rail under significant force — crush injuries occur if hands are in the clamp zone.
Dust from cutting rail steel contains iron particles and potentially manganese, requiring respiratory protection.
Cut rail ends are extremely sharp and hot immediately after cutting — they cause severe lacerations and burns.
Network Rail standards specify the approved cutting and drilling methods, tools, and quality requirements.
Fire risk exists from sparks landing on ballast, vegetation, or stored materials near the cutting location.

Prevent hearing loss	Rail cutting exceeds 100 dB(A) — even brief exposure without hearing protection causes permanent hearing damage.
Eye and burn injuries	High-speed metal fragments and sparks strike unprotected skin and eyes, causing serious injuries.
HAVS risk	Regular use of rail cutting and drilling equipment without time management causes permanent hand-arm vibration damage.

Do

Don't

Wear double hearing protection (plugs and muffs) when cutting rail as noise exceeds 100 dB(A)
Wear a full face visor and safety glasses to protect against metal fragments and sparks
Confirm the possession and safe system of work are in place before starting any rail cutting
Monitor vibration exposure time and rotate operators to stay within daily action values
Keep hands clear of drill rig clamps and cutting tool guards during all operations
Extinguish sparks landing on vegetation or combustible materials near the cutting position
Allow cut rail ends to cool before handling and mark them as sharp edge hazards
Wear RPE when cutting rail in enclosed areas where metal dust concentrations build up
Inspect cutting blades and drill bits before use and replace worn items immediately
Brief the team on the cutting sequence, spark control, and hot metal handling procedure

DON'T cut or drill rail without confirmed double hearing protection in place
DON'T operate rail cutting or drilling equipment without a full face visor and eye protection
DON'T allow sparks to land on dry vegetation, stored materials, or cable runs unchecked
DON'T exceed vibration exposure time limits when using rail cutting or drilling equipment
DON'T place hands near drill clamp zones or cutting blade guards during operation
DON'T handle freshly cut rail ends without heat-resistant gloves — they cause severe burns
DON'T carry out rail cutting without an approved possession and safe system of work
DON'T use damaged or worn cutting blades — they increase the risk of blade failure
DON'T leave cut rail offcuts lying in the track area where they are a tripping hazard
DON'T stand directly in line with the cutting disc — metal fragments are ejected at speed

See also: Rail Safety Awareness | Grinding and Cutting Safety

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