The World of Hand-Held Grinders

In the world of the steel fabrication shop, hand-held grinders are used every day.  Although they are fairly innocuous looking tools, they are actually quite hazardous if handled improperly.  And, injuries from these tools can range from minor cuts to amputations, or even worse.

Hand-held grinders are used to grind, or smooth and shape steel to a nice finish before painting.   They are used much like the disk sander that you might use when doing woodwork.  Hand-held grinders in the steel fabrication shop are meant to take several different types of blades, but to keep it simple, let's reduce that to two categories:  1.  a "hard" inflexible disk; and 2. a flexible disk (like a sanding disk or buffing "blade).

            7" Grinder with "hard" disk properly guarded

When using the "hard" disk, a guard is required on the grinder.  The guard is designed to keep pieces of a broken disk from hitting the grinder operator.  Although the guard may protect a workers's fingers, it's primary purpose is to keep broken blade pieces from causing harm.  

With the "flexible" disk, or "sanding" disk, a guard is not required.  The guard might protect the operator's hand from contacting the disk, but remember, the primary purpose of the guard is to protect the worker from flying pieces of a broken disk.

  

       4.5" grinder with flexible disk and no guard

         4.5" grinder with flexible disk and guard

Are broken "hard" disks common?  Well, not in my experience, but it does happen and there have been deaths as a result of pieces striking workers.  The good news is that with the proper precautions, we can reduce the likelihood of injuries when using hand-held grinders.

1. Always inspect disks for imperfections, cracks, and other damage.  Performing a "ring" test may help identify cracks that you may not be able to see.
2. Always follow the appropriate lockout/tagout (LOTO) procedures when changing disks.  In this case, LOTO means unplugging the tool before you change disks or guards.  And, be sure that you keep your hands clear of the trigger plugging it back in.
3. Wear gloves when operating this tool.  The disks operate at high speed and can "kick" back at you.  Gloves can prevent many minor injuries to your hands.
4. Never use the grinder above chest height. 
5. Always wear the appropriate Personal Protective Equipment (PPE).  In this case, at least use safety glasses, hearing protection, gloves, and a face shield.  Our shop reduced eye injuries in our shop by 65% after we required the wearing of face shields in addition to safety glasses.  Although all previous eye injuries were minor, it is evident that face shields work!

Because these tools are potentially hazardous, we conduct training on the use of grinders beginning at safety orientation.  Then, throughout the year, we also conduct tool box safety talks on grinder safety.

Recently, we conducted a tool box safety talk about grinders emphasizing the use of guard and we always end with a reminder of the LOTO procedures.  Imagine my surprise when, about 20 minutes after the training session, I was called the the first aid room to find an employee with a grinder injury.  He had just completed a blade change (a "hard" disk) and had followed the proper LOTO rules.  But, when picking up the grinder to begin work, the glove web between thumb and forefinger contacted the grinder's trigger.  The spinning disk pulled his gloved left forefinger into the blade pinching it between the blade and the guard.  He had an ugly gash on his left forefinger, but luckily, required only a few stitches - no permanent injury.

So, even when you think you are following all of the safety rules, PPE, LOTO, etc., you must always remain diligent when using a grinder.  And always keep you mind focused only on what you are doing.

Expert?

Have you ever noticed that "if you're from out of town, you're an expert," but in your own workplace you don't know anything?

A few days ago I told a worker that he was using the wrong PPE and then told him what he should be using.  Well, that started a rant about how "OSHA doesn't say that I have to.  I looked it up."  I carefully explained that the standard was a performance standard. You know, that's where the relevent OSHA standard tells you what to achieve but not exactly how to achieve the goal?  Then I explained why the PPE that he was using did not meet the criteria.

Ironically, I had trained this employee in the proper procedures, but for some reason, after several years of conducting the operation with the appropriate PPE, he had decided that he would not do it that way anymore.   Then the inevitable "show me where OSHA says I gotta."  I then carefully explained "performance standard," and why his choice of PPE was inappropriate.  Again, ranting and raving that I need to speak with his immediate superior, etc.  Obviously, the employee received a disciplinary note in his personnel file and an admonition that continuing to use the wrong PPE would result in more severe discipline.

So, as you might imagine, I visited his immediate superior to explain the situation, how I handled it, and told him what I had explained to his subordinate.  I was met with, "I looked it up in the OSHA standard and it doesn't say that."  Again, a carefully crafted explanation of "performance standard," OSHA interpretations, and "best practices" ensued.  Then, as you might expect, the "I need it in writing from someone that says I gotta."

Yes, I know that I should be the last word on the issue, but that does not often work in the real world.  Nevermind that I was hired because of 30+ years of safety experience, a degree in Occupational Safety and Industrial Hygiene, past safety teaching experience at a community college, and the OSHA 500 course authorizing me to teach OSHA 10 and 30 hour courses.  So, I pulled out an article that I had written a few years ago, added a pseudonym at the bottom of the article.  The article explained the situation in exactly the terms that I had verbally given both he and his subordinate (obviously, because I had written the article), but now the name of the author wasn't my name.  He read the article and said, "that's better, now I understand.  You need to communicate more like this guy."  Really?

I have had no compliance problems with this issue since.  I know, I could have gone up the line to the supervisor's superior, but I'm not sure that the consequences would have been worth the effort.  The immediate problem was solved and it looks like I may have a strategy for solving future problems.

But, the guy that wrote the article was from outside the company, so he knew better!  Imagine that!

Thanks to the people at The Mesothelioma Center (at www.asbestos.com) for this post.

Beware of Dangerous Asbestos during Construction

Asbestos once was considered a miracle mineral for its unique ability to resist heat and strengthen almost anything. It was used extensively throughout the construction industry and lauded for its versatility and affordability.

Unfortunately, it is also toxic when its microscopic fibers are unknowingly inhaled or ingested, leading to a variety of long term respiratory health issues, including asbestosis, lung cancer and malignant mesothelioma.

Although its use has been significantly reduced in recent decades, it remains a serious threat to anyone involved in the renovation, remodeling or demolition of a structure built before the mid-1980s.

Beware of the danger. No level of friable asbestos exposure is considered safe. If you believe you’ve been exposed to asbestos it’s important to see a doctor and discuss possible treatment centers.

Workers should take the proper precautions when working on an older residence or commercial building. Asbestos likely will be in the flooring, ceilings, walls, plumbing and electric fixtures.

Many common building materials contain asbestos. When these products begin to deteriorate or if someone drills, sands or disturbs them, the fibers often enter the air.

Although the immediate danger may seem minimal, the asbestos fibers can become lodged in the lining around the lungs. Over time, they will cause inflammation and scarring, which can lead to serious problems.

Protective gear should be worn, helping avoid any inhalation. A firefighter, for example, will wear a special breathing apparatus when entering an older building where the toxic fibers are in the air.

Construction workers should take similar precautions. In newer construction, roofing shingles often still contain asbestos, which is designed to resist heat.

Any clothes worn when working on a remodeling project should be left at the worksite or properly cleaned before coming home to avoid subjecting others to the unwanted exposure.

The use of asbestos may have dropped dramatically, but the dangers have not.