Grinding SWMS

Grinding operations in metal fabrication include angle grinding, bench grinding, pedestal grinding, and belt sanding of welded joints, cut edges, and surface preparation. The primary hazard is disc or wheel burst, which can project fragments at lethal velocity. Metal dust generated during grinding contains the same constituents as the base metal — grinding stainless steel produces chromium and nickel dust, while grinding carbon steel weld preparations generates manganese-containing particles. Noise exposure from grinding typically exceeds 95 dB(A) and hand-arm vibration from sustained angle grinder use can cause vibration white finger. This template maps controls to the binding codes of practice effective 1 July 2026.

Legal Requirements

regulation

WHS Regulation 2025 Part 4.7 — Plant and Part 4.3 — Noise

hrcw category

General fabrication work with plant hazards

code of practice

Managing Risks of Plant in the Workplace, Managing Noise and Preventing Hearing Loss (binding 1 July 2026 under Section 26A)

section 26a binding

Yes — effective 1 July 2026. Non-compliance is admissible as evidence of breach.

Hazards

Hazard	Consequence	Likelihood
Disc or wheel burst projecting fragments at high velocity	Lacerations, eye loss, facial injuries, death	Unlikely
Metal dust inhalation containing manganese, chromium, or nickel	Chronic lung disease, cancer with carcinogenic metals	Likely
Noise exposure exceeding 95 dB(A)	Permanent noise-induced hearing loss	Almost Certain
Hand-arm vibration from sustained angle grinder use	Vibration white finger, carpal tunnel syndrome	Likely
Spark and hot particle projection	Burns, fire ignition of combustible materials	Likely
Entanglement of loose clothing or gloves in rotating disc	Lacerations, degloving injuries	Possible

Controls (Hierarchy of Controls)

Inspect all grinding discs and wheels before use and discard any showing damage or wear beyond limits

Ensure all grinders have guards correctly fitted and adjusted before operation

Provide local exhaust ventilation or on-tool dust extraction for all grinding operations

Issue Class 5 hearing protection and enforce mandatory use in grinding areas

Limit daily grinding exposure time to manage hand-arm vibration dose within action levels

Provide anti-vibration gloves and select low-vibration grinder models where available

Prohibit loose clothing, jewellery, and loose gloves near rotating grinding discs

Fit-test safety glasses with side shields and full-face shields for all grinding operations

Recent Prosecutions

Orica Australia Pty Ltd$1,200,000

Workers exposed to metal dust without adequate ventilation or health monitoring, resulting in occupational lung disease.

2024 — SafeWork NSW v Orica Australia Pty Ltd [2024]

KML Auto Parts Pty Ltd$375,000

Apprentice injured during metal working operations with inadequate training and supervision.

2022 — SafeWork NSW v KML Auto Parts Pty Ltd [2022]

What Your SWMS Must Include

✓Disc and wheel inspection procedure with rejection criteria

✓Guard fitment verification in pre-start checklist

✓Noise exposure assessment and hearing protection selection

✓Hand-arm vibration exposure management plan with daily time limits

✓Dust extraction requirements based on base metal composition

Need a compliant Grinding SWMS?

Our WHS consultants build task-specific SWMS that address disc burst, noise, vibration, and dust hazards for your grinding operations.