Angle Grinding — Safe Work Method Statement
Safe Work Method Statement for angle grinding operations including cutting, grinding, and surface preparation using handheld and bench-mounted angle grinders, in compliance with Australian WHS legislation and AS/NZS 4024.
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Angle grinder operations are one of the highest-frequency causes of serious injury in the Australian construction and manufacturing industries. Safe Work Australia data consistently identifies angle grinders as among the most hazardous portable power tools, with disc fracture, kickback, and loss of control causing lacerations, amputations, and eye injuries. The WHS Regulations require that plant be used in accordance with the manufacturer's instructions and that all guarding be kept in place — removing the guard from an angle grinder is both a criminal offence under the WHS Regulations and a leading cause of serious injury.
Angle grinding is not classified as High Risk Construction Work under the model WHS Regulations in itself, but it is routinely a component of HRCW activities including structural demolition, steel frame erection, and formwork work, and a SWMS is required in those contexts. Hot work permits must be issued for angle grinding wherever spark exclusion zones cannot be established, as sparks can travel up to 10 metres and remain hot enough to ignite combustible materials for several seconds after landing.
Disc selection is critical to safe operation. Every disc must be inspected for cracks or damage before fitting, must be rated for the angle grinder's maximum RPM (which must not exceed the disc's rated speed), and must be appropriate for the material being worked. Cutting discs must not be used for grinding side-loads, and grinding discs must not be used for cutting. Discs must be stored dry and protected from impacts. Flanges must be correctly sized and torqued, and the wheel guard must be positioned to deflect sparks and disc fragments away from the operator.
Customise this template by documenting the specific disc types and sizes to be used, the maximum grinder RPM, the materials to be worked, the spark exclusion zone dimensions, the hot work permit reference, and the PPE required including face shield standard (AS/NZS 1337) and hearing protection.
This SWMS applies in all Australian jurisdictions. Grinder-related safety is also addressed in Safe Work Australia's guidance on using angle grinders safely.
Personal Protective Equipment
High Risk Construction Work Types
- •Work in an area that may have a contaminated or flammable atmosphere
Risk Assessment
1.Disc and grinder inspection before use
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Disc disintegration causing projectile injuries | Catastrophic | Inspect all grinding and cutting discs before fitting for cracks, chips, delamination, or damage. Check the maximum RPM rating printed on the disc is equal to or greater than the grinder's no-load speed. Verify the disc has a current manufacture date (most discs expire 3 years from manufacture). Perform a ring test on vitrified wheels. Never use a disc that has been dropped or struck. Fit the correct flange and backing pad for the disc type. Conduct a 60-second test run at full speed in a protected area before commencing work. | Moderate | Operator |
| Electric shock or tool failure from damaged grinder | High | Inspect the grinder's body, power cord, plug, and guard before each use. Remove from service any grinder with damaged insulation, cracked housing, defective guard, or inoperable trigger safety switch. Ensure the grinder is connected via an RCD-protected circuit. Confirm the guard is correctly positioned to deflect sparks and fragments away from the operator. Never operate a grinder with the guard removed. Record and tag equipment that is removed from service. | Low | Operator |
2.Setting up the workpiece and work area
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Fire from grinding sparks igniting combustible materials | High | Clear all combustible materials (timber, cardboard, plastics, flammable liquids) within a 3-metre radius before grinding. Shield immovable combustibles with fire-resistant welding blankets. Identify any cable trays, plastic conduit, or pipe insulation that could be ignited. Position the workpiece so sparks are directed away from personnel and combustibles. Issue a hot work permit if grinding in an area with fire risk. Have a fire extinguisher accessible within 5 metres. | Moderate | Operator / Site Supervisor |
| Workpiece movement causing loss of control of grinder | High | Secure the workpiece using clamps, a vice, or by other positive mechanical means before grinding. Do not rely on another person to hold the workpiece during grinding. Ensure the work surface is stable and the workpiece cannot shift, rock, or fall during the operation. Set up cutting operations so cut-off pieces fall safely and do not trap or pinch the disc. Use appropriate work supports for long or heavy material. | Low | Operator |
3.Grinding and cutting operations
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Laceration or amputation from disc contact | Catastrophic | Maintain a two-handed firm grip on the grinder at all times using both the primary handle and the side handle. Never remove the side handle. Keep the grinder guard positioned between the disc and the operator's body at all times. Never use a cutting disc for grinding or vice versa. Do not use excessive force — allow the disc to do the work. Engage the disc spindle lock only when the disc has completely stopped rotating. Position bystanders outside the spark exclusion zone (minimum 3 metres). | Moderate | Operator |
| Hearing damage from sustained grinder noise | High | Angle grinders typically produce 95–105 dB(A). Hearing protection rated minimum SLC80 20 (earplugs or earmuffs) must be worn by the operator and all workers within 5 metres. Limit continuous grinding sessions to 30-minute intervals with 10-minute breaks away from the noise source. Where practicable, schedule high-noise grinding during times when fewer workers are nearby. Erect noise barriers for prolonged grinding operations. | Low | Operator / Site Supervisor |
| Silica dust inhalation during concrete or masonry grinding | High | When grinding concrete, masonry, or stone, use a diamond cup wheel with an integrated vacuum shroud connected to a HEPA-filtered dust extraction unit. As a minimum, wear a P2 respirator; if dry grinding without extraction is unavoidable, use a supplied-air respirator. Wet grinding with continuous water suppression is preferred where the tool and workpiece permit. Prohibit dry sweeping of grinding residue — use wet mopping or vacuum with HEPA filter. Establish a restricted entry zone to prevent unauthorised exposure. | Moderate | Operator / Safety Officer |
4.Post-operation cleanup and disc removal
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Burns from contact with hot workpiece or disc | Moderate | Allow the grinder disc and workpiece to cool before touching. Grinding discs can reach several hundred degrees Celsius during operation. Use thermal-indicating stickers or chalk on workpieces to confirm safe handling temperature. Do not place a hot grinder on or near flammable surfaces. Dispose of used or damaged grinding discs in a designated sharps/metal waste bin, not in general waste. Wear cut-resistant gloves when removing and handling used discs. | Low | Operator |
Relevant Codes of Practice
Worker Acknowledgement
By signing below, I confirm that I have read, understood and agree to comply with this Safe Work Method Statement.