A contract welder suffered a serious facial injury while using a grinder to remove slag from a weld. As he began grinding, the grinder kicked back when it hit a protruding bolt, causing the grinding disk to make contact with his face. An investigation found that while he was trained and authorized for the task, he was not following the safe method of work and was only wearing safety glasses instead of a required face visor. To prevent future incidents, recommendations included delivering toolbox talks on safe grinding positions and enforcing the PPE standard requiring a visor for all grinding.

1. British Steel Learning From Events 1
Works Area: Steelmaking
Date of incident: 17/10/2016
Business Unit: BOS Plant
Type of incident: Recordable Injury
Event – Serious facial Injury during grinding activity
Findings
• T
• A Contract Welder was working as part of the structural team on the Vessel 3
recommissioning project.
• He was using a 4.5” (110 Volt) grinder to remove some slag from a butt weld
on a box beam.
• As he commenced the grinding task, the grinder body contacted with a
protruding bolt head on the box beam and caused the grinder to kick back
towards his face.
• The unexpected movement from the grinder kick back caused the rotating
grinding disk to make contact with his face causing a deep laceration to the
left cheek which required 10 stitches.
• The individual was working in a standing position with the grinder at shoulder
height with some access limitations to the box beam he was working on.
• The grinder was in good working with the relevant test certification.
• The individual is a trained & competent Welder with 8 years' experience. He
was authorised for the task he was undertaking & uses grinders regularly.
• The individual was wearing safety spectacles. A full face visor was available at
the point of work but was not used.
• The safe method of work for the task was clear, understood but was not
followed
• The safety spectacles were marked by the grinding disk indicating that they
prevented further, serious eye damage.
• Deliver a brief/toolbox talk to all grinder users to include:
• Safe body position when grinding
• PPE standard – Visor or Screen MUST be used for all
grinding activities.
• Use positive safety conversations and audit processes to ensure
compliance for correct use of hand/electrical tools and PPE for the
task
• Clarify, confirm and communicate the British Steel eye and face
protection standard when undertaking grinding activities across
other areas of the business.
Recommendations / Actions
Mark left by grinding disk
on safety glasses