1. Grinder Use Safety Training

2. Introduction
Grinders are dangerous tools that can cause severe injuries or even death.
Grinders should be chosen for the reason of performing the job in the safest manner first and saving time last. Use other tools when the associated inherent hazards are less severe.
The following slides explain the Freeport site’s expectations regarding grinder use and some general hazards and precautions.
In case of a discrepancy between this presentation and the manufacturer’s recommendations, the manufacturer’s recommendations take precedence.
Nov 2005

3. Freeport Grinder Use Training Requirements
A training course, including a practical test, must be completed successfully by every person who uses a grinder.
A practical test must be successfully completed once every 24 months
Any unsafe use will result in suspension of permission to use grinders.
Nov 2005

4. Grinder Related Injuries
On December 12, 2005, a 30-year old man died from blood loss after his leg was cut by an angle grinder.
On January 11, 2006, a grinding disk spun off a grinder and struck a person in the kneecap. Stitches were required.
In March of 2008 a contractor was struck in the neck when a grinder kicked back resulting in 30 stitches.
Grinders have
contributed to
fatalities!
May 2010

5. Most Recent Grinder Injuries
February 13, 2010 – Oyster Creek, Texas – While waiting for the grinder to power down, the individual’s wrist came in contact with the grinding wheel requiring 20 stitches.
March 22, 2010 – Deer Park, Texas – A grinding wheel came apart and struck the individual's arm requiring 7 stitches.
Freeport is taking measures to achieve the vision of an injury-free workplace.
Grinders have
contributed to
fatalities!
May 2010

6. What are the Common Hazards of Grinder Use?
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
Inhaling dust and fumes generated
Explosion or fire
if sparks ignite flammable or combustible materials nearby or below grinding operation
Electric shock from frayed or defective power cord
Noise
Musculoskeletal disorders (MSDs) from
repetitive use
awkward body positions
May 2010

7. Common Causes of Grinding Incidents
Using the wrong wheel for the job or grinder
Improper mounting of wheel or guard
Careless handling
Repetitive motion
Improper PPE use
Improper use of grinder
May 2010

8. Critical Grinder Wheel Safety Issues
Some Grinding wheels can be surprisingly delicate. They can be easily damaged if handled carelessly.
Store new wheels carefully in a dry area close to the grinding operation.
When you have to carry one, do it very carefully.
Take special care not to drop it or to bump it against anything.
Never use a wheel that has been dropped or received a heavy blow, even if there is no apparent damage.
Replace wheels that are badly worn or cracked.
May 2010

9. 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 various 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 disks 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.
May 2010

10. Wheel Example Cutting Blade Max RPM Size of Disk Type of Material
can be used on
May 2010

11. 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
May 2010

12. 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.
Typical Wire Buffing Wheel
Typical Wire Cup
Follow manufacturer’s instructions for mounting approved accessories or attachments.
Cup Stone
May 2010

13. 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
the blade itself
Never operate without its guard in the proper place
Use a guard supplied or approved by the tool manufacturer
Report any missing, broken, or disabled guards
“Proper” placement of tool guard may vary. Handles can be moved on some angle grinders (to allow for right or left handed operation).
Unlike in the photo above, the guard must be between the handle and the wheel.
May 2010

14. 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
May 2010

15. 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 pace
May 2010

16. Be sure to maintain use of PPE for as long as hazard remains !!!
Proper Grinder PPE
Goggles or safety glasses with side shields 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 when 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 the possible need for respiratory protection.
may be required for some grinding operation, depending upon the material of construction of the work piece being ground
Local variations to PPE will be managed at a site level
Be sure to maintain use of PPE for as long as hazard remains !!!
May 2010

17. 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
May 2010

18. 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.
May 2010

19. Critical Safe Behaviors for all Powered Tools, continued
Ensure all guards, grips, handles, etc. are in place
Prevent unintentional starting of the tool
don’t carry powered tools plugged in with finger on switch
turn switch to off position when not in use
Never carry a tool by the cord or hose.
Never yank the cord or the hose to disconnect cord
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
May 2010

20. Additional Grinder Specific Critical Behaviors
Adjust handle and disk guard. The handle on an angle grinder can be mounted for either right or left handed users.
All angle grinders must be equipped with a handle. ANY exceptions must have written approval from Leadership prior to use.
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
May 2010

21. Additional Grinder Specific Critical Behaviors
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
Do not touch the ground portion of the work piece until you are sure it is cool.
Do not use liquid coolants with portable grinders. It could cause the metal to shatter.
Make sure that the grinder is placed in a resting position that assures it can not be accidentally turned on
May 2010

22. Portable Grinder Safety Checklist
Attached is a link to a Portable Grinder Quick Reference Card that can be used as a reminder of the critical behaviors associated with portable grinders for those persons
performing work using a portable grinder
observing those performing work using a portable grinder
Grinder Use Checklist
May 2010

23. Bench Grinder
Nov 2005

24. The graphic below is courtesy of the Safety, Health, Environmental Technology Division of Georgia Tech Research Institute, Tech Guide No. 2, Published (Other local safety designations may apply instead of Z-87)
Nov 2005

25. Bench Grinder
If you damage a wheel or accessory during your work stop and replace the wheel or accessory - Do not leave damaged accessories for the next person to use
Make sure that you unplug power from the grinder prior to performing any work to the grinder.
Make sure that the bench grinder is located on a sturdy and stable bench or pedestal specifically made to support the bench grinder.
Nov 2005

26. Bench Grinder Using Bench Grinder
Turn on grinder and let the grinding wheels reach full speed prior to starting work on the material.
Apply pressure to the wheel slowly and square with the wheel.
When complete, turn off the grinder and make sure it comes to a complete stop before leaving the area.
If the items that are to be worked on are very small then the proper holding tools must be used to grip the work for grinding to secure from unexpected movement.
Nov 2005

27. Conclusion
Grinders are dangerous tools that can cause severe injuries or even death.
Grinders should be chosen for the reason of performing the job in the safest manner first and saving time last. Use other tools when the associated inherent hazards are less severe.
This Training is intended to increase your awareness of the dangers associated with the use of grinders. We are counting on you to use them safely in our facilities!
May 2010