Common Saw Defects and Saw-Related Injuries

Saws come in many shapes and sizes, both hand-powered and electrical, specifically designed for cutting different materials in different situations. A miter saw, for instance, specifically designed for cutting long pieces of wood at precise angles. A reciprocating saw, sometimes also called a sawzall, is ideal for detail work and for cutting holes in walls; because of this, they are often used in electrical work for installing electrical boxes or in plumbing for accessing pipes hidden behind walls. Other types of saws include table saws, band saws, compound saws, and circular saws.

As in any product with sharp, moving parts, there is the potential for defects or design flaws that can result in injury or death. These defects, once discovered, often result in a product recall by the manufacturing company. Common problem areas are blade attachment systems, motors, safety features, and bolts or other connectors.

Loosening bolts can result in catastrophic failure, including the detachment of moving saw blades; there have been dozens of documented incidents in which this was the case. Safety guards that malfunction or break can lead to lacerations or even amputations, or can cause debris to fly into the face of the operator. Motors that fail or seize can cause the item being cut to kick back, potentially injuring the user.

The Consumer Product Safety Commission reports that an estimated 93,880 saw-related injuries were treated in hospitals in the United States in 2001. Most of the reported injuries were classified as lacerations resulting largely from blade contact, and most injuries were to the fingers, hands, or lower arms. While a majority of the incidents were attributed to user error, many occurred while an experienced operator was using the saw for its intended purpose and all safety features were properly in use. However the details regarding nearly a fourth of the reported saw-related accidents were not available, so the prevalence of defect-related injuries with saws may be even higher than the CPSC report indicates.

Saws are used by many people in a wide variety of applications by a range of people from dabbling hobbyists to construction workers. Because they are such essential tools for completing many tasks, some type of saw can likely be found in most households.

DeWalt, for example, announced a recall of about 112,000 miter saws in 2001. At the time of the recall, DeWalt had received seven reports of laceration injuries caused by a poorly-designed blade attachment system. During the course of normal operation, the bolts which held the 12-inch blades in place had loosened, causing the rotating blades to break free from the saws.

In 2004, Robert Bosch Tool Corporation issued a recall on 120,000 Skil table saws. Motors driving the saw blades were loosening and in some cases even separating from the saw, causing kickback of the item being sawed. The company received eleven reports of broken or loose motors which, despite hazardous potential, had not caused any injuries.

A 2000 recall of Milwaukee Electric Tool band saws cited a faulty power switch. The defective switches would cause the blade to continue to run after the operating trigger was released, potentially resulting in serious injury, though none were reported from this particular defect.

In some cases, even the safety features malfunction. A 1996 recall by Ryobi America Corporation sought to repair about 150,000 table saws because of a defective safety switch. The lockout switch is supposed to stop children or others who are not supposed to use the saw from hurting themselves with the rotating blade. While no injuries were reported, the defective switches left unsuspecting owners and their families vulnerable.

Sources:

Consumer Product Safety Commission Report on Injuries Associated with Stationary Power Saws - http://www.cpsc.gov/LIBRARY/FOIA/FOIA03/os/powersaw.pdf
Consumer Product Safety Commission Recall Notice - DeWalt 12-Inch Miter Saw - http://www.cpsc.gov/cpscpub/prerel/prhtml01/01073.html
Consumer Product Safety Commission Recall Notice - Robert Bosch Tool Corporation Skil Table Saw - http://www.cpsc.gov/cpscpub/prerel/prhtml05/05063.html
Consumer Product Safety Commission Recall Notice - Ryobi America Corporation 10-Inch Table Saw - http://www.cpsc.gov/cpscpub/prerel/prhtml96/96088.html
Consumer Product Safety Commission Recall Notice - Milwaukee Electric Tool Band Saw - http://www.cpsc.gov/cpscpub/prerel/prhtml01/01014.html
All About Power Saws - http://power-tools.hardwarestore.com/learning/all-about-power-saws.aspx