An angle grinder is a very potent piece of equipment. With an angle grinder, your hands, fingers, body, and face are mere inches from the spinning attachment, which could be a grinding disc, a cutting disc, or a wire wheel.
Our analysis of BLS data on workplace injuries reveals two distinct groups of people are more likely to be hurt while operating angle grinders. People in the industry are either very young and just starting out, or they have been working in the field for at least 15 years.
Accidents are more likely to occur with the first group because they have not been adequately trained and thus do not understand the procedure, do not respect the equipment, or do not know how to use the safety measures on the grinders. The second type are the staunch traditionalists who refuse to adopt new approaches. Without proper safety gear, anyone working with an angle grinder runs the risk of serious injury. Indeed, that is a proven fact. Check out Australian General Engineering
Table of Contents
Can You Describe an Unsafe Grinding Operation You’ve Had to Deal With?
Just a few years ago, we manufactured a 5-inch grinder that could reach speeds of up to 10,000 RPM. Please note that we have installed a 5-inch guard on this angle grinder prior to shipping.
Many pieces of this equipment were suddenly being brought to us for repair. The variable speed of our 5" grinders was set to about 6,000 RPM, and we welded 9-inch guards onto each one (RPM). In any case, we concluded, "Eh, this is not secure." We opted for a shorter and more conventional 5-inch guard instead of the 9-inch one. We fixed the variable-speed dial and sent it back to the customer, making sure it worked properly across the board. In a series of phone calls, the customer said, "No, we've done it on purpose; please return our guards." We, as the producer, had to decline their request for a change.
When we dug deeper, we found out that they were attempting to grind a root weld on a 36-inch-diameter, 6-inch-thick-walled pipe. A 5-inch angle grinder with a 9-inch wheel would not be long enough to get to the bottom of the pipe to remove the root weld. Given the critical nature of this technique to the customer's success, it quickly made its way up the corporate food chain and was eventually approved by the company's global safety personnel. The idea for flat-head angle grinders came from our desire to ensure that they had some form of protection while working.
Why Is Using a Wheel That Is Too Big for the Grinder So Dangerous?
An unsafe phenomenon known as kickback is greatly amplified when a wheel binds up or becomes trapped in the workpiece during operation. Because of the tool's mass and the inertia of the spinning wheel within the motor, it will try to kick out of your hands if the tool is suddenly stopped. When this happens, it typically "kicks back" towards the operator.
What Is the Primary Function of the Guard?
If a wheel or disc were to shatter, the guard would collect the pieces and stop them from flying everywhere. When a wheel is broken, the guard must be thick enough and made of strong enough steel to contain the shards. Additionally, a locking mechanism is required to ensure that the guard will not open and expose the operator in the event of a malfunction. Most angle grinders come with a protective shield designed to prevent accidental bursts.
Once upon a time, all that was required to secure a guard to a grinder was a steel ring and a screw. We can't allow that to keep happening. Since a locking guard is now required, we fashioned one with seven separate locking configurations to accommodate your needs. Both the right and left sides of the tool can be locked into a cutting position, with a number of grinding positions in between. But it can't shift out of that position. Even if the disc cracked, it wouldn't fly apart and land on you.
How to Operate an Angle Grinder?
One-on-one instruction in safe angle grinder use is required for all new operators. The operation of an angle grinder always necessitates the use of two hands, one for holding the handle and the other for supporting the tool's weight. In order to prevent the angle grinder from grabbing and kicking back, it is best to let it get up to speed before lightly touching it to the work. At an angle of 15 degrees to 30 degrees, grinding discs are most effective.
Neither the operator nor anything else around should come into contact with the angle grinder, and the operator should avoid standing immediately behind the instrument.
Before they are set down or moved about the workplace, angle grinders must be entirely stopped rotating. Breaks should be taken on a regular basis to allow operators to rest their hands and arms.
What Makes the Angle Grinders So Dangerous?
An angle grinder is a very potent piece of equipment. With an angle grinder, your hands, fingers, body, and face are mere inches from the spinning attachment, which could be a grinding disc, a cutting disc, or a wire wheel.
Our analysis of BLS data on workplace injuries reveals two distinct groups of people are more likely to be hurt while operating angle grinders. People in the industry are either very young and just starting out, or they have been working in the field for at least 15 years.
Accidents are more likely to occur with the first group because they have not been adequately trained and thus do not understand the procedure, do not respect the equipment, or do not know how to use the safety measures on the grinders. The second type are the staunch traditionalists who refuse to adopt new approaches. You will get hurt using an angle grinder without a guard, we guarantee it. Indeed, that is a proven fact.
These accidents can be brought on by a number of factors, including but not limited to: flying abrasive and metallic particles, expelled materials, and direct contact with the tool itself. When used improperly, angle grinders can result in a wide range of injuries:
Contact with Wheel
Human flesh and bones are no match for an angle grinder, which can easily slice through stone, concrete, metal, and other hard materials. As a result, it's crucial that the driver avoid any accidental contact with the wheel at any time.
Inadequate security increases the likelihood of this happening. Wear gloves that provide a solid grip and make sure the safety guard is in place. Be cautious and focused at all times while using an angle grinder.
Wheel Breakage
Every abrasive wheel has the potential to shatter under the right conditions. You may reduce this danger by operating an angle grinder carefully and inspecting the discs often.
By understanding the disc's limits, you may prevent or lessen the likelihood of a disc failure. A disc should be used only while it is still in excellent shape, before its expiration date, and at or below its maximum speed. Never go over the wheel's specified maximum speed or expiration date.
If you're going to use abrasive wheels, be sure you put them on the right tool. The mounting of wheels in inappropriate ways, using improvised tools, or on equipment not intended for that kind of disc is a common source of accidents.
Contact with Projectiles
Both the wheel exploding (discussed in point 2 above) and the material being cut or ground might result in projectiles.
Avoiding flying debris is impossible in all cases, but you may lower your risk by selecting the appropriate cutting tool, wheel, and speed/feed settings for the material. Protective equipment, notably goggles and a hard hat, is essential for preventing injuries caused by projectiles.
Kickback
Accidents caused by kickback may be devastating. This occurs when the wheel or cutting speed of the angle grinder is incorrect, causing it to grasp and jam on the material being cut.
If this is occuring, check to be that you are using the correct wheel for the job and that the speed is correct. Increased danger from kickback is posed by wheels that are both dull and improperly fitted. Make sure you know what you're doing when it comes to mounting wheels, and replace damaged wheels as soon as possible.
As a result of the user losing control of the tool due to a kickback, the tool may fall to the ground or strike the worker, resulting in injuries to the feet and legs. Always use proper personal protective equipment, such as goggles, a hard hat, safety shoes, and gloves.
Use the proper disc at the right speed at all times.
Entanglement
While protective equipment is essential while working with an angle grinder, improper attire might put you at risk. In the same way that entanglement is possible with any spinning disc, this one may also get stuck.
Loose apparel, such as a tie or long, baggy sleeves, might become caught between the wheel and the workpiece and cause injury. Hair should be pulled back if it's too long. Trash and rags should be kept far from the spinning wheel so they don't get caught up in the mechanism.
Fire
You'll probably make a lot of sparks if you use an angle grinder. You may not be able to prohibit this from happening, but you should still take caution while using an angle grinder.
Using an angle grinder, for instance, near a refuelling station or wherever flammable or explosive materials are stored or used increases the likelihood of a fire or explosion. Sparks might potentially ignite combustible items in the vicinity.
If there are any flammable or combustible items in the vicinity, they must be moved or shielded before you start using an angle grinder.
Electric Shock
The fact that many angle grinders are electric means you should also think about the risks associated with using other types of portable electrical equipment. Avoid damage to the tool and your hands by doing a quick visual inspection before each usage, scheduling regular portable appliance testing, and keeping cords out of the path of the wheel.
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What Are Some Ways Operators Customise Their Tool That Might Seem Harmless but Are Very Unsafe?
The most common practise is obviously taking off the protective shield before using the tool. Since the guard is in the way, they claim they can't see anything. Even though this may have been the case in the past, today virtually all major manufacturers offer customizable safety options. The cutting/grinding guard is modifiable, so you can use it even when working in tight quarters.
Using the angle grinder's main handle rather than its side handle is a close second. Because it's inconvenient to use, many people forget to remove the side handle from the box once it's been opened.
Protective shield must be in place at all times when using an angle grinder. If a wheel or disc were to break, the guards would keep the pieces together, as Tuerk observed.
It is imperative that you always keep your hands on the tool at hand. When swinging a bat, it's much easier to maintain control if you have one hand on each handle.
To remedy this underutilization, we've designed a side handle that can be used in a variety of configurations. Our grinders are on the more compact side, but they still feature a side handle that can be attached to the left or right side. Our larger grinders have a side handle that can be mounted to the left, right, or on top of the gear housing.
The grinder's side handle can be rotated through 180 degrees, from left to right, thanks to the multiposition attachment, which consists of a steel bar that attaches to the grinder. There are two possible orientations for the side handle, at 90 and 45 degrees from the tool's centre of gravity. We've added a safety incentive for workers to keep the tool's side handle in place at all times. As a result, there can be no more claims that it is slowing down development.
Any worker caught on a major construction site without a guard or a side handle faces immediate termination. Your job will be eliminated. If the position is unionised, you will not be able to get fired. It has been decided to dismiss you from your position as an employee. Oftentimes, it is that bad.
Even toothed saw blades and other accessories not designed for use with an angle grinder have been known to find their way into the hands of some unscrupulous individuals. Every user manual in the industry expressly forbids the use of a toothed saw blade with an angle grinder, which should come as no surprise. Put it this way: Abrasive cutting discs can cause serious harm, but a saw blade designed for 3,500 RPM that has been attached to an angle grinder spinning at 10,000 RPM poses a much greater immediate risk. If that were to occur, the situation would deteriorate rapidly. It's real, we've seen it. There is a one hundred times greater chance of bribery here.
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What PPE Must the Operator Wear at All Times, No Exceptions?
If you want to keep your eyes safe, you should put on a pair of wraparound safety glasses. If you want to keep your hearing, you need to take precautions. If your angle grinder isn't particularly loud on its own, the disc's impact on the material will cause a significant increase in volume. You should definitely wear spark-proof gloves, and you might also want to think about donning some FR outerwear. Those measures are the bare minimum that should be taken.
Even if you already wear safety glasses on the job, you may also need a full-face shield to protect yourself from debris and other hazards. When using a grinder, keep a safe distance from the tool and the workpiece, especially if the latter is shiny, as sparks may fly in your direction.
Dust respirators should be worn when working inside or in a confined space, such as a tank. Learning the material at hand is mandatory. Wearing a respirator is recommended whenever grinding is being done, but is absolutely necessary when working with stainless steel or anything that might contain a leaded component, such as a wire brush used to remove lead paint.
The user may keep both hands on the handle for a firmer grip when cutting or grinding. For a more secure hold on the grinder, the user can combine the support of the rear handle with that of the side handle. Added supervision improves safety.
What Should Operators Look for in Their Grinding or Cutting Wheel Before Work?
As soon as you remove a disc from its packaging, you should examine it for defects. Investigate for flaws like chips and cracks to ensure the item is in good condition. Throw away anything that raises suspicion. Put it back where it belongs and take it off the tool.
As soon as the wheel has been installed and checked, it should be run for at least one minute without any load on it. In that time, you'll be able to tell if the disc has any cracks or not. Keep it facing away from store patrons and employees if you must use it there. After making a part swap, let the disc idle for one minute to make sure everything is still holding together. This recommendation can be found in the majority of angle grinder instruction manuals, but I highly doubt that many users actually follow it. Also found in the ANSI B7.1 standard for abrasives.
To Increase Safety, What Are Some General Best Practices Users Should Adopt?
Every day, after putting it away and taking it out of a tool crib, you should let your angle grinder run for one minute without applying any load. The device and its companion piece can be tested in this way. Since you can't be sure that no one else will pick up and use the grinder while you're away, you should take the same safety measures before taking a break.
The safest course of action if you drop your angle grinder with a part attached is to replace the part. Replacing a cutting or grinding disc is cheap compared to the cost of medical treatment for an accident.
As a result, it can be concluded that the operator is the most crucial factor in ensuring a risk-free operation. Never play the instrument if you've been drinking or using drugs. If you notice anything out of the ordinary, notify your supervisor or a safety officer. It is too important to disregard. We need to keep an eye out for one another.
When you're not feeling well, it's not wise to lug around a heavy weapon. Using these machines is physically demanding; if you start to feel tired, take a break. Stop thinking about anything other than the task at hand.
Remember that if an accident occurs while using an angle grinder, you won't have time to react.
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What Are the Safety Measures in Using an Angle Grinder?
- Think carefully about whether or not an angle grinder is the best tool for the job before you buy it. If so, look for one that has interchangeable handles so that you can use it comfortably with either your left or right hand.
- Many right-handed grinder users seek out models with a dead-man switch or automatic shutoff feature integrated into the handgrip. As soon as the user lifts their finger from the sensor, power is cut off.
- Never use a grinder that is larger or more powerful than is necessary; lightweight tool guards are much easier to handle, and automatic cut-off switches may not be available on smaller models or be practical for certain operations.
- The guard needs to be positioned so that it covers at least half of the disc and sits between the disc and the operator. If you're using a grinder with a cutting disc, don't go any deeper than twice the disc's thickness into the workpiece, as this can cause the disc to break or "grip" the material, leading to kickback.
- Help those who work with angle grinders get the training and information they need to do their jobs without risk.
Before Use
Take these precautions before turning on your angle grinder:
- The disc and its cover are in good working order, the handles and guard are secure, and the disc has been fitted with the appropriate flange and locking nut (a disc that has been dropped may have developed cracks and should not be used) (otherwise the disc can shatter at high speed)
- Use only the manufacturer-recommended tightening tool to protect both the disc and the grinder.
- The correct type of disc is used depending on the material being cut or ground. Grinding discs are used for grinding, and cutting discs are used for cutting.
During Use
When using an angle grinder, keep in mind the following safety guidelines:
- While grinding, be sure to employ both hands. While waiting for a grinder to "run-up" to operational speed, its weight can be supported with one hand while the other grasps the tool's handle or the dead-man switch (if present).
- You need to be careful not to press down too hard on the workpiece with the grinder's handle, or the disc might grab and cause the tool to kick back.
- Don't ever grind against anything that could scratch or damage the disc.
- Keeping the object at an angle of 15° to 30° with respect to the grinding wheel is recommended. Make sure whatever it is you're working on is securely attached to a larger object or clamped in a bench vice. Keep the work at chest level while grinding.
- Keep your feet shoulder-width apart and your back straight to enhance your stability and concentration.
- When sitting on the floor, take frequent breaks to rest your hands and arms and to prevent any grinding that may occur between your legs.
- Make sure the grinder's disc has stopped completely before putting it down.
- Before you change discs, make sure the power is turned off to prevent electrocution.
- When not in use, unplug the grinder and place it on a bench, cutting disc up.
Conclusion
A serious injury is possible with the use of an angle grinder because of its high power. Those who have not received proper training, who do not respect the equipment, and those who refuse to adopt new methods are more likely to be injured while using an angle grinder. A 5-inch grinder that spins at up to 10,000 RPM is an example of a tool that could cause injury if used improperly. Instead of using the longer and more unusual 9-inch guard, the producer went with the shorter and more standard 5-inch one. Customers wanted to make sure they were protected while they worked, so manufacturers developed flat-head angle grinders.
The protector's primary role is to corral the fragments and prevent them from scattering. The steel must be thick enough to contain the shards, and the guard must be locked in place so that the operator is not exposed if there is a failure. The cutting edge of the tool can be locked into place, and the grinding wheel can be set to any of several positions in between, but it cannot move from its cutting position.
Angle grinders are extremely hazardous power tools that should only be used by those who have received extensive, one-on-one training. It's heavy, so you need both hands to hold the handle, and the tool has to be turned off before you can set it down or move it. Those who have not received proper training, who do not respect the equipment, and those who refuse to adopt new methods are more likely to be injured while using an angle grinder. Abrasive and metallic particles in the air, materials being ejected, and accidental contact with the tool itself are all potential sources of injury. It's crucial to keep your hands off the wheel at all times.
Wheel breakage, projectile contact, kickback, entanglement, and PPE are just some of the hazards that must be considered when operating an angle grinder. To avoid disc failure and subsequent wheel damage, drivers should be aware of the disc's lifespan and maximum speed and use it only when the disc is in perfect condition (before its expiration date) and at speeds lower than that. If you use the right cutting tool, wheel, and speed/feed settings, you can keep yourself safe from projectiles. Injury to the worker can occur if the tool falls to the ground or is thrown at him as a result of a kickback. Goggles, a hard hat, safety shoes, and gloves are all essential pieces of PPE to keep you safe from projectiles.
Angle grinders are potentially dangerous pieces of portable electrical equipment that pose risks of fire, electric shock, and other injuries if used improperly. If an individual's clothing is too long, they should tie it back, trash and rags should be kept away from the spinning wheel, and safety equipment should be in place at all times. Also, drivers need to check the vehicle visually before each use, schedule regular portable appliance testing, and keep cords out of the way of moving parts. We've made a versatile side handle and included a safety incentive for workers to keep it in place at all times. Toothed saw blades and other accessories not intended for use with an angle grinder have been known to find their way into the hands of unscrupulous individuals, and any employee caught without a guard or a side handle faces immediate termination.
Personal protective equipment (PPE) must be worn at all times. Users of grinders should protect themselves by donning goggles, spark-proof gloves, FR outerwear, and a full-face shield. They need to wear dust respirators and keep a safe distance from the tool and the workpiece if they are inside or in a confined area. After taking a disc out of its packaging, operators should check it for flaws and discard any items that raise red flags. Safety can be increased with the addition of more watchful eyes.
The most critical information presented here is a set of guidelines for safe use of an angle grinder by any user. To ensure the integrity of the wheel, it is recommended to run it unloaded for at least one minute, turn it away from customers and employees, and let the disc spin freely for at least one minute. The operator is the single most important factor in ensuring a risk-free operation; if a part is dropped, the safest course of action is to replace the part. Last but not least, always report unusual occurrences to your supervisor or a safety officer. Try to find an angle grinder that allows you to swap out the grips, has a dead-man switch or an automatic shutoff, has tool guards that aren't cumbersome to carry around, and covers at least half of the disc. Don't cut any deeper than twice the thickness of the disc, and make sure people who use angle grinders in the workplace have the knowledge they need to work safely.
Make sure the angle grinder's disc, cover, handles, and guard are all in safe working order, and that the disc has been properly flanged and locked in place before using. Use both hands, keep the object at an angle of 15° to 30° with respect to the grinding wheel, grind at chest level, and rest your hands and arms often. Make sure the power is off before you change the discs. The grinder should be unplugged and stored on a workbench with the cutting disc facing up when not in use.
Content Summary
- An angle grinder is a very potent piece of equipment.
- Our analysis of BLS data on workplace injuries reveals two distinct groups of people are more likely to be hurt while operating angle grinders.
- Without proper safety gear, anyone working with an angle grinder runs the risk of serious injury.
- When we dug deeper, we found out that they were attempting to grind a root weld on a 36-inch-diameter, 6-inch-thick-walled pipe.
- A 5-inch angle grinder with a 9-inch wheel would not be long enough to get to the bottom of the pipe to remove the root weld.
- The idea for flat-head angle grinders came from our desire to ensure that they had some form of protection while working.
- Additionally, a locking mechanism is required to ensure that the guard will not open and expose the operator in the event of a malfunction.
- Most angle grinders come with a protective shield designed to prevent accidental bursts.
- Once upon a time, all that was required to secure a guard to a grinder was a steel ring and a screw.
- One-on-one instruction in safe angle grinder use is required for all new operators.
- Our analysis of BLS data on workplace injuries reveals two distinct groups of people are more likely to be hurt while operating angle grinders.
- Be cautious and focused at all times while using an angle grinder.
- You may reduce this danger by operating an angle grinder carefully and inspecting the discs often.
- By understanding the disc's limits, you may prevent or lessen the likelihood of a disc failure.
- If you're going to use abrasive wheels, be sure you put them on the right tool.
- The mounting of wheels in inappropriate ways, using improvised tools, or on equipment not intended for that kind of disc is a common source of accidents.
- This occurs when the wheel or cutting speed of the angle grinder is incorrect, causing it to grasp and jam on the material being cut.
- Make sure you know what you're doing when it comes to mounting wheels, and replace damaged wheels as soon as possible.
- While protective equipment is essential while working with an angle grinder, improper attire might put you at risk.
- The fact that many angle grinders are electric means you should also think about the risks associated with using other types of portable electrical equipment.
- Using the angle grinder's main handle rather than its side handle is a close second.
- It is imperative that you always keep your hands on the tool at hand.
- To remedy this underutilization, we've designed a side handle that can be used in a variety of configurations.
- The grinder's side handle can be rotated through 180 degrees, from left to right, thanks to the multiposition attachment, which consists of a steel bar that attaches to the grinder.
- We've added a safety incentive for workers to keep the tool's side handle in place at all times.
- Even toothed saw blades and other accessories not designed for use with an angle grinder have been known to find their way into the hands of some unscrupulous individuals.
- Every user manual in the industry expressly forbids the use of a toothed saw blade with an angle grinder, which should come as no surprise.
- If you want to keep your eyes safe, you should put on a pair of wraparound safety glasses.
- Investigate for flaws like chips and cracks to ensure the item is in good condition.
- As soon as the wheel has been installed and checked, it should be run for at least one minute without any load on it.
- After making a part swap, let the disc idle for one minute to make sure everything is still holding together.
- Since you can't be sure that no one else will pick up and use the grinder while you're away, you should take the same safety measures before taking a break.
- The safest course of action if you drop your angle grinder with a part attached is to replace the part.
- Remember that if an accident occurs while using an angle grinder, you won't have time to react.
- Think carefully about whether or not an angle grinder is the best tool for the job before you buy it.
- If so, look for one that has interchangeable handles so that you can use it comfortably with either your left or right hand.
- Never use a grinder that is larger or more powerful than is necessary; lightweight tool guards are much easier to handle, and automatic cut-off switches may not be available on smaller models or be practical for certain operations.
- When using an angle grinder, keep in mind the following safety guidelines:While grinding, be sure to employ both hands.
- Keep the work at chest level while grinding.
- Make sure the grinder's disc has stopped completely before putting it down.
FAQs About Metal
Wear Protection: It is necessary to protect yourself from debris that flies around while you cut the stone with angle grinders. Make sure you wear ear protectors, safety gloves, and most importantly goggles.
While metal sparks have the potential of reaching 2,000 degrees Fahrenheit (or 1100 degrees Celsius), those produced when using an angle grinder have a small mass, not enough to cause a fire, in most cases.
Abstract. Angle grinders are amongst the most dangerous tools used in industry and agriculture. Over 5000 documented injuries are related to their use each year which are commonly triggered by a shattering of the abrasive wheel. These injuries are often accompanied by suboptimal health and safety standards.
While grinding metal, sparks are produced because of Friction. The rotating grinder cuts through the metal molecules, rubbing against them and producing heat. Some particles get loose in this process and burn because of this heat.
The noise level of 100 mm Angle Grinders when 'free running' for example can vary from 95 to 100 dB(A). This is dependent on factors such as bearing condition, gearbox wear and the age of the tool. Some of the better manufacturers can supply noise level data on the performance of the tool.