Grinding and Cutting Safety

Angle grinders, disc cutters, and abrasive cutting tools are among the most frequently used and most dangerous hand tools on site.
Disc bursts occur when a cutting or grinding disc shatters during use, sending fragments at ballistic speed into the operator.
A hot works permit is required for all grinding and cutting operations that produce sparks on construction sites.
The correct disc type and size must be used for the tool and the material — mismatched discs increase the risk of failure.
Guards must be fitted, correctly positioned, and secure before the tool is used — they deflect fragments and sparks from the operator.
Grinding and cutting generate silica dust from concrete and stone, welding fume from metal, and noise exceeding safe limits.
Kickback occurs when the disc binds in the cut, throwing the tool violently back towards the operator.
Sparks from grinding travel up to 10 metres and can ignite combustible materials in the surrounding area.
On-tool extraction or water suppression must be used when cutting concrete, stone, or masonry to control silica dust.
Operators must be trained in the specific tool being used and wear the correct PPE throughout the operation.

Disc burst	A shattered disc sends fragments at lethal speed — correct disc selection, guard positioning, and inspection prevent catastrophic failure.
Silica dust	Cutting concrete and stone without dust control generates dangerous silica dust — on-tool extraction is mandatory.
Fire from sparks	Grinding sparks travel far and retain heat — a hot works permit and combustible material clearance prevent fires.

Do

Don't

Use the correct disc type and maximum size for the tool and the material being cut.
Fit the guard correctly and check it is secure before switching on the tool.
Obtain a hot works permit before grinding or cutting operations that produce sparks.
Use on-tool extraction or water suppression when cutting concrete, stone, or masonry.
Wear safety goggles, hearing protection, gloves, and RPE as required for the task.
Inspect the disc before each use for chips, cracks, or damage that could cause failure.
Clear combustible materials from the area before starting grinding or cutting operations.
Allow the disc to reach full speed before applying it to the material being cut.
Secure the workpiece firmly — loose material causes kickback and loss of control.
Switch off and disconnect the tool before changing discs or adjusting guards.

DON'T use a disc that is the wrong type, wrong size, or rated below the tool's RPM.
DON'T operate a grinder without the guard fitted, positioned correctly, and secured.
DON'T grind or cut without a hot works permit where sparks are produced.
DON'T cut concrete or stone without dust extraction or water suppression in place.
DON'T use angle grinders without safety goggles, hearing protection, and gloves.
DON'T use a chipped, cracked, or damaged disc — replace it immediately before use.
DON'T grind near flammable materials without clearing the area first.
DON'T force the disc into the cut — let the tool speed do the work.
DON'T hold the workpiece in your hand while cutting — clamp or secure it properly.
DON'T change discs or adjust guards while the tool is connected to the power supply.

See also: Hot Works Permit Requirements | Disc Cutter / Cut-Off Saw Safety

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Toolbox Talk Record