ELMAK HSE TRAINING

Portable Grinder Safety

Background
The portable grinder is used in the field or
maintenance shop to grind excess metal
from welds, remove rust, and for special
finishing operations.
Since this tool is hand operated, the quality of
the work depends upon the ability and
experience of the operator …
as does safe job completion.
Background, continued
Since the grinder is such a
common tool
(you will find one or more on almost every
maintenance or construction job)

the risks involved with them may

tend to be taken for granted
 Angle Grinder Use
Angle grinders generate sparks. Obtain a hot work permit before use. Keep work area clear of
debris and flammable materials.
Do NOT use in areas where there is grain dust or other combustible dust accumulation.

• Use the correct wheel for the machine’s size and speed, and the work to be
performed.
• A cutting disc should not be used for grinding.
• The RPM rating of the disc/blade must be higher than that of the angle grinder.
• Adjust guards to deflect flying particles away from operator.
• Use an 180° guard between operator & wheel.
• Before use inspect wheels for cracks, defects and wear . Replace worn discs.
• Perform “ring test” as appropriate.
• Allow grinder to come to full speed and warm up before use and to a complete
stop after use.
• Do not grind on the side of the wheel.
• Do not use liquid coolants.
• Always use two hands. Keep hands away from rotating wheel and avoid
continuous vibration.
• Wear proper PPE including eye & hearing protection; leather gloves; natural
fiber clothing; apron and respiratory protection as needed.
• DO NOT wear loose fitting clothing or have hanging strings.
• Maintain good footing, balance & work position.
• Do not carry grinder with finger on the switch.
What are the Common Hazards of
Portable Grinder Use?
o High speed flying particles … a grinding wheel’s speed
can be greater than a mile a minute
• from the grinding wheel itself
• from the work piece being ground
o Inhaling dust and fumes generated
o Explosion or fire
• if sparks ignite flammable or combustible materials
nearby or below grinding operation
o Electric shock from frayed or defective power cord
o Noise
o Musculoskeletal disorders (MSDs) from
• repetitive use
• awkward body positions
Common Injuries Due to
Grinders/Grinding Activities

1. Cuts Grinders have

2. Strains contributed to
fatalities !!!
3. Particles in the eye
(flying particles cutting
major artery for example)
 Common Causes of Grinding
Incidents
1. Using the wrong wheel
i. for the job or grinder
2. Improper mounting
i. of wheel or guard
3. Careless handling
4. Repetitive motion
5. Improper PPE use
6. Improper use of grinder
Critical Grinder Wheel Safety
Issues
Some Grinding wheels can be surprisingly delicate.
They can be easily damaged if handled carelessly.
o Store new wheels carefully in a dry area close
to the grinding operation.
o When you have to carry one, do it very
carefully.
o Take special care not to drop it or to bump
it against anything.
o Never use a wheel that has been
dropped or received a heavy blow, even
if there is no apparent damage.
o Replace wheels that are badly worn or
cracked.
Using the Right Wheel
Ensure the wheel is designed for the machine’s size and speed
and the material of construction of the work piece

 Grinding disks are made from varying types of abrasive

materials. They are classified according to weight, size, arbor
hole size (hole in the middle) and Rotations Per Minute (RPM)
and material to be used on. This information can be found on
the disk.
 Grinding blades are to be used for GRINDING only, DO NOT
use to cut material. Use only the grinding face, not the back
side of disk.
 Cutting blades are classified according to size, bearing arbor
hole size and thickness. This information is also found on the
blades.
 Cutting blades are used for CUTTING only. DO NOT grind with
them. Use only the edge.
Wheel Example

Cutting Blade

Max RPM

Size of Disk

Type of Material
can be used on
Wheel Mounting Safety
 Disconnect power source before adjusting, oiling or changing accessories
 Use only parts supplied or approved by the grinder's manufacturer
 nuts, flanges, guards, blotters, etc.
 Ensure wheel maximum speed is higher than grinder maximum speed
 the grinder motor should burn up rather than the wheel flying apart
 Inspect wheel or attachment for cracks or flaws
 Clean wheel and grinder
 Perform a “ring test” on wheels prior to mounting (not applicable to all type wheels
or other attachments and accessories)
 Gently tap a dry clean wheel with a light nonmetallic tool—perhaps
screwdriver handle for light wheels or wooden mallet for heavier ones
 The tap should produce a clear metallic “ping.” If the sound is more like a dull
thud, the wheel is probably cracked and shouldn’t be used.
 Be sure the wheel fits freely on the spindle.
 Check that the arbor hole is the proper size for the grinder to be used
 The spindle nut must be tightened enough to hold the wheel in place, without
distorting the flange
 some manufactures require wrenches for tightening the wheel
 Ensure guard is replaced in the appropriate position
 After mounting wheel or brush and replacing the guard, stand to the side and allow
a one minute run-up at no load to test integrity and balance of the wheel
Other Accessories or Attachments

 Do not use unless:

 The manufacturer recommends or approves
its use on the product
 The accessory limitations and specifications
match those of the grinder
 speed, size, mounting and guarding
requirements, etc.
 The use of the accessory does not require the
removal of or defeating of any guards,
barriers or other safety-related devices
 unless they are replaced by other appropriate
guards or protective devices.

Follow manufacturer’s instructions for

mounting approved accessories or attachments.
 Guard Mounting Safety
 Grinders come equipped with
a wheel guard that must
remain in place at all times
to protect the operator from
flying sparks and material
 Never operate without its
guard in the proper place
“Proper” placement of tool
 Use a guard supplied or
approved by the tool guard may vary. Handles
manufacturer can be moved on some
 Report any missing, broken, angle grinders (to allow for
or disabled guards right or left handed
operation).
Unlike in the photo above,
the guard must be between
the handle and the wheel.
Proper Handling of Grinders
 Always use two hands when using a
portable grinder
 To maintain control
 The high speeds of the wheel can cause the
grinder to fly off the metal
 To keep both hands away from the hazard of the
high speed rotation
 if a hand or finger hits the moving wheel
surface, injuries will result
 if grinding on small pieces, may need to secure
the work in a vise … DO NOT HOLD IN YOUR
HAND
Repetitive Motion Precautions
 Use firm hand grip force for control but without excessive force
 Avoid anything that inhibits blood circulation.
 squatting for extended periods
 improperly fitted gloves
 other restrictions to comfortable body mechanics
 Avoid continuous vibration exposure.
 Keep wrists as straight as possible
 Avoid repeated bending of wrists and hands.
 After each period of extended operation, exercise to increase
blood circulation
 flex wrists
 change body position
 Minimize extent of reaching
 to maintain better control of the tool and better body position

To prevent potential repetitive motion injuries consider the need to

reposition the work piece or your body
rotate job duties
change work place
 Proper Grinder PPE
 Goggles AND a full face shield
 to prevent chips or particles from getting into your eyes
 particles WILL fly in any grinding operation
 take appropriate precautions on removing goggles or safety glasses to ensure
particles don’t fly into your eye even AFTER the grinding operation is done
 Leather Gloves
 to protect your hands from flying particles and sharp edges created during the grinding
operation, as well as the edge of the wheel itself
 Hearing protection
 Proper attire
 don’t wear anything loose that could get caught in the rotation
 secure scarves, ties, loose hair, and dangling jewelry
 if you’re wearing a long-sleeved shirt, button it at the wrist
 Consider also the possible need for a dust mask
 may be required for some grinding operation, depending upon the material of
construction of the work piece being ground

Be sure to maintain use of PPE for as long as hazard remains !!!

Proper Use of Grinders
 Unless otherwise designed, grind on
the face of the wheel.
 serious injury or damage could occur if
the side of the wheel is used
 use disc wheels for side-grinding
 light side-grinding is permissible on cup or
saucer wheels
Critical Safe Behaviors for all
Powered Tools
 Know and Follow all Manufacturer’s Instructions
 Use tool only for its intended purpose
 Maintain tools in proper condition
 sharp & clean, lubricated
 all guards in place
 ensure any repairs performed by qualified persons
 Do not alter tools
 to force pieces that don’t fit
 or otherwise use the tool for an unintended purpose
 Perform a prior to use inspection of the tool
 Protect against electrical shock
 use appropriate grounding
 ground plug in place, GFCI as appropriate
 inspect cords & connections
 don’t abuse cords, keep away from heat, oil & sharp edges,
inspect for frays, cuts, etc.
Critical Safe Behaviors for all
Powered Tools, continued
 Ensure all guards, grips, handles, etc. are in place
 Prevent unintentional starting of the tool
 2 motion positive on/off switch required
 don’t carry powered tools plugged in with finger on switch
 Never carry a tool by the cord or hose.
 Never yank the cord or the hose to disconnect cord
 Avoid accidental starting. Do not hold a finger on the switch button
while carrying a plugged-in tool.
 All portable electric tools that are damaged shall be removed from
use and tagged "Do Not Use.“
 Protect others in work area
 don’t allow cords to become trip hazards
 minimize number of employees in hazard zone
 ensure all in hazardous areas are using appropriate PPE
 consider work in adjacent or below areas
Additional Grinder Specific
Critical Behaviors
 Allow grinder to come to full speed before contacting work
surface
 Remove material or debris that might be ignited by sparks
 Keep a properly charged fire extinguisher available
 Do not grind non-ferrous materials.
 Maintain steady pressure on the work piece
 sudden “bumping”, pounding or impact could damage the wheel
 Do not apply excessive pressure to the wheel or disc so that the
motor slows noticeably of the work gets hot
 could stress the wheel, overheat the work piece and reduce your control
 Avoid letting the wheel rest on one spot for too long.
 could cause the work to burn or the wheel to crack and explode.
 Keep good footing and maintain good balance
 Never attempt to grind in an awkward position.
 A portable grinder can kick and glance off the work if not properly
controlled
 Allow grinder to come to complete stop before removing PPE or
setting tool down
Summary
 Don’t take grinder safety for granted
 Understand and respect the hazards
 Before using a grinder, learn how to eliminate, reduce and
protect against letting those hazards result in injury
 If observing others using a grinder, reinforce the appropriate
behaviors and coach for improvement on those at risk
 Remember the close proximity rule – If you have employees
within 10 Ft of your grinding operation they must maintain
the same level of (eye / face ) protection.

Zero Accident is our Goal! Everyday!