In June 2021, a tragic incident occurred at a commercial construction site in Brisbane. A worker lost his life due to injuries sustained while using a 9-inch (230mm) angle grinder. As he was cutting the base of a structural steel member, a small metal shard was violently ejected from the cutting work, striking his neck. Notably, the angle grinder was unguarded at the time of the incident.
The investigation is ongoing, and the exact cause of the accident has yet to be confirmed.
Safety Concerns
Angle grinders have a notorious history of involvement in serious incidents, including fatalities. Common injuries range from amputated fingers and severed tendons to deep cuts on the face, upper body, or legs. These incidents are not confined to any single industry; they can happen anywhere.
The increased power and size of a 9-inch (230mm) angle grinder make it particularly dangerous. It can cause severe kickback and a gyroscopic effect, making the tool difficult to control. Hence, conducting a risk assessment to explore alternative methods and tools is crucial before opting for a larger angle grinder.
Managing Health and Safety Risks
Effective risk management is a fundamental responsibility in any business operation in Queensland. This starts with a commitment to health and safety from business managers. In the event of an incident, it’s essential to demonstrate to regulators that an effective risk management process was in place. This requirement is part of the primary duty of care under the Work Health and Safety Act 2011.
The hierarchy of controls is a systematic approach to managing risks. It ranks control methods from the highest level of protection and reliability to the lowest. The goal is to eliminate the hazard as the most effective control. If elimination is not possible, the next best controls should be implemented to reduce the risks.
Preventative Measures
Employers and self-employed individuals must control the risks associated with power tools, including angle grinders. Before operating larger angle grinders, the following precautions should be taken:
- Ensure Proper Guarding: The correct guard supplied by the manufacturer must be fitted.
- Match the Disc and Spindle Flange: The right-sized disc must be fitted, and the mounting hole should match the spindle flange.
- Check Rated Speed: Discs must be marked with the maximum permissible operating speed (RPM), and the angle grinder should display its maximum operating speed. The disc’s rated speed must not be less than the grinder’s.
- Inspect Discs: Before use, inspect discs for damage. Do not reuse damaged discs.
- Select the Correct Disc: Use a grinding disc only for grinding. Using a cutting disc for grinding increases the risk of it breaking.
- Follow Installation Instructions: Discs must be installed correctly, and the center nut should be tightened according to the manufacturer’s instructions. Using improper methods like a punch and hammer can damage both the disc and grinder.
- Handle Properly: Hold the angle grinder with both hands, and insert the side handle on the side that provides the best grip for the task.
- Full Speed Operation: Run the grinder up to full speed before cutting or grinding.
- Use Correct Flange and Lock Nut: Ensure the correct spindle flange and lock nut are used and fitted as per the manufacturer’s instructions. Incorrect combinations can cause disc breakage.
- Establish Exclusion Zones: Set up exclusion zones to protect others from potential injuries if control is lost or the disc breaks.
Engineering and Administrative Controls
Engineering controls such as guarding should be implemented to minimize hazards like the ejection of metal. Guards are crucial for protecting against grinding debris, sparks, and disc disintegration. The AS 1788 standard provides guidance on guarding abrasive wheels, while AS/NZS 60745 outlines safety requirements for handheld electric tools, including grinders.
If the guard is removed:
- There is nothing to stop debris or broken pieces of the disc from hitting the worker.
- The risk of a worker’s hand contacting the unguarded disc increases.
- The disc is more likely to be damaged when the grinder is put down, as the weight of the grinder rests directly on it.
Photograph 1 depicts a 9-inch (230mm) angle grinder correctly fitted with a guard and the right-sized disc.
Administrative controls, though lower in the hierarchy, are essential and should complement higher-order controls. These include:
- Providing information, training, instruction, and supervision to ensure safe operation.
- Ensuring manufacturer’s operating manuals and instructions are accessible.
- Offering practical, hands-on training that considers literacy levels, work experience, and specific skill requirements.
- Aligning worker training, experience, and competency with task requirements.
Personal Protective Equipment (PPE)
Even with engineering and administrative controls, some risks may remain. These should be mitigated with appropriate PPE, such as:
- Safety goggles, glasses, and face shields.
- Hearing protection like earmuffs.
- Dust masks suitable for the task.
- Gloves, leather aprons, and jackets (workers must avoid loose clothing or jewelry and securely tie back long hair).
- Safety footwear that is suitable, comfortable, and has a non-slip sole with appropriate tread. Regular checks are necessary to ensure the treads are not worn or clogged.
Continuous Improvement
Administrative control measures and PPE rely heavily on human behavior and supervision and are less effective when used alone. It’s crucial to regularly review and monitor the control measures to ensure they are working as intended.
Regular evaluations and updates to safety protocols can prevent future incidents and enhance overall workplace safety.
Conclusion
This tragic incident underscores the importance of stringent safety measures and the need for constant vigilance. By adhering to safety standards and employing a comprehensive risk management approach, businesses can protect their workers and prevent such incidents.
