Wear your PPE! Grinder mishap...

We all have done it, took a shortcut or come up with an excuse. Screw that, I'm buying a faceshield. This came from our safety officer on this project:

All,

One of our sub contractors had two grinding disks blow apart while in operation today. Fortunately the employee was wearing all the appropriate PPE. The employees faceshield defeated the debris as it flew apart at 10,000 rpm's. Not even a scratch from the debris.
IMPACT report will be finished soon.

The disks were Brill-Tex (rated at 13,300rpm's) purchased from Crown the local supplier down the street.
The disks were new out of the box and were not exposed to any other alloys that would have plugged the disk.
I wanted every one to know about this ASAP because it's possible that there are more in the plant because of the local supplier scenario.
We have gathered up all the 4" and also the 7" that were purchased and they will be sent back to the manufacturer.

Thanks

Mark
Project Management Safety
VDU/Coker Project

 

Happpens more than you think. There was a feature in Street Rodder int he 80s about a guy that about died building his car. a 7" disk exploded and part of it lodged in/next to his heart!

I cringe when I see the OCC guys spinning those little 4" disks with an electric angle grinder. Most of the disks arent rated for those RPMs (at least all the brands we get). We use air tools at much lower speeds.

 

But that would make good tv...

Paul Jr...."ya know, things were going smoothly until Vinnie took a cutoff wheel to the throat."

 

I took a bodyshop cl*** in high-school, and the teacher told us he had a friend who had his kneecap (petella bone) CUT OFF by an exploding disk.

 

I think it was on that "Real TV" show that they showed a guy that took a grinder wheel that "exploded" to the head, and a huge chunk (4" or so) was lodged in his forehead above one of his eyes. It was pretty crazy because he was still wide awake and walking around while he was in the waiting room at the hostpital.

 

I know a guy that would help out at his Dads Tool Shop as a teenager. ( 15 or 20 years ago...)
The Shop had a Back room where they could do some work.
He was in there and somehow had a Harddisk explode on him.
The people in the store just heard a loud noise...
The Disk broke his Skull and damaged his Brain.
He survived but will need help for the rest of his life.

 

Just in case you didn't understand; WEAR YOUR PPE!

 

Wow, I didn't know exploding wheels was such a problem. I just became shop foreman at the Formula SAE shop at school... would it be wise of me to make a rule that everyone using a grinding wheel wear a face shield? They already have have to wear safety gl***es while doing pretty much anything. I think I already know the right answer...

 

They figured that is what happened.
In all the chaos it must have been hard to see what happened first...
And the guy doesnt remember anything about that day.

Yeah... We'd better take these Tools serious.

 

Yeah, I always wore some Z87 goggles and hearing protection, but I'm going to get a faceshield, I'm just too pretty....

 

Yeah, when I was in one of my apprenticeship cl***es to be a millwright, we were told to hold the grinder/grinding disc down in an empty bucket to test it. If it did come apart, the bucket would act as a shield against the pieces. Of course it's also not under load at that point....

 

It does happen................ not just to the other guy. This was about 8 months ago.

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ACCIDENT/INCIDENT ALERT
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October 2004
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Fatal Grinder Accident at Quarry
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Incident
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A welder was carrying out maintenance on a quarry excavator bucket. He was using an angle grinder to prepare surfaces for welding when the disk disintegrated.
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Cir***stances
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The hand-held angle grinder was fitted with a 230 mm diameter cutting-off wheel and when it disintegrated, fragments penetrated the victim’s chest and abdomen. He was rushed to hospital by rescue helicopter but died the same day.
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Investigation
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This is continuing but initial inspections show that the grinding machine and cutting disk were not compatible - and the grinder was not fitted with a guard.
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Recommendation
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Grinding machines and abrasive wheels should always be used in accordance with the manufacturer’s instructions.

In particular:
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1. • Always ensure the maximum speed (the no load rpm) marked on the abrasive wheel is greater than the rated speed of the grinder.
   
   
   
2. • Do not use grinding wheels that are larger than the maximum recommended size, or worn down wheels from other grinders.
   

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Angle grinder and disintegrated disk
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1. •

1. [/font]Never use grinding wheel power tools without the wheel guard attached to the tool and positioned for maximum safety.
   
   
   
   
   [*]• Store and handle abrasive wheels with care and inspect them for chips or cracks before installing. Do not use any wheel that may be damaged.
   
   
   
   [*]• Refer to Australian Standard 1788 - [font=Times New Roman,Times New Roman]Abrasive Wheels [/font]for more detail.
   
   

 

Yeah, that is another thing I have noticed alot on these reality shows is their total disregard for safety. When was the last time you saw any grinder on one of thse shows with a shield on the grinder? I can't claim to have seen them all, but the ones I have seen, the shields are missing.

I wonder how many kids will get themselves hurt because they think they don't need them, like Paul JR. does...

 

last year I welded the ****** crossmember in a 49 chev. I couldnt get in with the grinder where I needed to. I asked one of the guys to ditch the guard for me so I could finish up. He did, and as he handed it back told me it was a bad idea. Being ignorant and in a hurry it took all of 5 seconds for the grinder to bite, kick, and remove a knuckle from my left hand.

I just started using a face shield, I didnt like getting hot sparks up my nose anymore.


AND DONT FORGET HEARING PROTECTION. I bought a set of ear plugs not to long ago. I already have a 30% loss do to guns, uncapped motors, dragracing and stock cars. Suprisingly, I can wear the ear protection, baraely hear the grinders, but still hear the stereo. Most audiologists can make you a set of custom fit molded ones for less than a hundred dollars. think about it, it's worth it

 

I've heard these stories from my Machine shop professor
years ago.

I always test a new wheel on my grinder by spinning it
before going to work. Be sure to point the grinder so it
won't destroy anything if it does come apart.


I also started wearing safety gl***es under my face shield,
a stray piece of Aluminum came of my jig saw once and
got around the face shield into my eye. My magnet trick
doesn't work with Al.

 

My friend, the lead mechanic at the GM garage in my hometown, had a bench grinder wheel explode. It cut the inside of his forearm pretty bad. He slapped a shop rag on it and bent his arm at the elbow to stop the blood. My dad was the ER doc and made him keep it that way for xrays. There was a chunk of the wheel that had entered a vein and the bent elbow stopped it from migrating to the heart. Probably would have killed him. I never stand in line with a grinder at all.

 

I believe that there is something called a "Ring Test" when dealing with grinder wheels. If you hold it up by the center and hit the side of it, like you would a tuning fork, and it rings, it is supposed to be good to use, but if it makes a dull "clunk" noise, it is trash and you should throw it away.

Anyone ever hear of that before, can someone confirm that before everyone that reads this throws all their grinding wheels away?

 

This seems to be a good time to add; KEEP DIE GRINDERS at right angles to your face. And wear a GOOD FACE SHIELD!
I have one that has a chin guard.

I have been experiencing mounted stones and burrs from off shore suppliers, COMMING OFF THE SHAFT!

They may be smaller than a disk, but they sure can mess up your skin!
(let alone your eyes!)

 

I work for a heavy industrial contractor up here and we've developed a grinder safety policy which is now mandatory. In the past one of our largest contributors to work place injuries was incidents relating to grinders (lacerations, foreign bodies in eyes). There has been a dramatic reduction in incidents since we've been enforcing this policy. Note we require monogoggles under a face shield when grinding.


Hope this saves someone an injury.

A. PURPOSE ​

To establish safe work practices for the use and handling of grinders.

B. BENCH AND PEDESTAL GRINDERS

1. Face shield with monogoggles shall be worn.

2. Tool rests and tongue guards shall be properly set within 1/8" of wheel.

3. Stand clear of wheels and leave guards down until grinder reaches its maximum speed.

4. Do not grind on the side of wheels.

5. Do not adjust the work rest while the wheel is in motion.

6. Do not use a wheel that is worn out of round until it is trued.

7. To change the wheel or make adjustments on 110-volt pedestal and bench grinder, de-energize the push-****on or switch and unplug the 110-volt cord.

8. The Electrical Department designated Competent Person must be contacted before changing wheels or making adjustments on 220-V and 440-V pedestal and bench grinders.

a. De-energize the push-****on or switch, throw disconnect switch to "Off" position and lock and tag disconnect switch.

b. The Electrical Department should be contacted for de-energizing.

9. All bench and pedestal grinders are equipped with:

a. A protection hood.

b. An adjustable guard-hood guard.

c. Steel back-up flanges. All straight abrasive wheels shall be mounted between steel safety flanges of equal size, not less than one-third (1/3) the diameter of the wheel.

10. When installing new wheels, the following rules shall apply:

a. With organic (resinoid) bonded wheels, care should be taken to tighten end nut only enough to drive the wheel and prevent slippage.



b. With inorganic (vitreous) bonded wheels, the torque table below is recommended:

TYPE TORQUE (FT-LB)

Single spindle-hex nut:

2” diameter 60

5/8” to 1-1/4” diameter 35

1/2” diameter 20

3/8” diameter 10

Single spindle-threaded flange of spanner nut

3/4” to 1-1/2” diameter inclusive 15

Multiple screw mountings

5/8” diameter and up 20

3/8” to 1/2” diameter inclusive 10

NOTE: Multiple screw flanges are tightened gradually and uniformly in a crisscross pattern.

11. Designated Competent Persons shall perform initial inspection and subsequent maintenance of all grinders. Inspections are made on an established schedule and records maintained by the inspecting person(s).

12. The using craft/crew is responsible for maintaining the proper distance between the work rest and the wheel (1/8”). The work rest shall remain 90 degrees to the tangent of the wheel at the point of contact. The maximum allowable space between the wheel and the adjustable guard at the top of the opening shall not exceed 1/4”.

13. Grinders used for tungsten rods are marked and used only for that purpose.

C. PORTABLE GRINDERS

1. Are equipped with guards.

2. Operator shall wear face shield with monogoggles.

D. GENERAL

1. The RPM of a wheel shall always exceed the RPM rating of the grinder on which it is used.

2. RPM rating shall be marked legibly on grinders.

3. General purpose wheels are not to be used for grinding on soft metals such as aluminum.

4. Special adapters or arbors shall not be fabricated.
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5. Construction of wheel guards shall comply with the minimum requirements outlined in CSA-E1029-2-4-94(R1999)

6. Shirt tails shall be tucked in and loose fitting clothes are not be permitted while using grinders.

7. Employees shall warn personnel in the immediate area prior to grinding, and/or provide spark containment such as screens.

8. Ear protection is mandatory for operators.

9. Never use the cord to lower grinders from elevations.

10. Deflection screens may be needed to protect personnel or other equipment.

11. Perk's washers shall be used on all vitreous (inorganic) bonded wheels.

12. Each employee is responsible for the current inspection, condition of wheel (no chips), proper wheel RPM rating, proper washers, properly-spaced work rest, guards, and proper exhaust system.

13. On all portable tools, the control switch shall be constant pressure controlled without locking pin.

14. Wheels should be stored in a dry place with constant temperature above freezing and protected from physical damage.

E. ABRASIVE DISCS AND CUT-OFF DISCS

1. Grinding is to be performed on the rim face only of abrasive discs.

2. Check cut-off discs for chips - DO NOT USE IF CHIPPED.

3. Consider fire potential from sparks.

4. For bench applications, anchor small materials securely by mechanical means - DO NOT HOLD BY HAND. (Use vise grips or other suitable means.)

5. For applications where a portable disc is applied to work or work is hand-fed into disc, avoid binding through misalignment.

6. Consider the need for respiratory protection or ventilation systems.

7. Face shields, monogoggles, and ear protection are required when using disc grinders.

F. INSPECTIONS

1. Employees using grinders shall be responsible for safe operating conditions before putting the tool in use.

2. All grinders shall be inspected monthly by a designated Competent Person.

​

 

I remember my dad being rushed to the ER room when I was a kid because his 4 inch angle grinder kicked back and took off his fingers. He had them reattached but now when I use a grinder, I make DAMN sure to wear every bit of gear and stand out of the line of fire as I possibly can, while still being safe! You should also be careful around heavy equipment. A guy at my pop's work was just killed when a backhoe bucket readjusted itself on gravel and took his throat with it. Always be aware of what's around you and what your standing on!
**x
Brandy

 

Brandy, your dad's incident reminds me of another safety item;
GOOD TOUGH WORK GLOVES!

Bet there's lots of people out there that DON'T wear them!

 

Errr, what's "PPE" stand for?

 

Just a thought, but maybe if someone e-mailed the discovery channel& OCC and advised them of their legal liability if such a thing happened, things might change.

 

personal protective equipment.

 

I've spent a good portion of my life using surface grinders, building high tolerance injection molds. The ring test is something I'd do religiously!

I've used wheels that were anywhere from 46 grit to 120 grit. I've had a few
of them explode over the years, but those types of grinders have pretty good guards on them. Even some that ring tested good, exploded while dressing the wheel with the diamond dresser. I've dressed all kinds of shapes and radius's on grinding wheels. Moldmaking is fun!

Damn it, now it's got me missing being able to be a machinist! Back problems ****!

 

you gotta' watch those gloves too,rely on them mainly to prevent cuts.

not too wise to wear them whilst drilling or around rotating equipment,(milling machines,drill presses,lathes,etc...).

should they snag on something spinning,you too could soon be spinning,
or a part of you thereof.

 

The main thing to remember is never run an air grinder or electric grinder FULL SPEED......[OR FULL AIR -LINE PRESSURE]........... feather the trigger[adjust the regulator] and bear down on the wheel a little more to control the wheel speed......do that and you should be all right.

A LITTLE OVER HALF OF THE TOOLS SPEED CAPABILITY IN rpm'S IS A GOOD BALANCE AND DOES A DECENT JOB [A LOT MORE SAFELY]........

I HAVE BEEN HURT BY THIS KIND OF ACCIDENT AND IT REALLY DESERVES SOME SERIOUS ATTENTION FROM US ALL.

 

stealth, your right. I should have said, While grinding; ALWAYS use tough gloves.

 

i thought they were talking about a Purple People Eater shirt or something form the ***le...ive had many cutoff wheels explode on me,,it ****s,,one knocked the wind out of me once,,,**** them,,its like going to battle ,,wear your gear,,,

 

odd that i should be reading this now, i was using a cutting wheel on a 5" grinder on tues that came apart and caught a piece under my PPE. i spent last night having it removed and then the afternoon today with the surgeon using their tiny dremel tool to remove the fragments and rust rings that were left over. being a Welder by trade ive had flashburns before...but this ****ed so much worse!!!!

And the light....god the light hurts!!!!!!!!!!!!!!!!