PLT/Small Plant/TBT-PLT-015

Angle Grinder Safety

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Angle Grinder Safety

Toolbox Talk Record

Ref: TBT-PLT-015  |  Issue: 1  |  Date: March 2026
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What?

  • Angle grinders are one of the most versatile and most dangerous hand tools used on construction sites.
  • Disc breakage at high speed turns fragments into lethal projectiles travelling at over 100 mph.
  • The most common injuries are lacerations, eye injuries, disc burst injuries, and fire from sparks.
  • Guards must be correctly positioned to protect the operator and must never be removed.
  • Using the wrong disc type for the task causes disc failure and catastrophic breakage.
  • PUWER 1998 requires angle grinders to be suitable, maintained, and used by trained operators.
  • Kickback occurs when the disc jams in the material, throwing the grinder towards the operator.
  • Dead man switches must be functional — the grinder must stop when the trigger is released.
  • Noise from angle grinders exceeds 90 dB during most operations, requiring hearing protection.
  • Sparks from grinding travel up to 10 metres and ignite combustible materials including clothing.

Why?

Disc burst injuriesA shattering disc fires fragments at lethal speed into the operator and bystanders.
Laceration riskUnguarded or poorly controlled grinders cause deep cuts and near-amputations.
Fire hazardGrinding sparks travel far and ignite timber, insulation, and flammable materials.
Kickback dangerDisc jamming causes violent kickback that throws the grinder into the operator.
Do Don't
  • Inspect the grinder, disc, guard, and trigger before every use.
  • Use cutting discs for cutting and grinding discs for grinding only.
  • Ensure the guard is correctly positioned to protect from sparks and fragments.
  • Hold the grinder firmly with both hands and brace yourself against kickback.
  • Wear safety goggles, face shield, hearing protection, and gloves during use.
  • Check the disc maximum RPM rating matches or exceeds the grinder speed.
  • Clear combustible materials from the spark zone before starting work.
  • Allow the disc to reach full speed before applying it to the workpiece.
  • Disconnect the power before changing discs or adjusting the guard.
  • Let the disc stop completely before putting the grinder down.
  • DON'T remove or adjust the guard while the grinder is running.
  • DON'T use a cutting disc for grinding or a grinding disc for cutting.
  • DON'T use a disc that exceeds the grinder's maximum disc diameter.
  • DON'T operate a grinder with a defective dead man switch.
  • DON'T use a damaged, cracked, or warped disc — replace it immediately.
  • DON'T grind near combustible materials without clearing or protecting them.
  • DON'T force the disc into the material — let the tool do the work.
  • DON'T operate a grinder one-handed — always maintain a two-hand grip.
  • DON'T use an angle grinder without hearing and eye protection in place.
  • DON'T point the spark stream towards other workers, fuel, or gas cylinders.

See also: Disc Cutter and Cut-Off Saw Safety | Grinding and Cutting Safety
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