Product Overview

Summary: This Grinding and Deburring Safe Operating Procedure sets out clear, safe methods for using grinders and deburring tools in Australian workplaces. It helps control the significant risks of flying particles, wheel failure, noise, vibration and manual handling while improving finish quality and productivity.

Grinding and deburring are routine tasks in metal fabrication, maintenance and construction, but they are also a common source of serious eye injuries, lacerations, burns and long-term hearing and vibration-related conditions. This Safe Operating Procedure provides a structured, step-by-step method for planning, setting up and carrying out grinding and deburring work using angle grinders, bench grinders, pedestal grinders and handheld deburring tools. It focuses on practical risk controls that align with Australian WHS legislation and recognised industry standards, making it easier for you to demonstrate due diligence.

The document helps businesses move away from informal, “this is how we’ve always done it” practices to a consistent, documented approach that protects workers and equipment. It addresses selection and inspection of grinding wheels and consumables, guarding requirements, safe body positioning, control of sparks and hot work risks, housekeeping, and correct shutdown and maintenance processes. By implementing this SOP, organisations can lift the quality of finished components, reduce rework and downtime, and provide clear guidance for training new workers and apprentices in safe grinding and deburring techniques.

Key Benefits

• Reduce the risk of eye injuries, cuts, burns and other incidents associated with grinding and deburring tasks.
• Ensure compliance with Australian WHS legislation and relevant standards for plant, PPE, noise and hazardous manual tasks.
• Standardise grinding and deburring techniques across teams, improving finish quality and reducing rework.
• Extend the life of grinding wheels, discs and equipment through correct selection, inspection and use.
• Support effective onboarding and refresher training with clear, step-by-step instructions and responsibilities.

Who is this for?

• Fabrication Supervisors
• Workshop Managers
• Boilermakers
• Metal Fabricators
• Maintenance Fitters
• Apprentices and Trade Assistants
• WHS Managers and Advisors
• Production Managers
• Engineering Managers
• Site Supervisors (Construction and Manufacturing)

Hazards Addressed

• Eye and face injuries from flying sparks, metal fragments and shattered grinding wheels
• Lacerations and crush injuries from contact with rotating wheels and discs
• Burns from hot work, sparks, and heated workpieces
• Inhalation of metal dusts, fumes and grinding residues
• Noise-induced hearing loss from prolonged exposure to high noise levels
• Hand–arm vibration syndrome from extended use of vibrating tools
• Fire and explosion risks from sparks near flammable materials or vapours
• Electric shock from damaged cords, plugs or poorly maintained equipment
• Manual handling injuries from awkward postures, forceful exertions and handling heavy components
• Slips, trips and falls caused by offcuts, swarf, leads and poor housekeeping in grinding areas

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Equipment Types (Angle, Bench and Pedestal Grinders, Deburring Tools)
• 3.0 Roles and Responsibilities
• 4.0 Competency, Training and Authorisation Requirements
• 5.0 Required PPE and Safety Equipment
• 6.0 Pre-Use Inspection of Grinders, Guards, Leads and Accessories
• 7.0 Selection and Handling of Grinding Wheels, Discs and Deburring Tools
• 8.0 Workspace Setup, Housekeeping and Control of Sparks
• 9.0 Step-by-Step Grinding Procedure
• 10.0 Step-by-Step Deburring Procedure
• 11.0 Hazard Identification and Risk Control Measures
• 12.0 Noise, Vibration and Dust Control Requirements
• 13.0 Hot Work, Fire Prevention and Permits (Where Applicable)
• 14.0 Lockout, Tagout and Isolation for Maintenance and Wheel Changes
• 15.0 Emergency Procedures and Incident Response
• 16.0 Inspection, Maintenance and Storage of Equipment
• 17.0 Recordkeeping, Monitoring and Review of the SOP

Legislation & References

• Work Health and Safety Act 2011 (Cth and harmonised state/territory variants)
• Work Health and Safety Regulations 2011 (Cth and harmonised state/territory variants)
• Safe Work Australia – Code of Practice: Managing risks of plant in the workplace
• Safe Work Australia – Code of Practice: Managing noise and preventing hearing loss at work
• Safe Work Australia – Code of Practice: Hazardous manual tasks
• AS/NZS 4024 series: Safety of machinery
• AS/NZS 1337.1: Personal eye protection
• AS/NZS 2161 series: Occupational protective gloves
• AS/NZS 1270: Acoustics – Hearing protectors
• AS/NZS 3000: Electrical installations (Wiring Rules)