A two-minute inspection at the start of every shift catches almost every preventable abrasive-wheel failure. This checklist is the one we issue with every Abrasive Wheels Course certificate, designed to be printed, laminated and kept on the wall behind the grinder.
The pre-shift checklist
1. Power and isolation
- Power cord intact, no exposed conductors, no kinks at the strain relief.
- Plug top intact, earth pin straight.
- RCD or PRCD present and tested at the start of the shift.
- Emergency stop accessible and free-moving.
- Lockout / tagout devices available.
2. Machine condition
- Spindle rotates freely with no audible bearing roughness.
- Vibration is normal at idle.
- Mounting bolts tight (bench grinders especially).
- Switch operates smoothly, returns to off position.
- No oil or coolant leaks under the machine.
3. Guards and shields
- Peripheral guard fitted, secured, clean.
- Tool rest gap less than 3 mm (bench/pedestal grinders).
- Work shield/visor in place and clean (bench/pedestal grinders).
- Spark deflector in correct position.
- Side guard (where fitted) secure.
4. Wheel condition
- Marking visible and matches the task.
- Maximum RPM and surface speed printed.
- No visible chips, cracks or chemical staining.
- Resin-bonded wheels within their expiry date.
- Vitrified wheels: rings clean (in mid-shift wheel change).
- Outer flange seated, retaining nut tight, blotters present.
5. Operator PPE
- Wraparound impact-rated safety glasses to EN 166.
- Face shield available for hard masonry.
- Hearing protection (SNR 25+ minimum).
- FFP2 / FFP3 mask available for the day's tasks.
- Cut-resistant gloves for handling.
- Safety boots (S3 minimum).
- No loose clothing, jewellery or hair near the machine.
6. Work environment
- Floor clear of slip/trip hazards within 2 m of the grinder.
- Good lighting on the workpiece.
- Spark zone (10 m radius) clear of flammables.
- Fire extinguisher within arm's reach.
- Ventilation adequate; LEV operating where fitted.
7. Documentation
- Operator's Abrasive Wheels Certificate is current.
- Operator's written authorisation covers today's tasks.
- Risk assessment for the task is on file.
- Hot-work permit (if needed) is signed and posted.
Recording the inspection
For sites that maintain a daily register, an entry takes 30 seconds:
| Date | Operator | Machine | Wheel | Result | Initials |
|---|---|---|---|---|---|
| 10/05/2026 | J. Murphy | 9" angle grinder | 230 mm cutting disc, 6,600 rpm | Pass | JM |
What to do when something fails the inspection
- Stop. Isolate the power.
- Tag the machine "Do Not Use" with date, name and reason.
- Remove the affected wheel to the damaged-wheel quarantine.
- Notify the supervisor.
- Schedule the repair and re-inspect before returning to service.
Why a daily inspection beats a monthly one
Most failures happen between formal inspections. The pre-shift check is the only inspection that catches a chip introduced by yesterday's drop, a guard knocked loose by a bumped trolley, or a flange that has loosened over the weekend.
Train every operator to the same standard
The pre-shift checklist forms part of the practical module of our Abrasive Wheels Course. Every operator finishes with a copy of this checklist and a tested understanding of what each item means.
