Equipment
Grinding Equipment
Tools and abrasive wheels used for grinding.
Documents
- 202518 Dec
LTI: Leg injury while using hand-held grinder
A worker cutting wood with a hand-held grinder suffered a serious calf injury when the tool slipped, struck the floor and bounced back. The flash discusses prompt power shutdown and medical care, tool suitability, omitted toolbox discussion and perceived time pressure behind choosing a grinder rather than a hand saw.
- 202414 Aug
Angle Grinder Finger Injury
A worker fractured their left little finger between a table and wrench while changing an angle grinder’s wire wheel. The flash identifies an incorrect method, absent formal training, missing impact-resistant gloves and failures in permits, risk assessment and supervision. Actions included revised assessment, formal training and review of supervisors’ responsibilities.
- 20234 Apr
Hand injury from portable grinder
A subcontract worker sustained a 3 cm hand laceration after inadvertently starting a portable grinder during flowline fabrication at a spool base. The flash identifies incorrectly positioned wheel protection, reduced grinder safety features and lower-protection gloves, and recommends guarding checks, consistent subcontractor equipment requirements and appropriate stop-work intervention.
- 2022Sep
CHIRP Maritime FEEDBACK 68 (September 2022)
Maritime incident digest examining unsafe work aloft, a timber-cargo overboard casualty, fatal crane-access falls, engine maintenance, navigation errors, tug capsizing and flooding, hot-fuel burns and an eye injury. Commentary addresses continuous harness connection, rescue planning, towage competence, watertight closures, maintenance programmes and accountability during permitted work.
- 202231 May
Near miss: grinder disc rotation set up in the wrong direction
A diver’s pre-operational checks identified reversed disc rotation on a GR29 underwater grinder modified for left-handed cutting, creating a risk of the cutting disc lock nut coming off. Work stopped and the tool was quarantined. The flash describes changing handle and guard orientation while retaining the original rotation direction.
- 202212 May
Explosion – hot work in a flammable atmosphere (Transport Malta)
A tanker explosion followed angle-grinder use to remove stubborn ramp bolts during dry-docking preparations. Sparks travelled towards a fuel-oil tank vent; nobody was injured. The flash examines perceived time pressure and unawareness of nearby flammable gases, and records refresher webinars reinforcing stop-work authority and improved work planning.
- 20212 Dec
Watch your hands!! Person injured while using an angle grinder
A crew member sustained severe left-arm lacerations while cutting washing-machine dunnage with an angle grinder fitted with a wood-cutting disc. Vessel movement preceded loss of control. The flash identifies absent guarding, unsecured timber and inadequate work preparation, and recommends suitable tools, risk assessment, toolbox talks and supervision.
- 20212 Feb
Injury to Fingers During Grinding Activity
An operator injured fingers on both hands after inadvertently restarting a grinder used to cut and shape wood during maintenance. Preliminary findings identified unsuitable tool selection, a non-recommended toothed saw blade and absent safety gloves. Actions included replacing button-controlled grinders with paddle-switch models, refresher training and reviewing the maintenance risk assessment.
- 202028 Sep
Deliberate failure to follow instructions: unsafe/quarantined tools brought back into use
A vessel inspection found crew using a quarantined selector-switch grinder because approved paddle-switch models were considered too bulky. The flash identifies unsecured quarantine storage and inadequate supervision. It recommends making quarantined devices temporarily unusable or locking them away, and reports a hazard hunt for selector-switch grinders.
- 202015 Sep
Hand injury from portable hand-held angle grinder
A worker cleaning equipment with a wire-brush angle grinder suffered a deep hand abrasion when the glove was drawn into the brush. The flash identifies an incomplete risk assessment, missing side grip, unsafe positioning, absent formal training and inadequate supervision, and records corrective actions addressing these shortcomings.
- 202025 Aug
Unsafe use of hand grinder with damaged disc
This flash reports use of a grinder with a damaged disc and the potential for serious projectile injuries. It identifies inadequate hazard awareness, gaps in task risk assessment and failure to embed earlier lessons. Actions include inspecting vessel grinders and discs, discarding damaged discs and refresher abrasive-wheel safety training.
- 2019Oct
MAIB Safety Digest 2/2019
A collection of marine accident lessons spanning merchant shipping, commercial fishing and recreational boating. Cases examine collisions, grounding, machinery failures, falls, fires and people overboard. Discussions emphasise passage planning, bridge teamwork, equipment maintenance, lifejackets, realistic recovery arrangements and emergency drills, with reproduced bulletins on vehicle-deck safety and retractable ballast securing.
- 20182 Oct
Grinding using a cutting disc
Seamen used cutting discs for grinding sea-fastening spots, causing discs to disintegrate and scatter pieces. Similar appearance and unusual thickness contributed to confusion despite warning markings. The flash identifies incorrect supply and absent checks, and describes stopping use, planned crew communication, careful selection and inspection, and purchasing requirements.
- 20172 Aug
Two cases of hand injuries – UK HSE
This flash reviews two HSE cases involving engineering firms: a hand injury during lathe polishing with emery cloth and gloves, and vibration-related symptoms among workers using powered hand tools. It highlights inadequate risk assessment, safe working guidance and training, alongside continued vibration exposure after symptoms arose.
- 2017Apr
MAIB Safety Digest 1/2017
A multi-case digest draws preventive lessons from merchant shipping, fishing and recreational boating accidents. It examines navigation, vessel flooding, fires, machinery injuries and people entering the water, with particular attention to unnecessary risk-taking, equipment suitability, maintenance, risk assessment and effective casualty recovery.
- 201618 Oct
Portable grinders – hand safety
An abrasive-wheel review during training aboard a chartered vessel identified significant faults with portable grinders requiring urgent attention. The flash highlights unsuitable and worn discs, recommends checking disc condition, size, type and rating before use, and states that abrasive wheels should be used only by trained, competent personnel.
- 20163 Oct
High potential near-miss incident: 440v cable damaged by grinder
During vessel mobilisation, a rigger/welder damaged a live 440 V cable while grinding aluminium protection covers in place over cables on the aft deck. The investigation identified inadequate task planning, permit coverage, risk assessment and toolbox communication, with no electrical isolation during work and delayed isolation afterwards.
- 201620 Sep
Fatal engine room fire on suction dredger Arco Avon
This flash summarises MAIB findings on a fatal engine-room fire aboard Arco Avon during sand loading. An engineer attempting fuel-pipe repair used a portable angle grinder before pressurised fuel ignited. Missing risk assessment and permit authorisation were identified as possible contributors to his underestimation of risk.
- 20161 Sep
Fire in the engine room on the suction dredger Arco Avon with loss of 1 life
Investigation of a fatal engine-room fire aboard Arco Avon during an attempted fuel-pipe repair. It identifies portable angle-grinder sparks as the probable ignition source and examines pipe fretting, hot-work controls, lone working, protective clothing, CO2 system operation and medical response. Recommendations address maintenance inspections and safety-management implementation.
- 201516 Jul
Poor storage leading to failure and disintegration of cutting discs
Several incidents involved cutting discs disintegrating during use. Manufacturer investigation identified inappropriate storage as the most likely root cause, with dampness degrading the resin binding bonded abrasives. The flash encourages reviewing disc storage and describes dry, frost-free conditions, protection and support to prevent damage and distortion.
- 201414 Jul
Punctured welding hose flash fire
An offshore vessel flash fire involved acetylene escaping from a damaged welding hose during air-operated grinding. No injuries occurred, and damage was limited to the hose. The account identifies poor hose protection and inadequate inspections, and describes suggested spark containment, maintenance inspections and a hose checklist incorporated into the permit-to-work process.
- 20144 Jun
Crewman suffered first aid injury during cutting operations
A crewman injured his right inner thigh when a hand grinder slipped during pipe bevel cutting. The investigation identified unsuitable scaffold adjustment and unstable positioning, despite fitted safeguards and correct PPE. Corrective actions addressed equipment and personnel positioning through training, toolbox talks and provision of a suitable working platform.
- 201325 Jun
Use of portable electrical deck equipment
This flash describes unsuitable ingress protection on portable electrical deck equipment and undersized replacement plugs on grinders, with potential overheating, burns or electric shock. Recommendations address minimum IP56 protection, use of more robust IP67 connectors, equipment checks, removal or correction of deficient equipment, and personnel awareness of electrical ratings.
- 20134 Apr
Explosion causing fatal injury during maintenance of Metocean buoy
A crewman suffered fatal injuries when grinder sparks ignited hydrogen inside a recovered metocean buoy, projecting instrument components outwards. Investigation identified corrosion, cracked battery cases, inadequate maintenance and unfulfilled purging procedures. The flash describes pressure equalisation, air or nitrogen purging, ignition restrictions and precautions against exposure to the compartment lid.
- 201225 Jun
Two recent incidents involving injuries
Two vessel incidents involved a crewman dropping an electric angle grinder after losing balance at the top of a ladder, cutting above his knee, and an engineer suffering finger lacerations when a compressor started. The compressor had not been isolated or tagged out because the task was considered a ‘two minute job’.
- 201220 Apr
Loss of Balance Results in Laceration to Leg from Grinder
An able seaman aboard a standby vessel lost his balance while using an electric grinder from the top of a ladder. The falling grinder cut his right leg above the knee, causing a 5 cm wound. Crew assistance and a platform doctor’s examination preceded referral to an onshore hospital.
- 201127 Oct
Grinding disc with defects
A welder identified a defective new grinding disc before use. Its steel inner ring appeared to have melted into the disc during manufacture, potentially allowing cracking during grinding and serious injury or damage. The flash highlights visual inspection of grinding equipment before and after use.
- 201129 Jun
Improper use of tools: bruising
A crewman used a grinding disc instead of the instructed wire wheel while preparing man-hole cover fasteners for inspection. The disc jammed and the grinder struck his shoulder, causing bruising and a minor abrasion. The flash highlights uncompleted risk assessments, disregarded instructions and absent task-specific training.
- 201021 Apr
Welding Operation Results in a Fire
During rig repairs in a shipyard, grinding sparks ignited a lightweight tarpaulin welding tent around a leg. A fire watchman attempted dry-powder suppression. The hydrant initially lacked water pressure; manually opening a fresh-water pump valve supplied the fire hose, allowing the fire to be extinguished.
- 200922 Apr
Fire in vertical lay system moonpool
A vessel moonpool fire occurred during pneumatic grinding of vertical lay system doors after flexible flowline recovery. Fall arrest equipment hindered the worker’s escape until a colleague released him. The flash identifies unrecognised flammable liquids and weaknesses in permit-to-work and risk assessment processes; fire teams controlled the incident without injury.
- 20052 May
Hand grinder injuries
Two portable-grinder incidents caused arm injuries following wheel binding and loss of two-handed control while a pipe slipped from its support. The flash highlights a removed stabilisation handle, recommends risk assessment, toolbox discussion and secure workpieces, and warns against reusing discs exposed to prolonged moisture or subsea use.
- 20051 Mar
Fatality: grinder incident
A welder died after an angle grinder wheel disintegrated during surface preparation for welding, sending fragments into his chest and abdomen. Investigation identified an incompatible cutting disc and missing guard. The flash highlights manufacturers’ instructions, wheel speed and diameter limits, guarding, careful handling and inspection before installation.
- 20051 Mar
Injury while grinding without PPE
A safety flash describes serious facial injury when a grinder wheel broke apart during cutting of an aluminium roof. The company identified an unsuitable wheel, missing grinder guard, absent face shield and ignored instructions. It reinforced correct tool selection, safe working practices and compliance with warning labels.
- 20043 Jun
Hazards Using Portable Powered Tools
The alert reports at least two recent instances of portable powered grinders or cutting wheels being used without guards at company sites. It identifies unguarded operation of these tools and saws as a regulatory breach and highlights deaths and serious injuries associated with unguarded tools in the oil and gas industry.
- 20031 Feb
Penetration injury to eye during blending repair weld
A boilermaker permanently lost vision in his left eye after a grinding-disc fragment penetrated his welding helmet during dragline repair-weld grinding. Preliminary findings identified restricted working space, suspected grinder jamming and possible lens substitution. Company actions included interim face-shield and safety-glasses requirements, helmet lens checks and workforce discussion.
- 20031 Jan
Punctured aerosol results in chemical burns
A technician preparing a lifting hook for inspection used a grinder with a wire brush cup. Projected particles or brush wires punctured a nearby paint-remover aerosol, spraying him and causing slight chemical burns. The contents did not ignite. The company reiterated returning aerosol cans to proper flammable storage before such work.
- 20028 Aug
Hand Grinder Incident Results in Arm Laceration
A safety alert describes an employee polishing a metal table with a hand-held pneumatic grinder. The grinding wheel became stuck in a table joint and broke off. The broken wheel struck the employee’s forearm, causing a laceration.
- 20028 Aug
Hand-Held Angle Grinder Injury
A rig welder modifying a rotary guard was dressing a weld with a hand-held angle grinder when its wheel shattered. A fragment struck his left leg below the knee, causing a two-inch cut requiring six stitches. The injury was classified as a restricted-work case.
- 20011 Jul
Grinding stone incident
A cup grinding stone burst while a pipe welder used a pneumatic grinder to bevel a pipe end, striking his shoulder. Investigation identified an unsuitable guard and incorrectly sized flange. The flash lists common abrasive-wheel mounting errors involving flanges, washers, tightening, cleanliness, arbour fit and blotters.
- 20012 Apr
Use of hand-held disc grinders
A worker died when a disc fractured during groove cutting in cast iron and a fragment penetrated his face shield. The flash identifies unsuitable disc size, application and speed rating, alongside removed guards and side handle. Lessons address manufacturer-approved consumables, guarding, tool suitability checks and adequately dimensioned face shields.
- 20019 Feb
Hand Grinder Incidents
Two handheld grinder accidents caused serious facial injuries through kickback. In the first, an electric grinder became entangled in a loose tarpaulin tie rope surrounding the workstation. In the second, a cutting disc snagged while cutting lengthways along a pipe held in a vice.
- 20005 Nov
Fatality: Cut – Off Wheel Fractures During Use
This alert describes a fatal injury during groove cutting in cast iron using an air-powered angle grinder fitted with a cut-off wheel. The wheel fractured in use, and a large fragment penetrated the worker’s face shield and entered their face.
- 20001 Jan
Grinding disc failures
This safety flash describes repeated grinding-disc failures aboard a member’s vessel. A newly fitted nine-inch disc fragmented during operation, narrowly missing two people, despite its speed rating exceeding the grinder’s. Further failures prompted withdrawal of the entire batch pending investigation; affected disc makes and sizes are identified.
- 1992
MAIB Safety Digest 2/1992
Marine accident summaries examine collisions, deteriorated ramp wires, engine-room fire, winch entanglement, grinding-disc failure and hatch-operation injuries. Separate fishing cases address vessel losses and liferaft deployment failures. Commentary discusses passage planning, supervised machinery operation, maintenance, firefighting training and access protection, alongside an appendix of investigations commenced during April–June 1992.
- 1990
MAIB Safety Digest 1/1990
Marine accident summaries examine collisions, groundings, flooding, fires, machinery failures and injuries aboard passenger, cargo and fishing vessels. Case comments address navigation, hot-work authorisation, dangerous-goods shipment, lifting adaptors, watertight arrangements and emergency preparedness. An appendix lists investigations commenced between July and December 1989; findings remain subject to correction.
- 198020 Jun
Safety Alert 98 - Flash Fire
An offshore production platform flash fire occurred when an air impact wrench connected to an instrument gas header exhausted gas that a nearby grinder ignited. A roustabout sustained slight burns. Quick-connect fittings were removed from the header, and signs identifying air and gas lines were planned.
- Undated
Platform Fire During Deck-Plating Replacement
BSEE investigates a platform fire during deck-plating replacement at HI A 379 B. Grinding sparks passed through fire blankets into a chemical storage area. The report examines conflicting hot-work documents, failure to remove flammable materials and inadequate pre-job discussion, alongside firefighting measures and a possible helicopter-related contribution.
- Undated
Fire During Plumbing Installation on Semi-Submersible Rig
Investigation of a fire during plumbing installation on the Diamond Ocean Valiant semi-submersible rig. Grinding sparks ignited stored flammable materials; damaged cutting hoses subsequently supplied fuel. The report identifies failures in fire-watch arrangements, combustible clearance and hot-work permit compliance, and describes firefighting under heavy smoke with repeated breathing-air depletion.
- Undated
Flash Fire During Vent and Drain Header Repairs
Investigation of a small flash fire during vent/drain header repairs on Platform A. Grinder sparks ignited residual hydrocarbons in a deck drain outside the immediate hot-work area. The report identifies inadequate preparation and spark containment, describes extinguishment and subsequent safeguards, and records no injuries, environmental impact or reported property damage.
- Undated
Thumb Laceration from Grinder During Compressor Bearing Replacement
BSEE investigates a thumb laceration during compressor bearing replacement at Devils Tower. A grinder fitted with a wire wheel slipped while removing gasket material. The worker received three sutures and returned to work the same day. Findings identify inadequate glove protection and omission of grinder use from the job safety analysis.
- Undated
Grinder Kickback Injures Hand During Pressure Safety Valve Replacement
An investigation describes a contractor’s hand injury while cutting mounting bolts during pressure safety valve replacement. A grinder used in restricted space bound, kicked back and shattered its cutting wheel. Findings examine tool selection, omitted job safety analysis, gloves and unused stop-work authority, noting that a limited torque clutch may have avoided kickback.
- Undated
Grinder Loss of Control Caused Hand Injury During Ladder-Cage Cutting
Investigation of a hand injury during ladder-cage cutting on the Boxer Platform. The worker lost control of a grinder after changing position and pulling it towards his body. Analysis identifies an unchanged guard orientation, unsuitable tool selection and a job safety analysis that omitted controls for changing the handle position.
- Undated
2009-028 Investigation of Fatality South Pass Area, South and East Additions, Block 90 Pipeline Right-of-Way OCS-G 26857, 18 July 2006, Gulf of Mexico, Off the Louisiana Coast.
Investigates a fatal crushing between pipe joints aboard the pipelay vessel Lorelay. The panel reconstructs grinding and conveyor operations, examines actuator controls and limit-switch interlocks, and leaves the initiating movement unexplained. Findings address deficient hazard analyses, task sequencing, supervision and formal training, with recommendations for additional protection and equipment checks.
- Undated
Silica: OSHA/NIOSH Hazard Alert - Worker Exposure to Silica during Countertop Manufacturing, Finishing and Installation
Joint OSHA and NIOSH hazard alert examines respirable crystalline silica exposure during natural and engineered stone countertop manufacture, finishing and installation. It compares exposure findings by stone type and task, and explains wet methods, local exhaust ventilation, exposure assessment, respiratory protection and medical surveillance alongside applicable OSHA requirements.