Kickbacks In a Table Saw – 10 Reasons & Fixes + Prevention

When discussing woodworking tools, kickback is a key topic. We’re human; tools are machines; misunderstandings between the two can cause kickbacks. 

Today, we’ll explore why kickbacks happen in table saws and how to prevent them. It’s vital for our safety and work efficiency.

Consequences of Kickbacks

Before we understand why kickbacks happen, it’s really important to know why stopping them matters. Think of it this way: once you know what could go wrong, you’ll probably be more hooked on this topic. It’s like a little teaser to keep you interested 😀

Injury to Operator: The most immediate and dangerous consequence is the risk of injury to the operator. This can range from cuts and bruises to more serious injuries like amputations or deep lacerations. Trust me, the piece of wood hits very badly! 

Damage to the Workpiece: Kickbacks can cause the workpiece to be thrown off the table saw, potentially damaging it beyond repair. 

Damage to the Saw: The force of a kickback can damage the table saw itself, affecting its alignment, calibration, or mechanical parts.

Safety Hazards in the Workspace: When a workpiece is thrown violently, it can create additional hazards, potentially injuring others or damaging other equipment.

Why Kickbacks Occur In Table Saws? 10 Reasons

To solve any problem, it’s crucial to first understand its cause. Once you know the reason, fixing it becomes much easier. So, let’s make finding a solution for kickback simple for you. 

We and our fellow woodworkers commonly observe the reasons we’re about to discuss below as major causes of kickback in table saws. 

In the case you want to know about kickbacks in a circular saw; must read our other article.

1. Improper Fence Positioning 

Forgetting to move the fence away when using the miter gauge on a table saw can result in dangerous kickbacks. This typically occurs due to oversight or haste during the setup process. 

In such instances, the wood can become pinched between the blade and the fence, leading to a situation where the wood is forcibly ejected backward. 

This issue arises because the fence, when not properly adjusted for using a miter gauge, obstructs the path of the wood, creating a pinch point that can violently propel the wood back toward the operator.

Learn more about Fence Alignment on a table saw. Follow the tips and get rid of kickbacks.

How to Fix It? Always double-check the position of your fence relative to the blade before you start a cut. Ensure enough clearance for the wood to pass through without getting trapped. A good practice is to develop a habit of adjusting the fence as part of your cutting preparation routine.

2. Inadequate Application of Forces 

During a rip cut, not applying the necessary forces – downward, forward, and diagonal – to the workpiece can lead to kickbacks, particularly when the diagonal force towards the fence is insufficient. 

This lack of adequate force application can cause the wood to lift or veer off its intended path, leading it to catch on the blade. 

Ensuring the workpiece is consistently aligned throughout the cut is vital to prevent such incidents, with the diagonal force playing a crucial role in maintaining this alignment.

We’ve also discussed the optimum cutting speed and force here: Cutting Wood Fast Vs Slow: Which Way Is Better or Worse?

How to Fix It? Use appropriate tools like push sticks or shoes to exert consistent and balanced force on the wood. Focus on applying diagonal force toward the fence to keep the workpiece firmly against it throughout the cut. This ensures a stable and controlled wood movement, reducing the risk of kickback.

3. Using Improperly Dried or Wet Wood

Kickback is more likely with wood that hasn’t been properly dried or is wet, as this condition can lead to warping or dimensional changes during cutting. Such warping increases the risk of the wood binding or pinching the blade, a common cause of kickback.

Here’s the detailed article on cutting wet wood with a table saw.

This issue arises from the inherent instability in improperly dried or wet wood, which can react unpredictably under the stress of cutting, resulting in dangerous kickbacks.

How to check if the wood is dried enough? Read our article to know everything in detail: Wet Wood vs. Dry Wood: Which is Harder or Easier to Cut? 

How to Fix It? Always use wood that’s properly dried. Conduct a moisture check before cutting. Make a partial cut for suspect wood and observe if the kerf closes up, indicating moisture. If it does, it’s advisable not to proceed with the cut.

Learn the concept of Kerf here: What is KERF in Woodworking?

4. Misalignment of Blade and Fence

Misalignment of the saw’s blade with the slot and fence can lead to wood wedging between them during a cut. This misalignment, often resulting from improper initial setup or a gradual shift over time, increases friction between the wood and the blade. 

The wedging and increased friction are key factors that contribute to kickback, as they disrupt the smooth passage of the wood through the blade.

How to Fix It? Regular maintenance and calibration are key. Make sure the blade and fence are perfectly parallel. Use alignment tools for accuracy and check the alignment periodically, especially after heavy use or any adjustments. 

This will ensure a smooth, straight path for the wood, minimizing the chances of it getting wedged and causing kickback.

5. Working with Warped or Twisted Boards 

Boards that are not flat, such as warped or twisted boards, can create problems during cutting, leading to kickbacks. Their irregular shape makes them unstable, causing them to move unpredictably. 

This unpredictable movement can lead to the wood pinching the blade, a common cause of kickback. The instability of non-flat wood is a significant factor in these dangerous occurrences, as it disrupts the controlled movement of the wood through the saw.

Learn more here: What Should You Never Cut on a Table Saw? 

How to Fix It: Always inspect wood for flatness before cutting. If a board is warped or twisted, it may need to be milled or planned to flatten it out. Using tools like jointers or planers can help prepare these boards for safe cutting on a table saw.

6. Case Hardened Lumber 

Wood that’s not dried correctly can become case hardened, making it prone to kickback. Case hardening occurs due to uneven drying, which creates internal stresses within the wood. 

When such wood is cut, these internal stresses can be released unexpectedly, leading to warping or the wood pinching the blade. 

This reaction, particularly in the absence of a riving knife or splitter, significantly increases the risk of kickback, as the wood’s sudden movement can interact dangerously with the saw blade.

How to Fix It? Avoid using case-hardened lumber. If you’re unsure about the condition of your wood, conduct a stress test by making a small cut and observing any changes in the wood’s shape. Use a moisture meter to check for even drying. 

If case hardening is suspected, it’s best to re-dry the wood evenly or use it for non-critical applications where precision and safety are less of a concern.

7. Low Blade Height

Setting the saw blade too low changes the angle of attack of the teeth, directing the cutting force towards the rear and increasing the likelihood of kickback. A higher blade setting directs the force downwards, reducing this risk​. 

How to Fix It? Adjust the blade height so that the gullets (the space between the teeth) are just above the top of the material being cut. This ensures the cutting force is directed more downwards, which is safer and more efficient. Regularly checking and adjusting blade height should be a part of your saw setup routine. 

Set your table saw blade at the correct height! How? Read Our detailed article on this topic: Table Saw Blades Optimum Height

8. Lack of Control Over the Wood

Failing to maintain a firm grip and control over the woodcut can result in kickback. This includes situations where the wood is not held down firmly on the table​. 

Insufficient grip and control over the wood while cutting can lead to the wood shifting, lifting, or veering off course, causing it to catch on the blade and kickback.

How to Fix It? Always use proper push sticks, push shoes, or feather boards to maintain control over the workpiece. Ensure your hands are safely away from the blade, and the wood is securely pressed down on the table throughout the cut. A consistent, firm grip and control over the wood are essential for safe operation. 

This reason varies greatly depending on the individual woodworker. When we consulted our team of woodworkers, some suggested excluding it as a cause for kickbacks. However, we believe it’s important to include this point, particularly for those who are new to woodworking or pursuing it as a hobby.

9. Dull Blade or Build-up of Pitch and Resin 

Saw blades can become dull over time and with use, materials like pitch and resin from cutting certain types of wood can accumulate on the blade. A dull blade doesn’t cut efficiently, causing friction and heat. Similarly, pitch and resin build-up also increase friction and heat.

How to Fix It? Regularly clean your blade to remove any pitch and resin build-up. Use appropriate solvents or cleaners designed for saw blades. Sharpen or replace your blade when it becomes dull. A sharp, clean blade ensures smoother cuts, reduces friction, and minimizes the risk of kickback.

Learn more about table saw blade lifespan and care.

10. Use of Wrong Blade Type and Blade Pinching

Using an inappropriate blade for specific operations can lead to clogging, and this issue is compounded when the workpiece pinches the blade. This pinching can occur when the workpiece gets stuck between the blade and the rip fence or when the kerf pinches the blade mid-cut. 

Together, these factors increase the likelihood of kickback, as the improper blade exacerbates the effects of the wood’s interaction with the blade.

How to Fix It? Always choose the right blade for your specific cutting task. Use a ripping blade for rip cuts and a crosscut blade for crosscuts. Ensure your workpiece is well supported and firmly against the fence to prevent shifting. 

Monitor the kerf during cutting, especially with wood prone to warping, to avoid pinching. Employing the correct blade and maintaining control over the workpiece will significantly reduce the likelihood of kickback.

For a Proper selection of saw blades, read our detailed article: Choosing Saw Blades – Is More Teeth Better?

Also, Read: Choosing Table Saw Blade For Hardwood – (Important Factors)

Summary

Cause of Kickback	How to Fix
Improper Fence Positioning	Double-check fence position relative to the blade for clearance.
Inadequate Application of Forces	Use tools like push sticks to apply consistent force, focusing on diagonal force toward the fence.
Using Improperly Dried or Wet Wood	Use properly dried wood and conduct moisture checks before cutting.
Misalignment of Blade and Fence	Regularly maintain and calibrate blade and fence alignment.
Working with Warped or Twisted Boards	Inspect wood for flatness and mill if necessary.
Case Hardened Lumber	Avoid using case-hardened lumber, conduct stress tests and moisture checks.
Low Blade Height	Adjust blade height so the gullets are just above the top of the material.
Lack of Control Over the Wood	Use push sticks, shoes, or feather boards for firm control.
Dull Blade or Build-up of Pitch and Resin	Clean the blade regularly and sharpen or replace when dull.
Use of Wrong Blade Type and Blade Pinching	Choose the correct blade for the task and ensure the workpiece is well supported.

Prevention Methods From Our Woodworkers

Use of a Riving Knife: The most effective way to prevent kickback is to ensure your table saw has a Riving knife. This tool sits behind the saw blade and prevents the workpiece that has just been cut from making contact with the backside of the saw blade, thereby reducing the risk of kickback​​​. 

Standing Position and Safety Gear: It’s important to stand to the side of the blade while working and to wear appropriate safety gear. This stance and protective equipment can mitigate the risks associated with table saw kickback​. 

Use of a Crosscut Sled: Implementing a crosscut sled is another way to prevent kickback. These jigs keep your hands away from the blade and position the fence in front of the blade instead of at the side, providing a safer-cutting method. 

Avoid Crosscutting with the Rip Fence: You should not use the rip fence for crosscutting; instead, use a miter gauge or a crosscut sled. This helps prevent the wood from getting jammed between the blade and the fence, which can cause kickback​. 

Avoid Cutting Crooked Stock: Crooked or irregularly shaped boards can be unpredictable and dangerous when used on a table saw. It’s best to correct their shape or avoid cutting them entirely​. 

Regular Blade Maintenance: It’s important to regularly check and maintain the saw blade to ensure it’s sharp and straight. A well-maintained blade is more efficient and safer, reducing the risk of kickback​. 

Staying Attentive: Staying alert and focused while operating a table saw is crucial. Distractions or inattentiveness can significantly increase the risk of accidents, including kickbacks​. 

Some Prevention Measures Of Kickbacks From OSHA

To prevent kickbacks when using a table saw, follow these safety measures:

• Use a spreader for ripsaws to prevent material from squeezing the saw or kicking back during ripping.
• Employ anti-kickback fingers to hold down the stock in case the saw kicks back.
• Operate the saw at the speed recommended by the manufacturer.
• Ensure sufficient clearance for the stock.
• Stand to the side of the saw blade to avoid injury from kickback.
• Guide the wood parallel to the rip fence to minimize kickback potential.
• Avoid crosscutting long boards on table saws.
• Use a filler piece between the fence and the saw blade when needed.
• Properly support all stock pieces, including cut and uncut ends, scrap, and finished products.

For more detailed guidelines, refer to the specific OSHA standards listed alongside each point and visit the OSHA website on table saw safety at OSHA Table Saw Safety.