Safe Operation of Pedestal and Bench Grinders
The Problem
Pedestal and bench grinders are powerful tools that can operate at speeds up to 100 kilometres per hour. While they are essential for many tasks, they also present serious hazards when not handled correctly. Every year, many workers suffer injuries due to overlooked safety practices. Today, we’ll address the key hazards and discuss solutions to ensure everyone operates grinders safely.
Identify the Hazards
- Unsecured Grinders: A shifting or unstable grinder can lead to falling equipment or accidental contact with the rotating wheel.
- Tool Rest and Guard Gaps: Incorrectly adjusted rests or guards can cause material to wedge or lead to wheel shattering.
- Loose Clothing or Accessories: Items like gloves, jewellery, or long hair can get caught in the wheel, causing serious injury.
Safety Practices and Preventative Measures
Secure the Grinder
Ensure the bench grinder is firmly secured to the workbench or other surface as per the manufacturer’s instructions. A stable grinder prevents movement that could cause contact with the wheel or falling equipment.
Adjust the Tool Rest Properly
Install and adjust the lower tool rest to maintain a gap of no more than 3 mm between the rest and the grinding wheel. A larger gap can allow materials to become wedged, potentially causing the wheel to shatter.
Re-adjust the gap as the wheel wears down, but only after the wheel has stopped completely.
Adjust the Upper Guard (Tongue Guard)
Check the upper guard to ensure the gap between the grinding wheel and the guard is no more than 6 mm. The tongue guard deflects sparks and contains wheel fragments if the wheel breaks. Always stop the grinder before making adjustments.
Dress for Safety
Avoid loose clothing, gloves, jewellery, or unsecured long hair when operating the grinder. These items can get caught in the rotating wheel, leading to severe injuries. Always tie back long hair, remove jewellery, and wear close-fitting clothing.
Real-Life Case or Scenario
A worker was using a bench grinder without checking the tool rest gap. During use, the material slipped between the rest and the wheel, causing the wheel to shatter. The fragments struck the worker, leading to facial injuries. This incident could have been prevented by a quick tool rest adjustment before operation.
Employee Responsibilities
- Ensure grinders are secure and properly adjusted before use.
- Adjust tool rests and tongue guards to meet the correct safety gaps.
- Wear appropriate clothing and remove any accessories that could pose a hazard.
- Immediately report unsafe grinders or damaged wheels to your supervisor.
Employer Responsibilities
- Provide well-maintained and secure grinders.
- Ensure guards, rests, and wheels are in good condition.
- Offer training on grinder safety practices.
- Replace or repair unsafe equipment promptly.
Discussion & Questions
- "What steps do you take to ensure the grinder is safe before using it?"
- "Has anyone here encountered issues with tool rest gaps or guard adjustments?"
"Do you have any concerns about operating grinders safely on this site?" Allow employees to share experiences and discuss any issues or concerns they may have.
Commitment/Action Plan
Let’s commit to performing a quick safety inspection of all grinders before use. This includes checking that they are secure, the tool rest and tongue guard are properly adjusted, and that you’re dressed safely for the task. By following these steps, we can prevent injuries and keep everyone safe.
Wrap-Up
Pedestal and bench grinders are excellent tools, but they can be dangerous if safety precautions are ignored. By securing the grinder, adjusting the tool rests and guards, and dressing appropriately, we can eliminate preventable hazards. Thank you for paying attention and making safety a priority.
Standards Overview
WorkSafe NZ requires all pedestal and bench grinders to:
- Be fitted with properly adjusted work rests and tongue guards.
- Have guards that fully enclose the wheel to contain fragments in case of breakage.
- Be regularly maintained and inspected by a competent person. These guidelines aim to prevent injuries caused by misuse or poor maintenance.
Disclaimer
These toolbox talks are provided for informational and educational purposes only and are not a substitute for professional legal, health and safety, or regulatory advice.
The content reflects recognised best practices and general industry standards as at the date of publication. However, it may not be applicable to all workplace environments or specific operational contexts.
It is the responsibility of the Person Conducting a Business or Undertaking (PCBU), as well as officers, workers, and other duty holders under the Health and Safety at Work Act 2015 (HSWA), to ensure compliance with all relevant laws, regulations, and WorkSafe New Zealand guidance.
The authors, presenters, and distributors of this toolbox talk disclaim all liability for any loss, damage, or injury arising from the use or reliance on the information provided. Users should seek advice from a suitably qualified health and safety professional or legal advisor for guidance tailored to their specific circumstances.
Always follow your organisation’s policies, procedures, and safe work practices to manage risks and maintain a safe and healthy workplace.
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