Darwin Worker Nearly Dies After Angle Grinder Slashes Face and Throat During Renovations

Introduction
A 71-year-old man in Darwin has narrowly survived a life-threatening accident involving a large angle grinder while renovating an industrial shed. The incident occurred earlier this year in the suburb of Winnellie, where the worker was using a 230mm (9-inch) grinder to cut steel wall frames above his head while standing on a ladder. NT WorkSafe has issued a warning about the dangers of using such tools improperly, emphasizing the need for thorough risk assessments and safer practices.

This tragic near-miss underscores the risks associated with high-powered tools and highlights the importance of workplace safety protocols, particularly when working at height or with unstable equipment.

Details of the Incident
The victim, a 71-year-old man, was renovating an industrial shed when the accident occurred. Key details include:

• The worker initially used a smaller 127mm (5-inch) angle grinder but switched to the larger 230mm (9-inch) grinder to expedite the task.
• The metal frame being cut may have sagged due to previous cuts, pinching the grinder’s cutting disk and contributing to the kick-back.
• The worker was standing on a ladder, which compromised his stability and ability to control the powerful tool.
• The extension lead powering the grinder may have caused electrical fluctuations, leading to unexpected stops and starts that exacerbated the kick-back.

The grinder slashed the man’s face, throat, and sternum, requiring immediate medical attention. Fortunately, he survived the incident, but it serves as a stark reminder of the dangers posed by improper tool use.

Regulatory Actions and Findings
NT WorkSafe investigated the incident and issued a public warning about the risks of using large angle grinders. Key findings include:

• The increased power, torque, and size of 9-inch grinders make them more difficult to control compared to smaller tools.
• Workers should conduct a risk assessment to identify alternative tools or methods before using such grinders.
• Some companies in the Northern Territory and across Australia have implemented voluntary bans on 9-inch angle grinders due to the high number of serious injuries and fatalities associated with their use.

NT WorkSafe also highlighted the importance of proper footing and balance, securing items being cut to prevent sagging, and ensuring electrical leads match the power requirements of tools.

Broader Implications for Workplace Safety
This incident serves as a critical reminder of the potential consequences of neglecting safety protocols, especially when using high-risk tools. Key takeaways include:

• Conducting thorough risk assessments before using large or high-powered tools.
• Avoiding modifications to power tools or electrical leads, which can compromise safety.
• Ensuring workers are properly trained and equipped to handle equipment safely.
• Implementing safer alternatives to high-risk tools whenever possible.

Union representatives and safety experts stress that older workers, like the 71-year-old victim, may face additional challenges related to physical stability and reaction times, making adherence to safety guidelines even more critical.

Facility Details
The incident occurred at an industrial shed in Winnellie , a suburb of Darwin. The site was being renovated, requiring precise cuts to steel wall frames. The use of ladders and high-powered tools in such environments poses significant risks if proper precautions are not taken.