Complete version of workshop safety production operating procedures for grinders
Among the industrial accidents that occur every year, there are not a small number of cases of splash injuries caused by improper operation of grinders. Because the rotation speed of a grinder can be as high as 8,000 revolutions per minute, if the operator is not careful, the debris flying out will have fatal consequences. So here, we will explain the safe operating procedures for grinders in the workshop once and for all.
You have to pass two tests before taking up the job.
The statement that workers must hold a special safety training certificate before operating a grinder means that temporary workers without any training are strictly prohibited from operating it. As for those who have drunk alcohol, are extremely tired, and are wearing gloves and hanging accessories, they are not allowed to turn on the phone. In an accident reported in a province in 2024, an untrained temporary worker directly operated the grinding wheel, and the grinding wheel shattered and the fragments hit the face.
Equipment inspection work cannot be handled casually. Before starting the machine, you should use your eyes to see whether there are cracks on the grinding wheel, whether there are any defects, and whether the flange is pressed reliably. In terms of electrical aspects, it is necessary to focus on checking whether the power cord is damaged, whether the ground wire is firmly connected, and whether the emergency stop button can realize the one-button power-off function.
In 2023, a case occurred in a workshop where a ground wire fell off, causing leakage. Fortunately, the emergency stop device worked at that time, so that no serious injuries were caused.
None of the safety devices can be used
The protective cover, spark damper, and workpiece holder of the grinder are all indispensable. Regarding the opening size of the protective cover, its width cannot exceed one-third of the diameter of the grinding wheel. As for the distance between the spark deflector and the grinding wheel, it cannot exceed nineteen millimeters.
In 2025, the safety supervision department of a certain place conducted a random inspection and found that a company actually removed the protective cover of the grinder and used it as a cover. Once this situation was verified, the company was asked to stop work and make rectifications on the spot, and was fined 20,000 yuan.
When it comes to electrical inspection, we should focus on three things. The first is to check the grounding resistance, the value cannot exceed four ohms. The second is to check the action time of the leakage protector, which must not exceed 0.1 second. The third is to check the cross-sectional area of the power cord, which must match the power of the motor.
I remember that an electrical fire broke out in a workshop in 2024. The cause was that the motor of the grinder was burned out. Later, after investigation, it was discovered that the disaster was caused by aging power lines and insufficient grounding devices. By the time the workers discovered it, the fire had already spread to where the wood was stacked.
Don’t skip this step when starting the trial run.
After a new grinding wheel or re-clamping, it must be tested without load for five minutes. First, jog to confirm the correct direction of rotation, and then idle to observe whether there are any abnormal vibrations and noises. In 2023, a company's newly installed grinding wheel was processed directly without trial operation. The deflection of the grinding wheel caused the workpiece to be scrapped and the grinding wheel chip collapsed on the spot.
During the test run, the operator must stand on the side of the object, keep his hands away from the grinding wheel and workpiece, and must not touch any rotating parts. Only after confirming that the situation is normal can the operator proceed with formal grinding work. If the vibration is very obvious or the sound is out of place, the machine must be stopped immediately for inspection. It is absolutely prohibited for the equipment to continue to operate with malfunctions.
The eight red lines in grinding operations cannot be touched
The grinding wheel is only allowed to use its circumferential surface for grinding. It is absolutely forbidden to put force on its sides. You cannot press the workpiece with great force for hard grinding, nor can you grind soft materials such as wood, copper, and aluminum. If you do these operations, it will cause the grinding wheel to become clogged and lose its balance. It is also strictly prohibited to use a hammer to hit the grinding wheel. Those smaller workpieces must be fixed with clamps. It is strictly forbidden to hold it directly with your hands. For a grinder, only one person is allowed to operate it. This can avoid mutual interference.
Positioning is really the key to saving your life. The operator must stand on the side of the grinding wheel in the direction of rotation to work, and must not stand directly opposite the radial line of the grinding wheel. It is strictly forbidden to reach out to touch or clean the table before the grinding wheel has completely stopped.
In 2025, there was a worker in a certain workshop. He reached out to wipe the iron filings while the grinding wheel was still spinning. As a result, three fingers on his right hand were cut off. He was later sent to the hospital and received 14 stitches.
Three steps to call it a day and don’t be lazy
After the grinding operation is completely completed, the power must be turned off first, and then the grinding wheel must stop rotating completely before cleaning up the iron filings and remaining coolant. When the size of the grinding wheel is worn to the limit diameter that can no longer be smaller, it must be replaced with a new one, and it must not continue to be used beyond the specified time.
A case that occurred in a certain company in 2024 showed that the company's grinding wheel had been used to the limit but was not replaced. As a result, a rupture occurred during the processing. The flying debris shattered the protective cover and scratched the workers at the adjacent work station.
At least once a week, you must check whether the grinding wheel is tight, whether the bearings are worn, and the condition of the cables. Inspection records must be kept. The distance between the rack where the grinding wheels are stored should not be less than 30 centimeters from the ground. Those grinding wheels that are damp must be dried before they can be used again. If the equipment is shut down for more than a month and then restarted, the insulation test and no-load test run must be carried out again.
Three steps to save yourself if something goes wrong, don’t hesitate
The sudden breakage of the grinding wheel will make people's first reaction be to retreat, lie down, or hide behind a solid cover to complete the action. This is very important. Never stare directly in the direction of the splash.
You need to immediately take a picture of the emergency stop switch, pull down the main power switch, and cordon off the specific area where the accident occurred to achieve spatial isolation. If someone shows symptoms of injury, the first step is to stop the bleeding and bandage it, and then call the emergency number 120. You must not move the injured parties by yourself.
If an electrical fire occurs, the overall power supply must be cut off immediately, and dry powder fire extinguishers or carbon dioxide fire extinguishers should be used to put out the fire. Water or foam fire extinguishers are absolutely not allowed to put out the fire. When facing an operating environment with combustible dust, explosion-proof motors and powerful dust extraction systems must be equipped. Once a large amount of dust clouds are gathered and sparks are generated, personnel must be evacuated immediately according to a pre-established plan. No hesitation is allowed.
The protective devices and emergency stop buttons of the grinders equipped in your workshop . Grinding Operation Safety Standards Grinding Operation Safety Standards. The full version of the workshop safety production operating procedures for grinders. When was the specific time of the last inspection? Now you are welcome to share and discuss in the message area below. If you think this suggestion is helpful and valuable, please help click the like button and forward this content to your colleagues who are working together.
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