1. Structural Collapse Technician Training
FEMA US&R Response System - Rescue Specialist Training
Appendix C Metal Burn Cutting - Instructors Slides + Notes
Structural Collapse Technician Training
Appendix C:
Metal Burn Cutting
Jan09

2. FEMA US&R Response System - Rescue Specialist Training
Appendix C Metal Burn Cutting - Instructors Slides + Notes
Unit Objectives
The student will understand the capabilities and limitations of all the types of metal burning that can be used in US&R operations
Understand how to efficiently and safely cut and remove multiple pieces of steel from a debris pile .

3. Enabling Objectives Discuss how to conduct a site hazard analysis
FEMA US&R Response System - Rescue Specialist Training
Appendix C Metal Burn Cutting - Instructors Slides + Notes
Enabling Objectives
Discuss how to conduct a site hazard analysis
Select appropriate PPE
Select the most efficient metal burning equipment based on needs of an incident
Discuss safety practices associated with the different metal burning equipment
Identify hazardous situations found when cutting and burning on a debris pile
Understand the safety practices to minimize risk to rescuers.
NEED TO RECOGNIZE
Ferrous vs non-Ferrous metal
Plated and/or Painted metal
Thick or Thin plate
Rebar – dirty or rusted
They all present different issues when Burn Cutting them

4. FEMA US&R Response System - Rescue Specialist Training
Appendix C Metal Burn Cutting - Instructors Slides + Notes
Enabling Objectives
Discuss the use & setup of the various types of metal burning equipment based on safety, material type & thickness
Identify special issues involved with
Compressed gas cylinders
Oxy / acetylene—use and safety
Gasoline / oxygen operation
Discuss proper breakdown, storage and shipping methods for the metal burning equipment in FEMA US&R Cache
Is speed an issue?
Is portability an issue?
What thickness material needs to be cut?
All should be discussed when instructor talks later about the advantages and disadvantages of each of the four systems

5. Topics to be discussed Oxy/Fuel process & Safety
FEMA US&R Response System - Rescue Specialist Training
Appendix C Metal Burn Cutting - Instructors Slides + Notes
Topics to be discussed
Oxy/Fuel process & Safety
Personal Protective Equipment
Types of Metal Burning Equipment
Oxy/Acetylene
Oxy/Gasoline
Exothermic/Oxygen Lance
Plasma Arc
Storage & shipping methods
There are just to introduce the scope of this class
Do not dwell too long on anything at this time
This is just the Road Map. All will be discussed in detail later
DO NOT GET AHEAD OF YOURSELF AT THIS TIME

6. FEMA US&R Response System - Rescue Specialist Training
Appendix C Metal Burn Cutting - Instructors Slides + Notes
Oxy Fuel Process

7. General Safety Guidelines
FEMA US&R Response System - Rescue Specialist Training
Appendix C Metal Burn Cutting - Instructors Slides + Notes
General Safety Guidelines
Metal burning requires strict compliance with all manufacturer’s safety guidelines
Biggest causes of injury
Burns from hot material or ultraviolet rays
Breathing toxic materials
Wear full PPE at ALL TIMES
Wear UV rated eye protection
Use proper respiratory protection
Work in 2 person teams
Disaster sites are often littered with combustible debris.
May need to consider the use of the type of Burn Cutting that will produce the least amount of sparks and molten material

8. General Safety Guidelines (cont.)
FEMA US&R Response System - Rescue Specialist Training
Appendix C Metal Burn Cutting - Instructors Slides + Notes
General Safety Guidelines (cont.)
Inspect all equipment prior to use for damage and leaks
Have a fire extinguisher or small hose line available for spot fires
Hydrate often
Consider the reaction of your actions before and while cutting a piece of steel or cable

9. Have a safety person watch the area for fire and other hazards
FEMA US&R Response System - Rescue Specialist Training
Appendix C Metal Burn Cutting - Instructors Slides + Notes
Have a safety person watch the area for fire and other hazards
A two person team works best
One person to burn and second person watches for hazards + tends hoses and equipment
Be aware of heavy equipment and other people working above and below

10. FEMA US&R Response System - Rescue Specialist Training
Appendix C Metal Burn Cutting - Instructors Slides + Notes
Two Person Team
The tender is the burner’s second set of eyes because the person burning is focused on the progress of the cut

11. Personal Protective Equipment
FEMA US&R Response System - Rescue Specialist Training
Appendix C Metal Burn Cutting - Instructors Slides + Notes
Personal Protective Equipment
In addition to the Std US&R PPE
Shaded eye protection
Leather gauntlet gloves
Respiratory protection ( Organic Vapor)
Consider the PAPR
The level of protection will be dependant on the Situation and type of Metal to be removed

12. 4 different scenarios requiring PPE selection
FEMA US&R Response System - Rescue Specialist Training
Appendix C Metal Burn Cutting - Instructors Slides + Notes
4 different scenarios requiring PPE selection

13. Personal Equipment Crescent wrench Striker/spare flint Tool belt
FEMA US&R Response System - Rescue Specialist Training
Appendix C Metal Burn Cutting - Instructors Slides + Notes
Personal Equipment
Crescent wrench
Striker/spare flint
Tool belt
Tip Cleaners
Spare Tips
Marking Paint
Tape Measure
Soapstone

14. Oxy-Acetylene Most common Oxy-fuel Process
FEMA US&R Response System - Rescue Specialist Training
Appendix C Metal Burn Cutting - Instructors Slides + Notes
Oxy-Acetylene
Most common Oxy-fuel Process
Oxy/Acetylene –cut ferrous only with limitations on size as will be discussed. May only cut ¼”plate with Backpack system

15. Oxy/Acetylene Advantages Commonly used in many industries
FEMA US&R Response System - Rescue Specialist Training
Appendix C Metal Burn Cutting - Instructors Slides + Notes
Oxy/Acetylene
Advantages
Commonly used in many industries
Wide variety of accessory equipment
Disadvantages
Has wide flammable limits
Limited by the withdrawal rate of 1/7 per hr

16. Oxy-Acetylene - Safety Practices
FEMA US&R Response System - Rescue Specialist Training
Appendix C Metal Burn Cutting - Instructors Slides + Notes
Oxy-Acetylene - Safety Practices
Do not operate Acetylene above 15 PSIG
Do not withdraw more than 1/7 of the cylinder contents per hour
Do not drain all of
cylinder contents
Keep components and
area clear of grease, oil and
other oxidizers/flammables

17. Oxy-Acetylene - Safety Practices
FEMA US&R Response System - Rescue Specialist Training
Appendix C Metal Burn Cutting - Instructors Slides + Notes
Oxy-Acetylene - Safety Practices
Always operate with cylinder secured in an upright position
Do not operate without Flashback Arrestors and reverse flow check valves
Always perform a
mechanical check for
leaking components

18. A small Leak can create a BIG event
FEMA US&R Response System - Rescue Specialist Training
Appendix C Metal Burn Cutting - Instructors Slides + Notes
A small Leak can create a BIG event
This event was caused by a leaking 12 cubic ft. acetylene cylinder similar to what may be carried in your US&R cache

19. Must be stored & operated in upright position
FEMA US&R Response System - Rescue Specialist Training
Appendix C Metal Burn Cutting - Instructors Slides + Notes
Oxy Acetylene Equipment
Acetylene cylinder
Always look for Cylinder Information Stamps
Must be stored & operated in upright position

20. Open cylinder 1 to 1 ½ turns
FEMA US&R Response System - Rescue Specialist Training
Appendix C Metal Burn Cutting - Instructors Slides + Notes
Acetylene Cylinder
Open cylinder 1 to 1 ½ turns
Compressed to a pressure of PSIG
Unstable in a gas form if above 15 PSIG

21. Oxygen Cylinder Compressed to a pressure of 2250 PSIG
FEMA US&R Response System - Rescue Specialist Training
Appendix C Metal Burn Cutting - Instructors Slides + Notes
Oxygen Cylinder
Compressed to a pressure of 2250 PSIG
Must be secured at all times
Must be capped in an upright position for transport or when not in use

22. Alternative oxygen sources - Liquid Oxygen
FEMA US&R Response System - Rescue Specialist Training
Appendix C Metal Burn Cutting - Instructors Slides + Notes
Alternative oxygen sources - Liquid Oxygen
The Dewar can evaporate 4500 Cu. Ft. of gas from a liquid contained in cylinder
External evaporator may be needed
Must be kept in an upright position
The Green compressed cylinder contains about 250 Cu. Ft. of Oxygen
For large jobs or extended burning periods, Liquid Oxygen (Dewars) is more practical and efficient than Compressed Oxygen Bottles

23. FEMA US&R Response System - Rescue Specialist Training
Appendix C Metal Burn Cutting - Instructors Slides + Notes
Liquid Oxygen - Dewar

24. Compressed Oxygen Trailer
FEMA US&R Response System - Rescue Specialist Training
Appendix C Metal Burn Cutting - Instructors Slides + Notes
Compressed Oxygen Trailer
Used when a large Demand is needed
A tube style Trailer Cannot be easily moved around a site
May not be readily available

25. Oxy Acetylene Equipment
FEMA US&R Response System - Rescue Specialist Training
Appendix C Metal Burn Cutting - Instructors Slides + Notes
Oxy Acetylene Equipment
Acetylene Regulator Oxygen Regulator
Do not operate above 15 PSIG
Regulates gas down to its working pressure
Stand off to side when opening cylinder
Regulator screw should be backed out and turn freely before opening cylinder

26. Flashback Arrestors Check valves Flashback Arrestor
FEMA US&R Response System - Rescue Specialist Training
Appendix C Metal Burn Cutting - Instructors Slides + Notes
Flashback Arrestors
Flashback Arrestor
prevents a fire from
burning back to the
cylinder
Check valves
Check valve allows gas to flow in one direction
A quick connect acts as a check valve
Quick connections make set-up and tear-down of torch & equipment much faster.
It also adds additional safety check valves
Pressure Relief devices are located on Cylinder and/or Control Valve

27. FEMA US&R Response System - Rescue Specialist Training
Appendix C Metal Burn Cutting - Instructors Slides + Notes
Hoses are Color Coded Also threaded differently depending on application
Oxygen is Green with Right-Hand threads
Fuel Gas is Red with Left-Hand threads
All fuel gas equipment has a groove on the fitting to indicate Left-Hand threads
Quick connections have different types of end fittings, which helps to ensure that the proper fuel or oxygen hoses are connected to the appropriate location

28. FEMA US&R Response System - Rescue Specialist Training
Appendix C Metal Burn Cutting - Instructors Slides + Notes
Hoses Get Abused in Debris Pile Are exposed to sharp edges, etc. Inspect for cracks/burns & other wear
Make sure hoses are rated for the fuel and proper tip size
Keep clean from grease/oil & other oxidizers

29. Torches Various lengths/styles and head angles
FEMA US&R Response System - Rescue Specialist Training
Appendix C Metal Burn Cutting - Instructors Slides + Notes
Torches
Various lengths/styles and head angles
Some are made for welding and have a cutting attachment
The size of the tip not the torch length determines the thickness of the cut
Select the proper sized torch for the Job. Large torches can be heavy, awkward. And fatiguing, especially in confined spaces.
Large torches are well suited for jobs that require big tips or a longer reach

30. Torch Tips Appendix C Metal Burn Cutting - Instructors Slides + Notes
FEMA US&R Response System - Rescue Specialist Training
Appendix C Metal Burn Cutting - Instructors Slides + Notes
Torch Tips
Small Acetylene Tanks will limit the tip size to be used.
Refer to the cubic foot per hour flow on the Tip Chart

31. FEMA US&R Response System - Rescue Specialist Training
Appendix C Metal Burn Cutting - Instructors Slides + Notes
Tip Selection Chart
Refer to Tip Charts for proper size tip needed for the material thickness to be cut
Excessive Tip Size will waste Oxygen
A 145 cu. ft. cylinder should not have a withdrawal rate of more than 21 SCFH
Refer to the chart above for safe tip size

32. Oxy-Gasoline - Petrogen
FEMA US&R Response System - Rescue Specialist Training
Appendix C Metal Burn Cutting - Instructors Slides + Notes
Oxy-Gasoline - Petrogen
Petrogen – cut ferrous only – cuts faster on thicker material, and may cut thicker material even with portable (Backpack) system. Uses Oxygen very rapidly

33. Oxy-Gasoline - Petrogen
FEMA US&R Response System - Rescue Specialist Training
Appendix C Metal Burn Cutting - Instructors Slides + Notes
Oxy-Gasoline - Petrogen
Advantages:
Can cut steel that is up to 14 in. thick
Will cut through various sized air gaps
Less likely to fuse itself back together
Not limited by the fuel cylinder size

34. Oxy-Gasoline - Petrogen
FEMA US&R Response System - Rescue Specialist Training
Appendix C Metal Burn Cutting - Instructors Slides + Notes
Oxy-Gasoline - Petrogen
Disadvantages:
Equipment is not available locally
Rescuers must understand that the Petrogen torch setup, tuning and usage is different than the oxy-acetylene setup
Failing to understand the differences will produce poor cutting results

35. Petrogen Safety Practices
FEMA US&R Response System - Rescue Specialist Training
Appendix C Metal Burn Cutting - Instructors Slides + Notes
Petrogen Safety Practices
Always perform a check for leaks
When checking for a fuel leak look for liquid fuel on the ground and couplings
Secure fuel tank in the upright position Fuel cannot flow with tank on its side

36. Petrogen Safety Practices
FEMA US&R Response System - Rescue Specialist Training
Appendix C Metal Burn Cutting - Instructors Slides + Notes
Petrogen Safety Practices
A flashback arrestor should be used on the oxygen line.
One is not required for the fuel line
Do not operate fuel tank below 10 psi

37. Petrogen Equipment Fuel Tank
FEMA US&R Response System - Rescue Specialist Training
Appendix C Metal Burn Cutting - Instructors Slides + Notes
Petrogen Equipment Fuel Tank
Holds 2.5 gallons of fuel
Equal to a 250 cu.ft. acetylene cylinder
Has a pressure relief on the filler cap
Has a safety valve on the pressure gauge & fuel valve
Use the freshest fuel available

38. Petrogen Equipment - Torches
FEMA US&R Response System - Rescue Specialist Training
Appendix C Metal Burn Cutting - Instructors Slides + Notes
Petrogen Equipment - Torches
Various lengths/styles and head angles
The size of the tip not the torch length determines the thickness of the cut

39. Petrogen Equipment Torch Tips
FEMA US&R Response System - Rescue Specialist Training
Appendix C Metal Burn Cutting - Instructors Slides + Notes
Petrogen Equipment Torch Tips
Tip has two pieces
Fuel enters the tip as a mist /atomized gasoline oxygen mixture
Has oxygen and pre heat ports similar to Oxy-Acetylene
If tuned properly, fuel entering tip should keep tip cool as it vaporizes

40. Petrogen Equipment Tip Chart
FEMA US&R Response System - Rescue Specialist Training
Appendix C Metal Burn Cutting - Instructors Slides + Notes
Petrogen Equipment Tip Chart
Serves as a basic starting point
Settings will depend on operator experience
You are not limited by the 1/7 per hour rule
Tip does not need to be as clean a for oxy-acetylene tip

41. Petrogen Equipment A big advantage of the Petrogen is that is can
FEMA US&R Response System - Rescue Specialist Training
Appendix C Metal Burn Cutting - Instructors Slides + Notes
Petrogen Equipment
A big advantage of the
Petrogen is that is can
be fully broken down
and repaired in field with a spare parts kit.
Always have extra Tips and accessory equipment on hand

42. Petrogen Equipment - Poor Practice
FEMA US&R Response System - Rescue Specialist Training
Appendix C Metal Burn Cutting - Instructors Slides + Notes
Petrogen Equipment - Poor Practice
Operator Error caused this overheated equipment
Typically caused by too close of a coupling distance or tuning the torch too lean
A coupling distance of ½” is a good safe starting point
Heat transferred from Tip & overheated mixer

43. FEMA US&R Response System - Rescue Specialist Training
Appendix C Metal Burn Cutting - Instructors Slides + Notes
Exothermic Torch
Exothermic uses a consumable rod with oxygen pushing through the rod. Its primary
Function is to melt the material
Exothermic – ferrous or non-ferrous metals, but will produce lots of molten metal & sparks + rough cuts. They are carried on many Rescue Rigs for quick cutting

44. Exothermic Torch Advantages Disadvantages:
FEMA US&R Response System - Rescue Specialist Training
Appendix C Metal Burn Cutting - Instructors Slides + Notes
Exothermic Torch
Advantages
Can burn through almost anything
Disadvantages:
Operator must wear full PPE
Large spark showers of molten metal
Area of work must be free of combustibles

45. FEMA US&R Response System - Rescue Specialist Training
Appendix C Metal Burn Cutting - Instructors Slides + Notes
Oxygen Lance
Uses exothermic technology but uses a much thicker and longer consumable rod
This allows the operator to be at a safer distance away from the material being cut

46. Plasma Arc - Electric arc & Compressed air
FEMA US&R Response System - Rescue Specialist Training
Appendix C Metal Burn Cutting - Instructors Slides + Notes
Plasma Arc - Electric arc & Compressed air
Advantages
Can cut ferrous
& non ferrous metal
Burns clean
Low slag & sparks
Disadvantages:
Systems that can burn thicker material are large + heavy
Also require 220v to operate
Plasma Arc - ferrous or non-ferrous metals – clean cuts, but need large, heavy machine for thicker cutting. Machine shown here will cut ½”max. plate

47. Basic Torch Handling Skills
FEMA US&R Response System - Rescue Specialist Training
Appendix C Metal Burn Cutting - Instructors Slides + Notes
Basic Torch Handling Skills
Make yourself as comfortable as possible
Try to work the torch like a pool cue or pivot using your hand or material/debris as a pivot point

48. Estimating Steel Weight - Area Method
FEMA US&R Response System - Rescue Specialist Training
Appendix C Metal Burn Cutting - Instructors Slides + Notes
Estimating Steel Weight - Area Method
12”
12”
Steel weighs 490 lbs per cubic ft
Steel 1” thick weighs 490pcf / 12” = 40.8 psf
For steel weight per square foot use:
1” thick Use 40 lbs
¾” Use 30 lbs
½” Use 20 lbs
¼” Use 10 lbs
12”
12” 1”
12”
This is a method for calculating the weight of steel sections
All one needs to remember is that one square foot of steel plate weighs about 40 lbs.
The slide gives weights for ¾, ½ & ¼”
Ask students for weight of 1/8”, 3/8”, 5/8”, 1 ¼” etc

49. Area Method Examples 1 & 2 Example 1 Example 2 36”x 2” 12”x 2” 36”x 2”
FEMA US&R Response System - Rescue Specialist Training
Appendix C Metal Burn Cutting - Instructors Slides + Notes
Area Method Examples 1 & 2
36”x 2”
Example 1
12”x 2”
36”x 2”
Example 2
Example of each will follow on next two slides
Web = 12”x 3.5 inches
Flanges = 24”x 5”

50. FEMA US&R Response System - Rescue Specialist Training
Appendix C Metal Burn Cutting - Instructors Slides + Notes
Area Method Example - 1
What is weight of this 36ft long steel section?
2” Steel = 2 x 40 psf = 80 psf
Area per ft = 2 x 3 sq ft + 2 x 1 sq ft = 8 sq ft
Weight per ft = 8 x 80 = 640 plf
Total weight = 640 x 36 = 23,040 lbs
Exact weight = plf (only 2% off)
Make sure all understand this example
This same example was used in SCT04
Pl 36" x 2"
Pl 12" x 2" ea end
Pl 36" x 2"

51. FEMA US&R Response System - Rescue Specialist Training
Appendix C Metal Burn Cutting - Instructors Slides + Notes
Area Method Example - 2
What is weight of this 20ft long steel section?
2 Flanges 40 psf x 5” x 2 ft x 2 = 800 plf
Web psf x 3.5” = 140
Weight per ft = = 940 plf
Total weight = 940 x 20 = 18,800 lbs
Exact weight = plf (only 2% off)
Again, take the time to assure everyone understands
Pl 24" x 5"
Pl 12" x 3.5”
Pl 24" x 5"

52. Area Method – Round Tube Shapes
FEMA US&R Response System - Rescue Specialist Training
Appendix C Metal Burn Cutting - Instructors Slides + Notes
Area Method – Round Tube Shapes
Get area by: Circumference x Length
Either Measure distance around w/ tape or
Multiply Diameter x 3 (exact is 3.14)
Think - cut & unfold tube
Weight per ft is 3 x Diameter x Wt, per sq ft

53. Area Method - Pipe & Tube Example
FEMA US&R Response System - Rescue Specialist Training
Appendix C Metal Burn Cutting - Instructors Slides + Notes
Area Method - Pipe & Tube Example
What is weight of this 16ft long steel pipe?
12” Diameter x ½” thick
½” Steel = 20 psf Area per ft = 3 x 1 = 3 sq ft
Weight per ft = 3 sf x 20 = 60 plf, Total = 960 lb
Exact weight = 61.4 plf (only 2% off)
For Sq Tube use 4 x Size x Wt per sq ft
For 8” Sq. x ¼” thick x 16ft (10psf for ¼”)
Wt per ft = 4 x 8”/12”x 10psf = 26.7 plf, 427lb
From AISC Hbk = 25.8 plf (only 4% off)
Make sure everyone follows the example
You can illustrate this very well by bending a piece of paper into the form of a pipe and taping it lightly together.
Then remove the tape and unfold it

54. Other clues for Steel Weight
FEMA US&R Response System - Rescue Specialist Training
Appendix C Metal Burn Cutting - Instructors Slides + Notes
Other clues for Steel Weight
Numbers painted on steel at the Mill / Shop
First number is Depth in Inches
Second is Weight Per Foot in Pounds
Third is Length in Feet
Usually located near the end
May be covered with other paint

55. Shipping & Storage Methods
FEMA US&R Response System - Rescue Specialist Training
Appendix C Metal Burn Cutting - Instructors Slides + Notes
Shipping & Storage Methods
All torches & hoses purged of combustible fuel
Remove quick disconnects if used to completely remove fuel
Store Petrogen torches, hoses & fuel tanks in a ventilated shipping box
Regulators are fragile and should be stored in protective oil free hard case
Refer to IATA and local guidelines for shipping compressed gases
Acetylene torches can be stored in a oil free hard case

56. Review Unit Objectives
FEMA US&R Response System - Rescue Specialist Training
Appendix C Metal Burn Cutting - Instructors Slides + Notes
Review Unit Objectives
The student will understand the capabilities and limitations of all the types of metal burning that can be used in US&R operations
Understand how to efficiently and safely cut and remove multiple pieces of steel from a debris pile .