Grinder Use Safety Training

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Grinder Use Safety Training
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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 sites
  expectations regarding grinder use and some
  general hazards and precautions.
• In case of a discrepancy between this
  presentation and the manufacturers
  recommendations, the manufacturers
  recommendations take precedence.

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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.

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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!
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Most Recent Grinder Injuries

• February 13, 2010 Oyster Creek, Texas While
  waiting for the grinder to power down, the
  individuals 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!
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What are the Common Hazards of Grinder Use?

• High speed flying particles a grinding wheels
  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

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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

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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.

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Using the Right Wheel

• Ensure the wheel is designed for the machines
  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.

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Wheel Example
Cutting Blade
Max RPM
Size of Disk
Type of Material can be used on
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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 toolperhaps 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 shouldnt 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

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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 manufacturers instructions for mounting
approved accessories or attachments.
Cup Stone
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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.
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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

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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

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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
  dont 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
• dont wear anything loose that could get caught
  in the rotation
• secure scarves, ties, loose hair, and dangling
  jewelry
• if youre 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 !!!
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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

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Critical Safe Behaviors for all Powered Tools

• Know and Follow all Manufacturers 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 dont 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
• dont abuse cords, keep away from heat, oil
  sharp edges, inspect for frays, cuts, etc.

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Critical Safe Behaviors for all Powered Tools,
continued

• Ensure all guards, grips, handles, etc. are in
  place
• Prevent unintentional starting of the tool
• dont 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
• dont 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

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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

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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

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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
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Bench Grinder
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• The graphic below is courtesy of the Safety,
  Health, Environmental Technology Division of
  Georgia Tech Research Institute, Tech Guide No.
  2, Published 1988. (Other local safety
  designations may apply instead of Z-87)

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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.

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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.

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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!