Grinding Safety

The portable grinder is used in the field or maintenance shop to grind excess metal from welds, remove rust, and for special finishing operations. Since this tool is hand operated, the quality of the work depends upon the ability and experience of the operator and also aware grinding machine safety as does safe job completion.

Common Injuries Due to Grinders:-

  • Cuts.
  • Strains.
  • Particles in the eye.

What are the Common Hazards of Portable Grinding machine Use?

AG 4 Grinding machine
AG-4 Grinding machine
  • High speed flying particles … a grinding wheel’s speed can be greater than a mile a minute.
  • From the grinding wheel itself.
  • From the workpiece 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 the frayed or defective power cord.
  • Noise.
  • Repetitive use.
  • Awkward body positions.

Common Causes of Grinding Machine 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 the grinder.

Hazard in grinding machine operation, safety in grinding machine

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.
  • Using the Right Wheel.
  • Ensure the wheel is designed for the machine’s size and speed and the material of construction of the workpiece.

Using the Right Wheel:-



  • Are made from varying 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 blades are to be used for GRINDING only, DO NOT use to cut material.  Use only the grinding face, not the back side of the disk.


  • 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.

Grinding machine/wheel RPM:-


Always check grinding wheel/cutting wheel Maximum RPM is greater than grinding machine Maximum RPM

  • AG-4 Grinding Machine RPM between 10800 to 12000 (Depend on manufactures, in India mostly use Bosch its RPM is 12000).
  • AG-4 Grinding Wheel RPM between 12500 to 13500 (Depend on manufactures).
  • AG-7 Grinding Machine RPM 8500.
  • AG-7 Grinding Wheel RPM 8000 -8500 (Not exceed 8500).


  • 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)
  • Be sure the wheel fits freely on the spindle.
  • The spindle nut must be tightened enough to hold the wheel in place, without distorting the flange
  • 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 the integrity and balance of the wheel

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.

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.
  • 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 Handling of Grinders

  • Always use two hands when using a portable grinder.
  • 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.

Proper grinder PPE:-

Goggles 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 on removing goggles or safety glasses to ensure particles don’t 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
  • Earplug, ear muffs.
  • Don’t wear anything loose that could get caught in the rotation
  • Secure scarves, ties, loose hair, and dangling jewelry
  • If you’re wearing a long-sleeved shirt, button it at the wrist
  • Consider also the possible need for a dust mask
  • May be required for some grinding operation, depending upon the material of construction of the workpiece being ground
  • 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 the cup or saucer wheels

Critical Safe Behaviors for all Powered Tools:-

  • Ensure all guards, grips, handles, etc. are in place.
  • Prevent unintentional starting of the tool.
  • 2 motion positive on/off switch required.
  • Don’t carry powered tools plugged in with the finger on the switch.
  • Never carry a tool by the cord or hose.
  • Never yank the cord or the hose to disconnect cord.
  • Avoid accidental starting. Do not hold a .finger on the switch button while carrying a plugged-in tool.
  • All portable electric tools that are damaged shall be removed from use and tagged “Do Not Use.“
  • Protect others in work area.
  • Don’t allow cords to become trip hazards.
  • Minimize the number of employees in the hazard zone.
  • Ensure all in hazardous areas are using appropriate PPE.
  • Consider work in adjacent or below areas.

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Saurabh Ranjan is Founder of I have dedicated & committed to publishing some innovative content and useful topics regarding Health, Safety & Environment, which will help and awareness to people for daily life. Also trying to continually improve my content for better awareness and suit to dedicated people.
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  1. I am glad you said to always use two hands on the grinder at a time. My dad works in a factory with this type of equipment. Thanks for the safety tips for using a grinder machine.

  2. It’s very useful information to safe workers.
    Really I appreciate your efforts.
    Thank you so much and God bless you.

  3. Thanks for sharing such useful information.
    Can you explain why do we need to use 3 core cable in single phase portable grinder thought it is having non conductive body.

  4. nice……Good contain and very simple language.Very useful for us specialy who is working in HSE field.Thank you so much sir.


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