Workers in a number of industries may be at risk of developing vibration injuries if the correct training and protective equipment is not provided, and welders are just one profession where workers may be at risk.
Due to the nature of the job, welders are required to use equipment such as grinders to to melt the edges of rigid materials together. However, grinders are handheld tools which can put you at risk of high levels of vibration exposure.
Excessive exposure to vibration can cause conditions such as Hand-Arm Vibration Syndrome (HAVS), Vibration White Finger (VWF), Whole Body Vibration (WBV) and Carpal Tunnel Syndrome (CTS) if the correct safety procedures and protective equipment are not worn.
In an interview, carried out by thefabricator.com, expert Adam Bujnowski answers questions on the best way to keep safe from vibration injuries when working as a welder.
The interview highlights that although safety has improved in these industries thanks to technology, like right-angle grinders with internal vibration-reduction systems and vibration-dampening gloves designed to reduce stress on the operator, risks are still prevalent.
“Emerging technology is on the horizon that will help operators manage the grinding vibration they receive by using wearable devices that monitor operator vibration exposure and help identify exposure thresholds,” said Adam Bujnowski, senior product safety engineer for Norton Saint-Gobain. “These significant improvements could have a tangible impact on an operator’s long-term safety.”
However, he explains that innovations won’t solve every safety concern, and operators can still be at risk if they don’t have sufficient training or ignore safety requirements.
In the interview, Adam goes back to basics to answer commonly asked questions on how to keep safe:
What are the most common questions you receive about abrasives safety?
Adam Bujnowski: The typical questions we commonly answer revolve around correct wheel usage. Am I using the right wheel, disc, or belt for the job? What is the correct operating speed? What is the product’s shelf life? Occasionally, a person wants to do something with the product or grinder that does not comply with ANSI or OSHA.
Fortunately, all these questions can be answered by contacting your manufacturer or Norton | Saint-Gobain Abrasives. Manufacturers develop abrasive grinding products to perform specific tasks on various materials, so reading and understanding the safety warnings is critical.
Before use, follow the safety guides provided with the abrasive product and the operation guide supplied with the grinder.
What PPE should operators use when grinding? Why?
AB: Most abrasive wheels, discs, and belts rotate at high speeds to effectively perform grinding. As a result, accidental contact with one of these products during operation may result in a critical injury.
One of the most important factors for safe grinding includes wearing appropriate PPE such as ANSI-rated eye and face protection, hearing protection, respiratory protection (type based on the material being ground), a protective leather or Kevlar apron, cut-resistant gloves, and safety shoes.
One common issue in the field is operators wearing welding masks and helmets that are not impact rated to ANSI Z87.1, Current Standard for Safety Glasses. Be sure the PPE you wear is of the correct type and rating.
What common injuries can result from not using right-angle grinders properly?
AB: When right-angle grinders are used properly with the correct protective equipment and guarding, they are very safe and efficient tools. However, if grinders are misused and PPE guidelines are not followed, they can cause severe injury.
Fractures and lacerations to the hands, face, and eyes are the most common. Long-term effects of vibration from powered hand tools include hand-arm vibration syndrome and back and shoulder injuries resulting from strain and overuse.
To minimize risks, be mindful of grinding ergonomics and take breaks during long stretches of operation. Prevent accidental startup of the machine during abrasive wheel changes or equipment repair and maintenance by disconnecting it from its power source.
What should be inspected on a wheel before use? Any red flags to keep an eye out for?
AB: Check all wheels for cracks or damage before use, as sometimes wheels can be damaged in storage. Don’t exceed the speed marked on the grinding wheel.
Check the grinder’s maximum operating speed against the established safe operating speed marked on the wheel; overspeed is the No. 1 leading cause of wheel failure. Use the side handle furnished with the grinder. Use all wheels at the proper grinding angles marked on them. Follow all symbols and warnings located on the wheel.
Review all applicable safety datasheets before using the product. Comply with ANSI B7.1, OSHA, and all safety materials provided with wheels and grinding tools. Don’t use wheels that have been dropped or otherwise damaged. And always handle and store grinding wheels carefully.
What about the grinders? What should be inspected before and after use? What is an ideal maintenance schedule for this equipment?
AB: Check your guard for wear or damage, and make sure you have the correct size and type of guard on your right-angle grinder. For example, if you have a type 1/41 wheel on your grinder, make sure the guard is suited to that cutoff wheel.
If your grinder comes with a side handle, it was designed to be used with two hands. Always inspect your machine’s auxiliary handle to ensure it is attached and adequately tightened, secure your workpiece, and use both hands on the grinder. And if possible, for best practices, measure the spindle on the machine with a tachometer once a month.
Run the wheel in a protected area, such as an empty 50-gal. steel drum, for one minute before grinding. Always maintain your tools as if your life depends on them.
Is there ever a time to remove or adjust a guard from its intended position on a tool?
AB: Most abrasive products (with some exceptions) require a guard. Guards have many functions, such as protecting the operator from an abrasive product’s breakage, deflecting sparks, collecting dust and swarf, and keeping body parts from encountering rotating abrasive products.
Always use the wheel guard furnished with the grinder, properly adjusted. A wheel guard set too high on a portable angle grinder will allow the wheel to hang below the guard. This improper setting may render the guard useless in the event of a wheel breakage.
On portable machines, position the guard so it is located between the operator and the grinding wheel. Make sure no bystanders are in front of the wheel guard’s open area to prevent injury if the wheel breaks.
If a wheel does break, inspect the guard and replace it if there is any sign of damage. Using a damaged wheel guard is extremely dangerous to the operator’s and bystanders’ safety. Guards that are cracked, deformed, bent, or severely worn may become ineffective in protecting against wheel breakage and must be replaced.
Further reading
Vibration injuries – Oakwood Solicitors
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Liam Hill is a Solicitor and Deputy Head of the Industrial Disease Team, having trained and qualified at Oakwood Solicitors. Liam joined us in 2013 after successfully completing the Legal Practice C…
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