Original article

Orthopedic injuries caused by angle grinders: a case series from a hospital in Popayán, Colombia

Lesiones ortopédicas causadas por máquinas pulidoras: serie de casos en un hospital de Popayán, Colombia

Juan Manuel Concha-Sandoval1,2 Daniel Ricardo Dueñas-López2 Emily Yurani Delgado-Gaviria2 Valentina Fajardo-Ruíz2 Diego Alejandro Goyes-Burbano2 Daneyi Andrea Gallardo-Lame2 Angélica Sofia Fernández-Erazo2

1 Susana López Hospital in Valencia, Department of Orthopedics and Traumatology, Popayán, Colombia.

2 Universidad del Cauca, Faculty of Health Sciences, Popayán, Colombia.

Open access

Received: 10/07/2025

Accepted: 06/18/2026

Correspondence: Juan Manuel Concha-Sandoval. University of Cauca, School of Health. Email: juanconcha@unicauca.edu.co

How to cite: Concha-Sandoval JM, Dueñas-López DR, Delgado-Gaviria EY, Fajardo-Ruíz V, Goyes-Burbano DA, Gallardo-Lame DA, et al. Orthopedic injuries caused by angle grinders: a case series from a hospital in Popayán, Colombia. Rev. colomb. ortop. traumatol. 2026; 40: e659. https://doi.org/10.58814/01208845.659

Cómo citar: Concha-Sandoval JM, Dueñas-López DR, Delgado-Gaviria EY, Fajardo-Ruíz V, Goyes-Burbano DA, Gallardo-Lame DA, et al. [Lesiones ortopédicas causadas por máquinas pulidoras: serie de casos en un hospital de Popayán, Colombia]. Rev. colomb. ortop. traumatol. 2026; 40: e659. https://doi.org/10.58814/01208845.659

Copyright: ©2026 The Author(s). This is an open access article distributed under the terms of the Creative Commons Attribution 4.0 International License, which permits unrestricted use, distribution, and reproduction in any medium, as long as the original author and source are credited.

Abstract

Introduction: Angle grinders are commonly used in occupational and domestic settings; however, inappropriate use may cause severe extremity injuries, especially to the hands and fingers.

Objective: To describe the clinical and epidemiological characteristics of orthopedic injuries caused by angle grinders, as well as associated risk factors, in patients treated at a referral hospital in Popayán, Colombia.

Methodology: A prospective descriptive case series was conducted between February 2024 and February 2025 at Hospital Susana López de Valencia in Popayán, Colombia. All patients with extremity injuries related to angle grinder use were included. Data collected included demographic and occupational variables, accident circumstances, use of personal protective equipment, tool modifications, material being cut, and anatomical characteristics of the injuries, including fractures and amputations.

Results: A total of 28 male patients were included, with a mean age of 42.30 years. The most affected age group was 40-49 years (28.60%). Most patients were manual workers from people belonging to socioeconomic stratum 1 (the lowest socioeconomic level in Colombia) (78.60%). Accidents occurred mainly at home (64.30%), in the afternoon (57.10%), and involved modified machines in 50% of cases. Nearly half of the patients (46.40%) did not use personal protective equipment. Wood was the most frequently involved material (89.30%). Injuries predominantly affected the left upper limb (50%), especially the hand and fingers (42.80%). Fractures were identified in 8 patients (28.60%), all involving phalanges, and seven amputations of hand digits (25%) were documented.

Conclusion: Angle grinder injuries mainly affect adult male manual workers, occurring mainly in domestic settings and frequently associated with a lack of personal protection. Use on wood, equipment modification, and absence of protective gear were identified as key risk factors. These findings underscore the importance of preventive and educational strategies.

Keywords: Accidental Injuries; Wounds and Injuries; Hand Injuries; Fractures, Bone; Amputation, Traumatic (MeSH).

Resumen

Introducción: las máquinas pulidoras son herramientas de uso frecuente en ámbitos laborales y domésticos; sin embargo, su utilización inadecuada puede causar lesiones graves en las extremidades, especialmente en manos y dedos.

Objetivo: describir las características clínicas, sociodemográficas y del accidente en pacientes con lesiones ortopédicas causadas por máquinas pulidoras, atendidos en un hospital de Popayán, Colombia.

Metodología: serie de casos de pacientes con lesiones secundarias al uso de máquinas pulidoras atendidos entre febrero de 2024 y febrero de 2025 en el Hospital Susana López de Valencia. Mediante la aplicación de un cuestionario ad hoc, se recolectaron datos de variables sociodemográficas y clínicas, así como información sobre el accidente.

Resultados: se analizaron 28 pacientes, todos de sexo masculino, con edad promedio de 42,30 años. El grupo etario más afectado fue el de 40-49 años (28,60%). La mayoría eran trabajadores manuales de estrato socioeconómico 1 (78,60%). Los accidentes ocurrieron principalmente en el hogar (64,30%), durante la tarde (57,10%) y con máquinas modificadas en el 50% de los casos. El 46,40% no utilizaba elementos de protección personal. El material más frecuente fue la madera (89,30%). Las lesiones comprometieron sobre todo el miembro superior izquierdo (50%), destacando la mano y los dedos (42,80%). Se documentaron fracturas en 8 pacientes (28,60%), todas en falanges, y 7 amputaciones a nivel de los dedos de la mano (25%).

Conclusión: las lesiones por máquinas pulidoras afectaron a hombres adultos trabajadores manuales, principalmente en contextos domiciliarios, con máquinas modificadas, al cortar madera y en ausencia de elementos de protección. Estos hallazgos resaltan la necesidad de estrategias preventivas y educativas.

Palabras clave: Lesiones Accidentales; Heridas y Lesiones; Traumatismos de la Mano; Fracturas Óseas; Amputación Traumática (DeCS).

Introduction

Grinding machines are widely used tools in both professional and domestic settings; they are used to cut or grind metal, wood, or stone surfaces. These machines consist of a motor that drives a cutting disc at high speed (Figure 1) and can cause serious injuries to the musculoskeletal system, resulting in varying degrees of disability and permanent sequelae.1-3 Various publications highlight the severity of these accidents and their association with operator inexperience or modifications made to the tool.1–3 Thus, the objective of this study was to describe the clinical, sociodemographic, and accident-related characteristics of patients with orthopedic injuries caused by polishing machines who were treated at a hospital in Popayán, Colombia.

Figure 1. Polishing machine and its parts.

Source: Created by the authors using a generative AI tool, under the authors’ supervision and with their editing.

Methodology

Study design, population, and sample

Retrospective case series with data collected from medical records and an ad hoc questionnaire. The study population consisted of patients with injuries resulting from the use of polishing machines who were treated between February 1, 2024, and February 1, 2025, at the Susana López de Valencia Hospital (second-level care) in Popayán, Colombia (N=28). Patients with injuries to the extremities caused by this type of machine who agreed to participate in the study by signing an informed consent form were included. Patients who, for administrative reasons, were not treated at the hospital and were referred to other institutions were exclude.

Procedures and Variables

Patients were identified consecutively during their care by the orthopedics and traumatology department at Susana López Hospital in Valencia. The ad hoc questionnaire was administered in person during the same hospitalization episode, once the patient was clinically stable and had provided consent to participate in the study. The questionnaire was administered on an individual basis as participants were seen throughout the study period. No telephone contact was made, nor were participants given a separate appointment solely for the purpose of completing the questionnaire. Clinical information related to the injury was supplemented with data from the medical record and the findings of the orthopedic evaluation.

The questionnaire collected information on the following variables: sex, age, occupation, municipality or city of residence, socioeconomic status, dominant hand, side of the injury caused by the polisher, and affected limb and region (upper limb: arm, forearm, or hand; lower limb: thigh, leg, or foot), presence of fractures or tendon injuries associated with the accident, need for amputation, day and time (morning, afternoon, or evening) of the accident, location of the accident, presence of modifications to the polishing machine, use of personal protective equipment at the time of the accident (gloves, goggles or face shield, work clothes, and boots), material being worked on at the time of the accident, and prior experience with the machine.

Statistical Analysis

Data analysis was performed using descriptive statistics. The distribution of the quantitative variable “age” was assessed using the Shapiro-Wilk normality test, and upon confirming its symmetric distribution, it was reported using the mean and its corresponding standard deviation. Qualitative variables, meanwhile, were expressed in absolute frequencies and frequencies.

Ethical Considerations

The study adhered to the ethical principles for conducting biomedical research involving human subjects as set forth in the Declaration of Helsinki4 and the scientific, technical, and administrative standards for health research established in Resolution 8430 of 1993,5 issued by the Colombian Ministry of Health. The study was approved by the Research Ethics Committee of the Susana López de Valencia E.S.E. Hospital at its meeting on February 27, 2024, Minutes No. 01-2024, with identification code 1900100023PYIDI20230004. The certification was issued on February 29, 2024. All patients were informed of their inclusion in the study, and their informed consent was obtained. The anonymity of their clinical data was maintained throughout the research.

Results

Based on the established criteria, 28 patients with limb injuries caused by polishing machines were identified, as shown in the following sample selection flowchart (Figure 2).

Figure 2. Sample selection flowchart.

Source: Own elaboration.

All patients were male. The average age was 42.30 years (SD: 13.90; range: 20-67 years). The most common age groups were 40-49 years and 50-59 years, with 7 patients in each group (25%). Regarding occupation, all were manual laborers. In terms of socioeconomic status, the majority belonged to stratum 1 (78.57%). The most common place of residence was Popayán (46.43%), followed by El Tambo (17.86%) (Table 1).

Furthermore, 26 patients (92.86%) were right-handed. Injuries caused by polishing machines primarily affected the left upper limb (50%), followed by the right upper limb (25%) and the left lower limb (17.86%). The most affected anatomical region was the hand and fingers (42.86%), followed by the leg (14.28%) (Table 1) (Figure 3).

Figure 3. Polisher injury in a 40-year-old patient affecting the fifth finger of the right hand.

Source: Image obtained during the treatment of one of the patients included in the study.

Fractures were identified in 8 patients (28.57%), all of which were in the phalanges of the fingers. In addition, 7 cases of finger amputation were documented (25%), all at the level of the proximal interphalangeal joint: 4 in the left hand and 3 in the right; 4 involved the index finger and 3 the middle finger. As for tendon injuries, these occurred in 15 cases (53.57%): 10 involved extensor tendons on the back of the hand (zones V and VI); 4 involved flexor tendons in zone II; and 1 involved the quadriceps femoris at the left knee (Table 1) (Figure 4).

Table 1. Sociodemographic and clinical characteristics of patients with injuries caused by polishing machines (n=28).

Variable	n	%
Sex
Male	28	100
Age group (years)
18-29	5	17,86
30-39	6	21,43
40-49	7	25
50-59	7	25
≥60	3	10,61
Occupation
Manual laborers	28	100
Socioeconomic stratum
Stratum 1	22	78,57
Stratum 2	5	17,90
Stratum 3	1	3,60
Municipality or city of residence
Popayán	13	46,43
El Tambo	5	17,86
Piendamó	2	7,10
La Vega	2	7,10
Taminango	1	3,57
Puracé	1	3,57
Bordo	1	3,57
Almaguer	1	3,57
Totoró	1	3,57
Toribío	1	3,57
Dominant hand
Right	26	92,90
Left	2	7,10
Laterality of the polishing-machine injury
Left	19	67,86
Right	9	32,14
Affected limb
Left upper limb	14	50
Right upper limb	7	25
Left lower limb	5	17,86
Right lower limb	2	7,14
Anatomical región affected
Hand and fingersa	12	42,86
Leg	5	17,86
Forearm	4	14,29
Arm	2	7,14
Wrist	2	7,14
Shoulder	1	3,57
Hip	1	3,57
Thigh	1	3,57
Knee	1	3,57
Presence of fractures
Yes	8	28,57
No
Presence of fractures
Yes	15	53,57
No
Amputation
Yes	7	25
No	21	75

aThe categories are not mutually exclusive, as some patients were involved in more than one anatomical region. The percentages were calculated based on the total number of patients included in the study (n=28).

Source: Own elaboration.

Figure 4. Anatomical areas affected by injuries caused by a polishing machine. A. Number of injuries by affected body part. B. Number of injuries by affected part of the hand.

Source: created by the authors with the assistance of artificial intelligence, under the authors’ supervision and editing.

Regarding the characteristics of the accidents, they occurred most frequently on Wednesdays (25%) and Sundays (17.86%), predominantly in the afternoon (57.10%). The most common location of the accidents was the home (64.30%), followed by the workplace (32.10%) (Table 2).

Table 2. Characteristics of the accident involving a polishing machine.

Variable	n	%
Day the accident ocurred
Monday	4	14,30
Tuesday	4	14,30
Wednesday	7	25
Thursday	4	14,30
Friday	3	10,70
Saturday	1	3,60
Sunday	5	17,80
Time of day
Morning	12	42,90
Afternoon	16	57,10
Night	0	0
Place where the accident ocurred
Work	9	32,10
Home	18	64,30
Other location	1	3,6
Machine modifications (n=14)
Removal of safety guard	14	100
Disc replacement	14	100
Use of personal protective equipment
None	13	46,40
Partial	9	32,10
Complete	6	21,40
Cutting material involved at the time of the accident
Wood	25	89,30
Metal	3	10,70
Prior experience with the machines and knowledge of the manual
No prior experience of knowledge of the manual	17	60,70
Prior experience, but no knowledge of the manual or training in machine use	6	21,40
Prior experience with the machine and knowledge of the operating manual	5	17,90

Source: Own elaboration.

Modifications to the polishing machine were documented in 50% of the cases. These modifications consisted of removing the guard and replacing the original cutting disc in 14 cases (Figure 5). In addition, most patients reported that they were not using any personal protective equipment at the time of the accident (46.40%), while 32.10% reported using partial protection (mainly safety glasses). The most common cutting material involved was wood (89.30%). Finally, 60.70% of the patients had no prior experience using the tool, nor did they have any knowledge of how it worked or of the safety recommendations.

Figure 5. The most common modification to the polishing machine found in the study: removal of the safety guard and replacement of the original disc.

Source: Created by the authors with the assistance of artificial intelligence, under the authors’ supervision and editing.

Discussion

Demographics of the Injuries

Injuries caused by polishing machines constitute a global public health problem.1-3 In the present study, all affected patients were men, which is consistent with the findings reported by Taboadela et al.6 in their series of 928 patients in Argentina (99.13%, 920 men), Acar et al.7 in a study of 79 patients in Turkey (100% men), and Al-Thani et al.8 in a series of 127 patients in Qatar (100% men).

The average age in the study population was 42.30 years (SD: 13.90), comparable to that reported at other trauma centers, such as the studies by Sozbilen et al.2 (42.30 years), Taboadela et al.6 (42 years), and Al-Thani et al.8 (34.90 years), confirming that these injuries primarily affect adults of working age. A crucial finding that underscores the risk of using this tool outside a regulated environment is the location of the accident; the present study determined that the home was the most common site (64.30%). This finding is consistent with the international literature, which reports that most cases are not occupational accidents. For example, Arik et al.9 reported in 2021 that 65% of accidents occurred in the home or garden, and Sozbilen et al.2 found that 74 of 82 cases (approximately 90%) occurred outside the workplace, often while performing minor household tasks. In this case series, the predominance of accidents in the home suggests that domestic use of the tool represents a significant source of injury, especially when combined with a lack of training, the absence of personal protective equipment, or modifications to the machine.

Risk Factors: Inexperience, Modification, and Protection

The following section addresses the risk factors for accidents involving this type of machinery and lists the findings identified at the evaluated medical center, which directly reflect the unsafe usage patterns described worldwide, highlighting the need to implement preventive measures.

Lack of experience and training

In this study, a lack of experience and unfamiliarity with the machine’s operating manual were observed in 60% of cases. The literature consistently highlights the importance of training. For example, Sozbilen et al.2 found that injury severity was higher in individuals with less than five years of experience, suggesting that inexperience increases the likelihood of serious injuries. Furthermore, in 2022, Asikin et al.10 reported a series of 13 patients with no training in the use of the tool who sustained injuries from a polisher during the lockdown caused by the COVID-19 pandemic. In this regard, the relationship between the prevalence of accidents at home and the machine operator’s lack of experience is evident, underscoring the importance of not using polishers under such conditions.

Tool Modification

Fifty percent of the polishing machines in the study had been modified, primarily by removing the safety guard and replacing the original cutting disc; this practice is a critical and well-documented risk factor. Arik et al.9 reported that in 53% of the cases analyzed, the disc guard had been removed. Removing the disc guard and improper use of the tool violate basic safety recommendations, such as keeping the guard installed and positioned between the disc and the operator. These practices, along with sudden entanglement or jamming of the disc during cutting, increase the risk of loss of control and kickback.13

Use of Personal Protective Equipment

In this series, 46.40% of patients did not use any protective equipment. This rate of inadequate use is consistent with other cohorts, such as that of Taboadela et al.,6 who reported that only 22.40% of their patients were using personal protective equipment at the time of the accident. The use of these items is crucial, as a direct correlation has been found between the use of protective gloves and less severe injuries.7

The Risks of Wood Cutting

In this study, wood cutting was the activity involved in 89.30% of cases. This percentage is notably high and aligns with recent research warning that cutting firewood is not an appropriate use for an angle grinder.9,11 In the study by Tsumura et al.,11 wood cutting was the leading cause of serious injuries. Similarly, Taboadela et al.6 found that 84.50% of their patients were cutting wood or firewood at the time of the accident and noted that performing tasks for which the tool was not designed constitutes the most significant risk factor. Likewise, Arik et al.9 found that 75% of the injuries involved cutting wood materials. The reason for this risk lies in the kickback mechanism (Figure 6), which occurs when the blade suddenly becomes jammed in the material, particularly wood, forcing the tool to snap back toward the operator and causing deep, severe injuries.

Figure 6. Kickback mechanism that occurs when the blade suddenly gets stuck in the material (particularly wood), causing the tool to swing toward the operator.

Source: Created by the authors with the assistance of artificial intelligence, under the authors’ supervision and editing.

Injury Patterns and Severity

The left upper extremity (50%) was the most affected in the sample of predominantly right-handed patients (92.90%), which is consistent with most studies reporting injuries on the non-dominant side (left hand affected in 62.07%–76%).6,9 This pattern is explained by the fact that the non-dominant hand typically holds the workpiece and is therefore more exposed to tool kickback. The most affected anatomical region was the hand and fingers, a finding consistent with previous series of injuries caused by polishing machines, which have reported a predominance of injuries to the hand, fingers, and forearm.2,6,7

Regarding tendon injuries, injuries to the extensor tendons on the back of the hand, in zones V and VI, were observed in 10 cases, representing the most common pattern of tendon injury in this study. Acar et al.7 and Taboadela et al.6 also identified the extensor tendon as the most injured structure; however, these studies also noted a considerable frequency of flexor tendon injuries.

Furthermore, the high rate of fractures (28.60%) and amputations (25% in 7 cases), all at the level of the finger phalanges, underscores the severity of these injuries and may be related to the disc’s high rotational speed (6,000–15,000 rpm). Taboadela et al.6 reported that 15.50% of their patients suffered traumatic amputations in previous series of injuries caused by hand-held polishing machines to the hand and forearm; the use of severity scales such as the Modified Hand Injury Severity Score (MHISS) and the Hand Injury Severity Score (HISS) has made it possible to classify a significant proportion of these injuries as moderate, severe, or major.2,4,6 This results in significant costs and considerable morbidity associated with the treatment of these complex injuries.1 Table 3 provides a descriptive overview of some published studies on injuries related to polishing machines, including country, study design, sample size, anatomical region evaluated, and main reported outcomes.

Table 3. Comparison of publications on injuries related to polishing machines.

Study	Country	Study design	n	Population/Anatomical region	Relevant finding
Curran et al.1	Ireland	Case series + literature review	3	Various orthopedic injuries	Describes severe musculoskeletal injuries from improper tool use, with high morbidity and substantial hospital resource consumption
Sözbilen et al.2	Turkey	One-year prospective study	82	Hand and forearm	Most injuries were non-occupational; they occurred frequently outside of work, including at home. Injuries were often severe, with high resulting disability; MHISS was used.a
Taboadela et al.6	Argentina	Descriptive retrospective study	928	Hand and fingers	Large case series. Predominance of young/adult men (mean age 42 years), low PPE use (22.40%), injuries more frequent in the non-dominant hand (55%), and variable severity according to HISS.b
Acar et al.7	Turkey	Retrospective study	79	Hand and forearm	All patients were male; the most frequently injured area was the dorsum of the hand, and the most affected structures were the extensor tendons. An association was found between glove use and lower severity according to MHISS.a
Al-Thani et al.8	Qatar	10-year retrospective hospital study	127	Polisher-related injuries in hospitalized patients, multiple anatomical regions	All vascular injuries in one-third, nerve injuries in 23.60%, and amputations in 9.40%.
Tsumura et al.11	Japan	Retrospective study	15	Injuries from using a grinder to cut wood	Nine of 15 patients used the tool inappropriately to cut wood; the main mechanisms were kickback and entanglement with a glove. Complete/partial amputations and tendon injuries with fracture were documented.
Asikiny & Razip10	Malaysia	Case series	13	Upper and lower limb	During the pandemic, cases increased among untrained individuals and in non-occupational settings. Among the 7 non-occupational cases, there were lacerations, open fractures, partial amputation, degloving, and tendon injuries.
Present study	Colombia	Descriptive case series	28	Limbs; predominantly hand and fingers	All patients were male, mean age 41 years, mostly manual laborers of stratum 1. Accidents predominantly occurred at home, in the afternoon, involving wood, tool modification, and absence of PPE.c Phalangeal fractures, digital amputations, and tendon injuries were documented.

aMHISS: Modified Hand Injury Severity Score.

bHISS: Hand Injury Severity Score.

cPPE: Personal Protective Equipment.

Source: Own elaboration.

Finally, the study’s limitations include the small number of cases and the lack of functional follow-up. Nevertheless, the findings provide valuable epidemiological information in a Latin American context, where these injuries have been rarely documented.

Conclusions

The results of this case series from the Susana López de Valencia Hospital in Popayán reflect a clinical and epidemiological problem that is common in trauma centers worldwide and has been reported in the literature. The patient profile (male, manual laborer, with little experience, and injured at home) and the mechanism of injury (use of wood-cutting tools with modified attachments or without guards) are modifiable factors that should serve as the basis for developing prevention programs focused on the safe use of these tools, with an emphasis on safety measures, protective equipment, and prior training.

Conflicts of Interest

None reported by the authors.

Funding

None reported by the authors.

Acknowledgments

The authors thank the Susana Science, Research, and Development SUCID research group at the Susana López de Valencia E.S.E. Hospital, classified and recognized by the Colombian Ministry of Science, Technology, and Innovation, for its academic and institutional support in the development of this work.

Use of Artificial Intelligence

The authors used digital tools to assist in the preparation and revision of the manuscript. ResearchRabbit, Consensus, Scopus, and Zotero were used for literature search, organization, and management. Nature Research Assistant and ChatGPT (OpenAI; models available on the platform during the manuscript drafting and revision process) were used to assist with literature review, text organization, grammatical review, structuring of results, descriptive calculations, and style editing. Google’s Gemini was used as a generative AI image tool to create conceptual figures. These tools were consulted on multiple occasions during the drafting and revision of the manuscript; therefore, it is not possible to specify a single date of consultation. The last revision with the support of these tools was conducted in June 2026. The tools did not modify the original data, did not replace the authors’ clinical, methodological, or statistical interpretations, and were not used to generate results not derived from the database. All calculations, references, interpretations, and conclusions were independently reviewed and verified by the authors, who assume full responsibility for the content of the article.

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