DL79 Auditing Health & Safety in a Secondary School Design and Technology Department

September 2009
September 2009 Auditing Health & Safety in a Secondary School Design and Technology Department DL79

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Contents
CLEAPSS 2009 Strictly Confidential Circulate to members and associates only

As with all CLEAPSS materials, members and associates are free to copy all or part of this guide for use in their own establishments.

CLEAPSS Brunel Science Park Kingston Lane Uxbridge UB8 3PQ Tel: 01895 251496 Fax: 01895 814372 E-mail: science@cleapss.org.uk Web Site: www.cleapss.org.uk

DL79 1 Auditing Health & Safety in a Secondary School Design and Technology Department.............1 September 2009..........................................................................................................................1 Contents 2

Auditing health and safety in a secondary school design and technology department.............................................................................................3 1. Introduction: about this guide and how to use it.....................................................................3 2. Department documentation.....................................................................................................5 3. Requirements for teaching rooms...........................................................................................8 4. Preparation and store rooms................................................................................................14 5. Fixed and portable machines................................................................................................15 6. Heat treatment and welding equipment................................................................................17 Appendix 1 Example H&S Audit Forms....................................................................................18 Appendix 2 Health & safety training audit for design and technology......................................26

Auditing health and safety in a secondary school design and technology department

1. Introduction: about this guide and how to use it

This guide will help a design and technology department to ensure that its equipment is appropriately installed and that it, and the rooms it is in, are appropriately used, maintained in good condition and, where relevant, comply with legislation. It will also help the department keep appropriate health and safety documents, including records of staff, teachers and technicians, training. There will always be some element of risk when using equipment in design and technology. The aim of risk assessment is to reduce that risk to as low as is acceptably possible. An audit of teaching, preparation and store rooms, and the equipment within them will help identify the nature of hazards and risks which result from using equipment and rooms. The audit will pinpoint where action is needed to reduce the risk and it follows that the outcomes of any audit cannot be ignored. The Management of health and safety at work regulations (1999) require employers to ensure that employees are provided with adequate training, which needs to be repeated periodically where appropriate. An audit and record of staff training can be used to check on new training needs and to ensure that refresher training has been carried out where needed. It should be noted that the employer has the ultimate responsibility for implementing and ensuring appropriate health and safety measures. For maintained schools the employer will be the local authority. For other state schools, including voluntary aided, foundation and academies, and independent schools, the employer will be the governors, owner or trustees. In any event, the employer may set their own guidelines which must be followed. For the effective management of health and safety in a design and technology department, there is also a need to produce or have easy access to a range of documents. A list of such documents is given in section 2. The various audit documents in this guide are based on the recommendations contained within British Standard 4163:2007, Health and Safety for Design and Technology in Schools and Similar Establishments. Although published by British Standards, this document is a code of practice rather than a specification. It is, however, based on legal requirements and the audit documents in this guide will help teachers to ensure that the equipment in their rooms meets these requirements. This guide has five further sections:

Section 2 outlines the documents that should be available in design and technology departments and why. Section 3 outlines the what CLEAPSS believes, drawing fully on BS 4163:2007, is required for healthy and safe practice in teaching rooms of the various sorts found in a D&T department. Section 4 outlines what CLEAPSS believes, drawing fully on BS 4163:2007, is required for healthy and safe practice in D&T preparation and storage rooms. Section 5 outlines the requirements for fixed machines and portable power tools used in workshops, and

Section 6 gives the requirements for heat treatment and welding equipment.

In addition:

Appendix 1 contains forms that can be used in an audit process of rooms and equipment. Appendix 2 contains guidelines and audit forms to enable staff training needs to be identified. Appendix 3 gives guidance on the key requirements for machines in workshops including the space required around machines and work benches, and work spaces in food technology rooms.

These appendices are also available electronically on the CLEAPSS Design and Technology CD-ROM and web site in a customisable form for users to download and use. See the section of the web site entitled D&T Resource. Although implications from the British Standard 4163 have been carried over into this guide, design and technology staff may find it useful to refer to it when conducting a health and safety audit in their department. British Standard 4163:2007, Health and Safety for Design and Technology in Schools and Similar Establishments. ISBN 978 0 580 50452 5 Published by BSI, 389 Chiswick High Road, London W4 4AL. Tel: 020 8996 9001. The following CLEAPSS documents are free to staff in member schools. At the time of writing, all local authorities in England and Wales subscribe to CLEAPSS and therefore all local authority maintained schools are members. The great majority of independent schools and colleges are also members. The documents are available on the CLEAPSS Design and Technology CD-ROM and on the secure part of the CLEAPSS web site www.cleapss.org.uk, within the D&T Resource.

Model Risk Assessments for Design and Technology in Schools and Colleges L235 Managing Risk Assessment in Design and Technology L254 Health and Safety maintenance of D&T Workshop Equipment

2. Department documentation
Heath and safety policy
Employers are required by law to have a health and safety policy. In practice, in schools this generally means the school has its own policy and this will frequently form part of the staff handbook. It is useful for a design and technology department to also have its own health and safety policy and this should reflect what is stated in the school policy. As a guide, a design and technology department health and safety policy should contain the following :

An outline of who the policy is for and what it is intended to achieve General aims of the policy Health and safety roles of staff in the department Health and safety training policy Procedures for risk assessment Access to, and storage of, equipment and resources Activities and procedures Emergency procedures Design and technology room rules for pupils Staff roles and emergency contacts

CLEAPSS has produced a model health and safety policy for design and technology departments (guide L260). The guide is on the D&T CD-ROM and can be downloaded from the D&T Resource on the CLEAPSS web site. A customisable version is also provided that can be adapted to meet the specific staff and circumstances of an individual department.

Chemicals stocklist
It is good practice to maintain an up-to-date list of chemicals used in the department, their amounts, location and hazard classification. Such a list would cover the requirements, implicit or explicit, in various regulations to do with chemicals and their hazards. A department that did not maintain a chemical stocklist as described would have to produce one or more smaller lists to satisfy the demands of the DSEA (Dangerous Substances and Explosive Atmospheres) Regulations 2002, or the Regulatory Reform (Fire Safety) Order 2005. In addition, a central chemical stocklist could be given to the staff that provide first aid to avoid loss of time in an emergency. The chemicals stocklist will also support risk assessment procedures in the department. The outcomes of the risk assessment process - chemical hazards and the relevant control measures - are best noted on the department schemes of work. CLEAPSS has drafted a basic chemical stocklist for D&T that can be downloaded from the CLEAPSS web site and the CLEAPSS D&T CD-ROM and can be customised by individual departments for their own use.

Risk assessments
The employer is required to provide risk assessments for all activities that involve any hazard and department staff need to have easy access to these risk assessments. In practice, educational employers provide model risk assessments, such as the CLEAPSS Model Risk Assessments for Technology, which are available on both the CLEAPSS D&T CD-ROM and web site. Employees are required to consult such model risk assessments and adjust them to meet the specific needs of local circumstances. The significant outcomes of any adjustments need also to be written down and we suggest this is best done on the relevant part of the scheme of work. In essence, a risk assessment involves the following stages:

Identify the hazards. Assess the likelihood of harm that may result from the identified hazards. Put in place control measures to remove, or reduce to an acceptable level, the likelihood of harm.

Risk assessments are often required for the activities that pupils carry out and will be required for using equipment and machines. It is important to recognise that risk assessments also need to be consulted and, if necessary, adjusted for activities that teachers and technicians do as part of daily work. This will include less frequent tasks such as machine maintenance and activities such as putting up notice boards or shelves.

Records of staff H&S training

It is essential that subject leaders know what health and safety training staff have undertaken so that gaps can be identified and a suitable training plan be set up where needed. For using many D&T machines there is a professional recommendation that refresher training is provided every five years. Although a very good idea, this is not compulsory. Ideally, training records should include copies of training certificates.

Design and technology room rules for pupils

Most design and technology department will have written rules and procedures that pupils are expected to follow. These could be included with the department documentation.

Records of equipment checks and maintenance

Equipment must be maintained in safe and effective working order. A documented maintenance check and record will enable effective management of the equipment, and its use. The regular checking of some D&T equipment is required by regulations. Where such checks, inspections or tests are made, the department should hold copies of the certificates which attest that the equipment is in good order and functioning correctly. Such certificates should be held of the following:

Annual (technically every 14 months) checks of LEV equipment (dust & fume extraction and, where fitted, extraction from laser cutters). Annual checks of gas equipment, including gas cookers, heat treatment equipment and gas welding equipment where present. Inspection of pressure vessels, where these apply.

In addition, there should be a 5 yearly check of fixed electrical and gas installations. These are usually arranged by the employer but, in the case of local authority schools, this may be delegated to individual schools. Portable electrical equipment has to be maintained in good condition. In most schools this is facilitated by a programme of inspection and test. The frequency and logistics of this will be determined by the employer, whose systems must be followed. Most have a policy that requires inspection and testing annually. However, HSE guidance suggests that different types of equipment and the way it is used should determine the frequency and detail of any inspection and/or test regime.

3. Requirements for teaching rooms

3.1 Teaching room / workshop
There are a number of checks that are common to all teaching rooms. These are: A clean and tidy room. Teaching rooms should be kept free of clutter, pupils work, materials, etc. To reduce the risk from dust, workshops should be cleaned using an industrial vacuum cleaner with suitable filters rather than by brushing. There are further special requirements for the cleaning of rooms used for food technology. Appropriate heating and ventilation. The temperature of the room should be maintained at a comfortable level throughout the year. This includes keeping the room cool in summer through the use of blinds, opening windows or suitable cooling systems. Food technology rooms may require special consideration for heating and ventilation. Light levels, natural and/or artificial, should be sufficient. For general teaching purposes 300 lux of light are needed and 500 lux are needed where visually demanding work, such as fine work with fabrics, is done. Up to 1000 lux may be required for finer work in workshops and in textiles rooms. Adjustable task lighting may also be required for some machines. (by way of illustration, 300 lux is roughly the light level in a well-lit room at night, 500 lux is the level needed for office work and a very sunny day will have light levels of over 10,000 lux.) Electrical shut off switch. The shut off switch should be lockable, accessible and working at all times This is essential in workshops and other rooms where machines are used, such as graphics rooms, rooms used for systems and control work and preparation rooms where machines are located. If such a system is in a food technology room then equipment such as fridges and freezers must be on separate circuits so that they cannot be inadvertently switched off. In workshops it is good practice to turn off the power at the end of the school day or at the end of the last lesson of the day. An electrical shut off system that is in a room that can be locked, such as an office or store room is an acceptable alternative to a key switch. RCD protection for socket outlets. It is a good idea, although not a requirement, to have all outlet sockets used by pupils protected by a residual current device. Gas and water shut off valves. These should be accessible and working at all times, and that the off position is clearly indicated. Ideally, these valves should be situated so that they are not easily interfered with by pupils. In workshops it is good practice for the gas valve to be shut at the end of the school day or at the end of the last lesson of the day or if the equipment is not to be used. The same should be done in food technology rooms, but only if pilot lights are not used on gas cookers. Security of hazardous or valuable materials and equipment. There should be provision to secure these, normally one or more lockable cupboards or a store room. Hazard / warning signs. Suitable warning signs to indicate hazards such as guards over moving parts, and to indicate safe exits should be displayed. Home-made signs are acceptable but where they exist, pictogram signs conforming to BS 5378, part 1, should be used.

First aid. Provision of first aid materials may depend on the requirements of the employer. There is no requirement for a first aid box in every room but it may be a good idea to have any equipment and materials needed for immediate remedial measures (see the CLEAPSS guidance leaflet PS65), easily available. Fire fighting equipment. Provision of fire fighting equipment will depend on the outcomes of the employers fire risk assessment. Where provided any fire-fighting equipment should be accessible and should be checked every 12 months A room of sufficient size. In England and Wales there are no legal limits on class size and hence on the size of the room. However, overcrowding can lead to accidents. For both workshops and food rooms a good rule of thumb is to allow four square metres for each pupil in the largest class group and an additional 20 square metres for fixed equipment and furniture. For a class of 20 pupils this would mean a room of 100 square metres.

3.2 Food technology area

In addition to the aspects in 3.1 the following relate to rooms used for food technology:

Regular floor cleaning. The floor should be properly washed at the end of each day. Floor coverings should be in good condition with no gaps and with no obvious dirt traps. There should be no gap between the base units of cupboards and the floor. Sealed worktops. There should be effective seals between worktops and adjacent walls and in joins in the work surfaces. Electric sockets for portable equipment . There should be sufficient electric socket outlets for staff and pupils to have easy access when using any portable electrical equipment. Outlets should not be near to sinks and it should not be necessary to trail leads across walkways or the hobs of cookers. Fixed appliances. Fixed equipment such as cookers, washing machines and tumble dryers should be properly connected to the electrical supply. Ideally laundry machines should be connected through a fused spur switch rather than using a plug and socket. Whatever is used, the socket or fused spur should be accessible and not hidden behind the machine. Safety chain fitted to gas cookers. Gas cookers should be fitted with a safety chain. The chain should be long enough to allow the cooker to be moved out for cleaning, but prevent the flexible gas pipe from being strained. The chain should be securely fixed at both ends. Hooks or clips should not be used. Fridges / freezers. It is essential that fridges & freezers are kept clean in in good condition, and that correct temperatures are maintained. Storage of pupils ingredients. Appropriate arrangements must be made for the storage of uncooked food and other ingredients brought in by pupils before the lesson, and for the storage of cooked foods until they can be taken home. A blast chiller is ideal. Portable food mixers / processors. These must be kept clean and in good order. Safety interlocks must be working. Pressure cookers. Pressure cookers are subject to the Pressure Vessel Regulations and must be checked regularly by a competent person (see CLEAPSS guide L214 Examining Autoclaves, Pressure Cookers and Model Steam Engines ).

3.3 Textiles area

In addition to the aspects in 3.1 the following relate to rooms used for textiles, as do any relevant aspects from the food technology checklist if such equipment is in the textiles room.

Electrical sockets for portable equipment. There should be sufficient socket outlets, conveniently sited for the number of electrical items used. Multi way adaptors and four way distribution boards should not be used. Every sewing machine should be connected to a switched socket outlet. Fixed electrical appliances. These should be kept in good condition and correctly connected to the power supply. Sewing machines. These must be maintained in good order, and located so that there is sufficient space around them. There should be a minimum of 500 mm between adjacent machines. Chairs should be of the correct height and there should be good levels of lighting. Sewing machines should be serviced every 12 months. Irons and ironing boards. These should be located in a safe position and near to an electric socket outlet. Wax pots. If these are used, they should be located in a safe condition so that there is no crowding. Good ventilation is needed to remove the fumes from hot wax.

3.4 Resistant materials area.

In addition to the aspects in 3.1 the following relate to resistant materials areas

Work benches. There should be sufficient circulation space around all work benches. A minimum of 750 mm of space around any work bench is needed. Adjacent work benches, therefore, need 1500 mm of space between them. See Appendix 1. Machinery. There should be sufficient clear space around fixed machines. Use the guidelines in appendix 3. It is an advantage, but not a legal requirement, to mark safe working areas around each machine. All fixed machines should be connected through a suitable isolating switch. This should normally be one of: a fused switch dis-connector conforming to BS EN 60947-3, a connection unit conforming to BS 1363-4, a circuit breaker conforming to BS EN 60898, residual current operated circuit breaker conforming to BS EN 61009-1.

Large machines should not be connected using a standard 13 amp plug and socket, but should be wired in with fixed wiring. Supply cables should be enclosed in suitable fixed or flexible conduit. Steel conduit is far more robust than plastic.

Electrical sockets for portable equipment. There should be sufficient electrical sockets for portable electrical equipment. Socket outlets that are used for small portable machines or for portable power tools should be controlled by the emergency stop system. Sockets for use with computers should be on a separate circuit so that data is not lost if the power is turned off. Extension leads should not trail across walkways. Extension leads should not be used for semi-permanent installations. (Note that BS4163 does not require the use of 110 volts systems for workshops but some employers may insist on this. There is also no national requirement for soldering irons to operate on voltages of less than 240 volts, but, again, some employers may insist on this.)

Emergency electrical stop system. All workshops and other teaching rooms where machines are used should be fitted with an emergency stop system. There should be at least four stop buttons, one on each wall and each should be between 1300 mm and 1500 mm above the floor. Stop buttons should not be obstructed by machines, furniture or other items. Stop buttons should be red in colour on a yellow background. Stop buttons should be labelled with a pictogram sign that conforms to BS 5378 part 1.

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Local exhaust ventilation. LEV is required for any woodworking machine that produces fine dust or sawdust, which might, depending on the risk assessment, include wood turning lathes and mortising machines. LEV is also needed for heat treatment areas and must be arranged to extract fumes at a low level. Overhead hoods no longer comply with regulations. Air compressor. These must be maintained in good working order. Under the Pressure Systems Safety Regulations 2000 pressure vessels, where the pressure multiplied by the internal volume of the pressure vessel exceeds 250 bar litres, have to have a written scheme of examination. They should be inspected regularly in accordance with that written scheme (often every 12 months) by a competent person. A written record of the outcomes of any inspection, and any required action, should be kept in the department. Low voltage power supply. In this situation, low voltage is defined as less than 25 volts. Where low voltage systems in trunking are available, the system must be in good condition and it should be fed via an isolating transformer.

Person protective equipment (PPE). All items of PPE should be stored carefully and easily available to users. Suitable eye protection should be provided in sufficient numbers for the maximum number of users. It should be clean and not excessively scratched so as to impair vision. Dust masks if required, should be to the appropriate standard. For casting, welding and forge work, appropriate heat-resistant gloves are also needed as well as specialist eye protection, if required. Aprons, though not PPE, are a good idea to help keep pupils clothes clean. Work and materials storage. If stored in the teaching room, such storage should be safe and tidy, Walkways should be kept clear, and stored material should not obstruct access to machines, doorways, fire fighting equipment, etc. Hand washing facilities. A sink with hot and cold water, soap and towels should be provided for hand washing.

3.5 Graphics area

In addition to the aspects in 3.1 the following relate to graphics areas.

Work desks / tables. These should be separated by sufficient space to allow easy and safe movement. Electrical sockets for portable equipment. There should be sufficient socket outlets for portable electrical equipment. Socket outlets that are used for small portable machines or for portable power tools should be controlled by the emergency stop system. Sockets for use with computers should be on a separate circuit so that data is not lost if the power is turned off. Extension leads should not trail across walkways. Extension leads should not be used for semi-permanent installations. Machines used for making graphics models (e.g. bandsaw, sanding machine, bench drilling machine). These should be connected as described in section 3.4 above. The machines should be secured to a bench or table and the electrical supply cable protected as described in section 3.4 above See also requirements for machines given in section 5. Emergency electrical stop system. All workshops and other teaching rooms where machines are used should be fitted with an emergency stop system. There should be at least four stop buttons, one on each wall and each should be between 1300 mm and 1500 mm above the floor. Stop buttons should not be obstructed by machines, furniture or other items. Stop buttons should be red in colour on a yellow background. Stop buttons should be labelled with a pictogram sign that conforms to BS 5378 part 1. Local exhaust ventilation. LEV is required for any woodworking machine that produces fine dust or sawdust and for air brush systems where hazardous materials are used. Air compressor. These must be maintained in good working order. Under the Pressure Systems Safety Regulations 2000 pressure vessels, where the pressure multiplied by the internal volume of the pressure vessel exceeds 250 bar litres, have to have a written scheme of examination. They should be inspected regularly in accordance with that written scheme (often every 12 months) by a competent person. A written record of the outcomes of any inspection, and any required action, should be kept in the department.

Low voltage power supply. In this situation, low voltage is defined as less than 25 volts. Where low voltage systems in trunking are available, the system must be in good condition and it should be fed via an isolating transformer. Person protective equipment (PPE). All items of PPE should be stored carefully and easily available to users. Suitable eye protection should be provided in sufficient numbers for the maximum number of users. It should be clean and not excessively scratched so as to impair vision. Aprons, though not PPE, are a good idea to help keep pupils clothes clean. Work and materials storage. If stored in the teaching room, such storage should be safe and tidy, Walkways should be kept clear, and stored material should not obstruct access to machines, doorways, fire fighting equipment, etc. Hand washing facilities. A sink with hot and cold water, soap and towels should be provided for hand washing.

3.6 Systems and control area

The requirements in 3.5 apply to systems and control areas, as appropriate. In addition, the following are also required: Fixed machines. These should be connected through a switched dis-connector, and have supply cables fixed down and protected. Etch tank. These must be maintained in good order, correctly connected to power and waste, with protective equipment to hand (eye protection and gloves). Etch tanks should ideally be set into a bench top, but where this cannot be done they should be fixed to the bench. The lid should be lockable.

4. Preparation and store rooms

Security. It should be possible to secure these rooms, generally by means of a lockable door. It may be necessary to restrict access to the room when machines are in use and the operator could be distracted. Hazardous materials and valuable equipment should be stored safely and securely. A clean and tidy room. The rooms should be maintained in a clean and tidy condition. Preparation rooms should be included in the cleaning schedule. Appropriate heating and ventilation. The temperature of the room should be maintained at a comfortable level throughout the year. This includes keeping the room cool in summer through the use of blinds, opening windows or suitable cooling systems . Hazard signs. These should be displayed where needed, e.g. eye protection, use of guards, etc. Storage. Bulky and heavy items should be stored at low level. Ladders must be used to access high level storage. Staff should be trained in the safe use of ladders. The employer may place restrictions on the height at which items can be stored. Ideally nothing should be stored above head height. Hazardous and/or highly flammable materials. Correct storage for substances in these groups is necessary. Liquids that are classified HIGHLY FLAMMABLE and EXTREMELY FLAMMABLE should be stored in an appropriate metal flammables cupboard. These are yellow in colour with the flammable symbol attached. Other hazardous materials should be stored in different cupboards. Additional small flammables cupboards may be needed in some teaching rooms for easy access to materials such as spray adhesives and spray paints. Food materials. These should be stored correctly and at correct temperature? Opened packets of dry foods such as flour, rice etc., should be stored in plastic containers fitted with lids. Care should be taken to see that lids or tops of containers are kept tightly closed and food products that need to be kept refrigerated after being opened should be kept in the fridge. Gas cylinders. Gas cylinder should be stored as required by the employer. All cylinders should be stored upright and secured so that they cannot fall over. Normally gases such as oxygen, acetylene and propane used for welding should be stored in well-ventilated, lockable, outside store cupboards. Cylinders in current use may be kept on a trolley in a well-ventilated area way from combustible materials and having direct access to the outside of the building. Cylinders of liquefied petroleum gas (LPG) used to provide a gas supply for soldering torches should be stored and used in the same way. Some employers required small cylinders of butane, used for miniature soldering torches, to be stored outside in well-ventilated store rooms. No gas cylinders of any type should be stored in cupboards designed for the storage of flammable liquids. LEV system. If one is fitted and used, it should be in good working order and there should be evidence of the annual (actually 14 monthly) check.

5. Fixed and portable machines

5.1 Fixed workshop machines check
Installation. All fixed machines must be bolted to the floor or bench. Electrical isolation. All fixed machines should be connected to the electrical supply through a fused switched disconnector or a lever-operated isolating switch. No fixed machine should be connected using a 13 amp plug. There should be easy access to isolators ie access should not be impeded by the machine, furniture, materials, or pupils work. No-volt and overload starter. All machines should be fitted with a no-volt and overload push button starter. This will normally have a green button that is used to start the machine and a red stop button. When the power is turned off the machine should not restart until the green button is pressed. A simple ON / OFF switch is not sufficient. Machines should ideally be fitted with a latching stop button ie a button that requires a deliberate action to release. Examples of latching stop buttons includes ones that have to be turned to release so that the machine can be restarted. Key switch. To prevent unauthorised use, key switches are required for band saws, circular saws, wood planing machines and other wood sawing machines such as radial arm saws and chop saws. The use of a padlock that can be passed through the lever of an isolator is an acceptable alternative. Some schools may choose to fit key switches to all machines but there is no requirement to do so. Emergency stop switch (often referred to as emergency stop buttons). Machines that are designed to be used from more than one position, such as planer / thicknesser machines, should be fitted with stop button switches that can easily be accessed for from all working positions. BS 4163 states that drilling machines should be fitted with a foot-operated emergency stop device so that the machine can be stopped without the operator having to let go of the spindle feed or work piece. A knee-operated device is acceptable for bench machines provided that it can be operated easily. Such switches can be retro-fitted in the case of older machines. BS 4163 states that a conveniently located mushroom-headed stop button or other suitable control device should be fitted to most other workshop machines. In some circumstances the usual stop button will comply with this but in many schools all machines are fitted with foot operated switches. Foot operated switches should control a single machine only, and should be positioned so that they are easily accessible and are not a trip hazard. Emergency stop switches should not be used as the usual way of stopping the machine. Stopping times. A check should be made to ensure those machines which are required to come to rest within 10 seconds after switching off do so. (Currently, this includes circular saws and similar wood-sawing machines, band saws, and wood planing machines.) Electrical conduit. All supply cables for fixed machines, including those that work on a 240 volt supply, should be enclosed within suitable fixed or flexible conduit. Steel, rather than plastic, is preferred for fixed conduit and heavy duty flexible conduit should be used. Some plastic conduit, especially lightweight flexible types has been found to deteriorate over time.

Drive guards. All drive belts and gear systems must be fully enclosed. Such guards should be fitted with an electrical interlock so that the power to the motor will shut off when the guard is opened. Some alternative systems are acceptable. These include access doors or guards fitted with a key-operated lock. The key should be kept in a safe place. Another alternative is to fix the guard in place with machine screws or bolts which are kept tight and which require a tool to undo. Knurled screws or thumb screws are not acceptable. Guards may be required for lead screws and feed shafts (where fitted) of metal turning centre lathes where there is a risk of entanglement. On metal turning centre lathes the hole in the change wheel guard that allows long work pieces to be passed through the hollow mandrel should be fitted with a cover plate held with machine screws. The screws should be kept tight so that a tool is needed to remove the plate . Work and cutter guards. Guards should be provided to cover cutters on machines and the work piece where necessary. Examples of cutter guards include the crown guard on a circular saw, the bridge guard of an overhand planing machine, chuck guards on drilling machines, mortising machines and metal turning lathes, guards for the blades on powered fret sawing machines, guards on horizontal and vertical milling machines, and eye shields on grinding machines. Crown guards on circular sawing machines should be set to cover the root of the saw teeth. Work or cutter guards do not need to be fitted with an electrical interlock although it is an advantage if this is provided. Where such an electrical interlock is provided it must be maintained in good working order not bypassed. Wood turning lathes are not required to have guards. All guards must be maintained in good working order, be set in the correct position and transparent parts should be kept clean. LEV. Where it is required, LEV should be in place and maintained in good order. Maintenance. A regular programme of machine checking and maintenance should be in place, with appropriate records kept. The CLEAPSS guide L254 Health and Safety Maintenance of D&T Workshop Equipment provides guidance on maintenance and the frequency of checks.

5.2

Portable mains electric and air powered tools check (including soldering irons)

General condition. All portable tools should be maintained in good condition, which can be verified by a quick visual check each time the tool is used. Electrical safety check. Each time portable electrical equipment is used a quick visual check should confirm that the body of the equipment, the plug and cable are not damaged. The plug should have shielded pins to the live and neutral connections. An electrical inspection and test should be regularly carried out (often known colloquially as the PAT test). As a minimum this should be every 12 months and may be required more frequently for equipment which might become electrically damaged during use. Work holding or cutter guards. Where fitted guards for the cutter or work piece should be in good condition. LEV. If LEV is required it should be in place and working correctly. If dust collection bags are fitted they should be in good condition. Maintenance. In addition to the general checks, there should be a regular programme of checking and maintenance of all machines, with appropriate records kept.

6. Heat treatment and welding equipment

Gas safety system. If a gas safety system is fitted, it should be in good order and working correctly If mains gas is used in conjunction with compressed air or oxygen, a suitable non- return valve should be fitted in the gas line. LEV. This must be set to extract fumes at a low level, i.e. not past the face of the operator. Note that overhead hoods may not comply with the COSHH Regulations because the fumes may be drawn across the face of the operator. Piped welding gas supply. This should be in good order, with all shut off valves working. The system should be checked every 12 months by a suitably qualified person to ensure that it is in good condition with no leaks. Gas cylinders. These should be secured upright and stored correctly with flash back arrestors fitted on welding equipment. It is essential that gas cylinder are stored correctly. There should be a notice to indicate the presence of flammable gases under pressure. The local fire brigade should be informed. Gas welding equipment. This must be checked annually regulators, hoses, blowpipe, etc. This is an essential requirement. Electric arc welding. This should have a power supply that is capable of supplying the required input current and be provided with an independent work piece earth, which should be checked for conductivity to earth every 12 months. Suitable screens, to prevent the glare of the arc affecting those not involved with welding, should be in place. A face shield and/or goggles, with correct filter density, should be provided. Other flammable gases. Containers of gases such as liquefied petroleum gas or small butane cylinders should be stored as outlined in section 4 above. Some employers may require these to be stored in outside, well-ventilated storage rooms.

Appendix 1

Example H&S Audit Forms

Health and Safety Audit of Design and Technology

Please refer to the audit guidelines for assistance in completing these forms. School: Overall checklist for use by head of Design and Technology Health and Safety Check List Department documentation School heath and safety policy in place and current COSHH identification procedures in place and recorded Department health and safety policy in place and current Risk assessments for pupils activities in place Risk assessments for teachers and technicians activities in place Records of staff H&S training received and needed Procedures and rules on H&S used with pupils COSHH check of LEV (Dust extraction) COSHH check of LEV (Fume extraction) COSHH check of LEV (Laser cutter) Check of gas cookers Check of gas fired heat treatment equipment Check of oxy-acetylene welding equipment Portable electrical appliance testing done Record of checking of equipment and machines Record of maintenance of equipment and machines Evidence of 5 yearly check of fixed electrical installation Evidence of check of fixed gas installation Further comments if needed and action required Yes No Comments

Health and Safety Audit of Design and Technology

Please refer to the audit guidelines for assistance in completing these forms. School: Checklist for food technology rooms Room name or number: Health and Safety Check List Room clean and tidy Heating / ventilation as required Light levels sufficient Lockable electrical shut off switch in place, accessible, working and labelled RCD protection for socket outlets Shut off valve for gas and water supply accessible, working and labelled Security of hazardous / valuable materials / equipment within the room Appropriate hazard and warning signs displayed First aid provision as required Appropriate fire fighting equipment in place Is the room of sufficient size for the average number in teaching groups Floors, clean, washed daily, no obvious dirt traps Condition of worktops and seal with walls Sufficient electric socket outlets for portable equipment location, condition Fixed appliances in good condition, correctly connected to power supply Safety chain fitted to gas cookers Fridges and freezers in good condition and working at appropriate temperatures Suitable arrangements in place for storing raw and cooked foods, and ingredients Portable food mixers / processors in good order, safety interlocks working Pressure cookers inspected regularly Yes No Comments

Further comments on this room if needed and action required (continue on a separate sheet)

Health and Safety Audit of Design and Technology

Please refer to the audit guidelines for assistance in completing these forms. School: Checklist for textiles rooms Room name or number: Health and Safety Check List Room clean and tidy Heating / ventilation as required Light levels sufficient Lockable electrical shut off switch in place, accessible, working and labelled RCD protection for socket outlets Shut off valve for gas and water supply accessible, working and labelled Security of hazardous / valuable materials / equipment within the room Appropriate hazard and warning signs displayed First aid provision as required Appropriate fire fighting equipment in place Is the room of sufficient size for the average number in teaching groups Sufficient electric socket outlets for portable equipment location, condition Fixed appliances in good condition, correctly connected to power supply Sewing machines in good order, located appropriately Irons and ironing boards in good order, located appropriately Wax pots, if used, are located in appropriate positions Yes No Comments

Further comments on this room if needed and action required

Health and Safety Audit of Design and Technology

Please refer to the audit guidelines for assistance in completing these forms. School: Checklist for resistant materials rooms Room name or number: Health and Safety Check List Room clean and tidy Heating / ventilation as required Light levels sufficient Lockable electrical shut off switch in place, accessible, working and labelled RCD protection for socket outlets Shut off valve for gas and water supply accessible, working and labelled Security of hazardous / valuable materials / equipment within the room Appropriate hazard and warning signs displayed First aid provision as required Appropriate fire fighting equipment in place Is the room of sufficient size for the average number in teaching groups Work benches spaced out appropriately Machines spaced out appropriately Sufficient electrical socket outlets for portable equipment location, condition Emergency stop system, sufficient, accessible, working, labelled If required, LEV in place and working, evidence of 12 monthly check If fitted, evidence of air compressor check If fitted, low voltage power supplies in good order and working PPE in place and used Work and/or consumable materials are stored correctly & not causing obstructions Appropriate hand washing facilities provided Yes No Comments

Further comments on this room if needed and action required (continue on separate sheet)

Health and Safety Audit of Design and Technology

Please refer to the audit guidelines for assistance in completing these forms. School: Checklist for graphics rooms / areas Room name or number: Health and Safety Check List Room clean and tidy Heating / ventilation as required Light levels sufficient Lockable electrical shut off switch in place, accessible, working and labelled RCD protection for socket outlets Shut off valve for gas and water supply accessible, working and labelled Security of hazardous / valuable materials / equipment within the room Appropriate hazard and warning signs displayed First aid provision as required Appropriate fire fighting equipment in place Is the room of sufficient size for the average number in teaching groups Work benches / tables spaced out appropriately Sufficient electric socket outlets for portable equipment location, condition If provided, machines connected through switched disconnector, fixed down, supply cable protected Emergency stop system, sufficient, accessible, working, labelled If required, LEV in place and working, evidence of 12 monthly check If fitted, evidence of air compressor check If fitted low voltage power supplies in good order and working PPE in place and used Work and/or consumable materials are stored correctly & not causing obstructions Appropriate hand washing facilities provided Yes No Comments

Further comments on this room if needed and action required (continue on separate sheet)

Health and Safety Audit of Design and Technology

Please refer to the audit guidelines for assistance in completing these forms. School: Checklist for systems and control rooms Room name or number: Health and Safety Check List Room clean and tidy Heating / ventilation as required Light levels sufficient Lockable electrical shut off switch in place, accessible, working and labelled RCD protection for socket outlets Shut off valve for gas and water supply accessible, working and labelled Security of hazardous / valuable materials / equipment within the room Appropriate hazard and warning signs displayed First aid provision as required Appropriate fire fighting equipment in place Is the room of sufficient size for the average number in teaching groups Work benches / tables spaced out appropriately Sufficient electric socket outlets for portable equipment If provided, machines connected through switched disconnector, fixed down, supply cable protected Emergency stop system, sufficient, accessible, working, labelled If required, LEV in place and working, evidence of 12 monthly check If fitted, evidence of air compressor check If fitted, low voltage power supplies in good order and working Etch tanks correctly installed and in good order with lockable lid Appropriate PPE in place and used. Work and/or consumable materials are stored correctly & not causing obstructions Appropriate hand washing facilities provided Yes No Comments

Further comments on this room if needed and action required (continue on a separate sheet)

Health and Safety Audit of Design and Technology

Please refer to the audit guidelines for assistance in completing these forms. School: Checklist for preparation and store rooms Room name or number: Health and Safety Check List Appropriate security (including lockable door) Room clean and tidy Heating/ventilation as required Appropriate hazard and warning signs displayed Appropriate storage of bulky/heavy materials stored safely and materials stored at height. Suitable ladders available Hazardous / flammable / highly flammable materials stored correctly and labelled Food materials stored correctly and at correct temperature If applicable, gas cylinders stored correctly If LEV system is fitted, is it working correctly, evidence of 12 monthly check Yes No Comments

Further comments on this room if needed and action required

Health and Safety Audit of Design and Technology

Please refer to the audit guidelines for assistance in completing these forms. School:

Checklist for machines (includes plastics equipment)

Room name or number: Machine Machine in Isolator in Key switch Make / model / type good general place & where e.g. Startrite 325 band saw order & fixed working? required. down NVOL in Conduit in place & good working? condition Stopping time OK? Drive guards in place with interlock or fixing device & in good order Work holding or cutter guards in place with interlock where required? LEV in place and working Evidence of maintenance programme

Appendix 2

Health & safety training audit for design and technology

Audit of staff health and safety training needs for teachers and technicians in secondary schools. All those whose job involves using the equipment listed should complete the form.
Name....................................................................... Job title.................................................................... Number of years in this job.................................

Teachers
Was your initial teacher training in design and technology? Yes / No If no, please state which subject/s formed the main basis of your training.................................................... ....................................................................................................................................................................... If D&T was not a focus of your initial training, have you ever had any additional training in D&T? Yes / No

Introduction The Design and Technology Association (DATA) operates a training scheme to provide health and safety training for design and technology teachers and technicians. This training is competency based and training can be modified as needed to suit the needs of those being trained. The DATA scheme has a core training element, specialist levels and specialist extension modules for teachers and technicians working in resistant materials. All those receiving training need to cover the core element, but the content can be modified to suit previous experience. The content of the units are outlined below. This form is designed to identify your training needs in all the areas, but completion of it does not imply that the necessary training will be provided immediately. DATA Core element training. Consists of three modules, essential for all teachers and technicians working in design and technology and introduced in 2004. Only those who were trained after this date will have experienced them. Please complete the form below.

Module

Tick this column if you have done the module

If you have had training, put the year in which training took place in this column

Tick this column if you can produce written evidence, of the training, e.g. a training certificate

Module 1 Developing a culture of health and safety Module 2 Risk Assessment Module 3 Health & safety awareness

DATA specialist level training. Consists of four modules Food technology, systems and control, textiles technology and resistant materials technology. The training includes materials and components relevant to the specialist area, and the basic equipment, processes and tools used in that specialist area. The first three of these are listed below. Please complete the form.

Module

Tick this column if you have had H&S training in this area of D&T

If you have had training, put the year in which training took place in this column

Tick here if you can produce written evidence of the training, e.g. a training certificate

Food technology
Food specialists please include here any food hygiene certification

Systems and control Textiles technology

Resistant materials specialist level training. This covers materials, processes, hand tools and the following machines: drilling machine, off hand grinder, disc / belt sander, polishing / buffing machine, power hacksaw, hollow chisel mortising machine, equipment for shaping plastics, brazing equipment, portable power tools operating at 240 volts. Please complete the form on the next page to identify your training needs for this equipment. Additional notes Training training is defined as being shown how to use the equipment by another competent person and demonstrating in a practical way to that person that you were able to use the equipment safely. Frequency of use frequent is defined as at least twice a week; occasionally is defined as two or three times a month; rarely is defined as once or twice a term.

Resistant materials specialist training

Equipment Tick if the equipment is in your school Tick if you are required to use this equipment as part of your job Frequency of use: F= frequent; O = occasionally; R = rarely Tick if you have ever had formal training to use this equipment The year of any formal training Can you produce written evidence, of the training, e.g. a training certificate

Drilling machine Off hand grinder Disc / belt sander Polishing / buffing machine Power hacksaw Mortising machine Plastics equipment Brazing equipment Portable power tools - portable drill - hand held router - portable electric jig saw - portable electric circular saw - portable electric biscuit cutter - portable electric planer

Wood sawing machines. This unit includes band saw, circular saw, bench mounted jig saw and radial arm saw and chop saw. Please complete the form below to identify your training needs for this equipment.
Equipment Tick if the equipment is in your school Tick if you are required to use this equipment as part of your job Frequency of use: F= frequent; O = occasionally; R = rarely Tick if you have ever had formal training to use this equipment The year of any formal training Can you produce written evidence, of the training, e.g. a training certificate

Band saw Circular saw Bench mounted jig saw Radial arm saw Chop saw

Planer / thicknesser separate overhand planer and thicknesser. This unit includes combined and individual machines. Please complete the form below to identify your training needs for this equipment.
Equipment Tick if the equipment is in your school Tick if you are required to use this equipment as part of your job Frequency of use: F= frequent; O = occasionally; R = rarely Tick if you have ever had formal training to use this equipment The year of any formal training Can you produce written evidence, of the training, e.g. a training certificate

Combined planer / thicknesser Overhand planer Thicknesser

Wood turning lathe, metal turning lathe, vertical milling machine, horizontal milling machine, welding, casting of non ferrous metals. Separate training courses are available for each of the machines and equipment listed below. Please complete the form below to identify your training needs for this equipment.
Equipment Tick if the equipment is in your school Tick if you are required to use this equipment as part of your job Frequency of use: F= frequent; O = occasionally; R = rarely Tick if you have ever had formal training to use this equipment The year of any formal training Can you produce written evidence, of the training, e.g. a training certificate

Wood turning lathe Metal turning lathe Vertical milling machine Horizontal milling machine Casting equipment Welding gas, arc, MIG, TIG (Specify type of welding)

Anything else? Please list below any other equipment in your school not included above that you are required to use
Equipment Do you use it? Frequency Training? Date?

Certificate?

Appendix 3

Key safety points for machinery, and space around machinery and work areas in workshops, food technology and textiles rooms
BAND SAW
Must have: key switch, LEV and must stop within 10 seconds of being switched off. When in use the top guide and blade guard must be as close as possible to the top surface of the material being cut, normally 5 to 10 mm. BLADE GUARD TOP GUIDE

Common workshop machines and equipment

1500

1000

1000

ADVISED SPACE AROUND A BAND SAW

BENCH JIG SAW

Must have: guard for blade, NVOL*. LEV should be provided. The machine should be bolted to the bench or to a suitable stand. It should be permanently connected to the electrical supply through an isolating switch or a fused spur switch. The supply cable should be enclosed in conduit. On this type of machine the guard is not very robust and can easily be broken. The foot is often not used correctly. LEV arrangements are often inadequate. *NVOL - No-volt and overload push button starter. The machine is started by pushing a green button. If the electrical supply is interrupted - e.g. power cut, the machine should not re-start unless the green button is pressed. If too much current is drawn the machine should stop.

Guard should cover blade.

Foot should rest on the work piece.

CIRCULAR SAW
Must have: key switch, LEV, crown guard, riving knife. Must stop within 10 seconds. The machine should be located in an area where the user cannot be distracted. A push stick should be used. When in use the crown guard must be as close as practicable to the top surface of the material being cut normally 5 to10 mm and should cover the root of the saw teeth. Take off table (shown in lowered position) 1.2 metres needed between rear of saw blade and rear edge of table. FENCE should project a maximum of 50 mm beyond front of saw blade. CROWN GUARD RIVING KNIFE ADVISD SPACE AROUND A CIRCULAR SAW

VERTICAL PANEL SAW

Must have: key switch, LEV. Must stop within 10 seconds. Blade should be fully guarded. A type of machine that is new to schools but which may become more common as vocational courses are introduced. It can be argued that it is safer to cut large sheets of timber on this type of machine than on a circular saw. Should be located in an area where user cannot be distracted.

CROSS CUTING OR RADIAL ARM SAWS

All types of radial arm saw must have: key switch, NVOL & LEV. All must stop within 10 seconds. Blade should be fully guarded. All should be located in area where the user cannot be distracted. Chop saws often poorly located and LEV is poor.

CHOP SAW

MODERN RADIAL ARM SAW

TRADITIONAL RADIAL ARM SAW

ADVISED SPACE AROUND RADIAL ARM SAW Note Some of the space on each side might be used for a power hacksaw or horizontal grinder provided that they are lower than the table of the saw.

3000

1500

1000

PLANING MACHINES
Planing machines must have: key switch, LEV. Overhand planers and combined machines must stop within 10 seconds. Hand fed thicknesser must stop within 10 seconds. Power fed machines do not have to stop within 10 seconds.

When in use, the cutter block must be fully guarded. machines should be located in area where the user cannot be distracted.

COMBINED OVERHAND PLANER / THICKNESSER

ADVISED SPACE AROUND PLANER / THICKNESSER

THICKNESSER

Kickback fingers should be provided. If none are provided then only one piece of timber should be fed in at a time.

THICKNESSER ON FLOOR STAND

SANDING MACHINES
Must have: LEV. Sanding machines are classified as high risk woodworking machines.

BELT SANDER (BANDFACER)

BOBBIN SANDER

DISC SANDER
Disc sander must have quadrant guard. The gap between the table and the disc / belt should be as small as possible usually 3 mm to 5 mm.

ADVISED SPACE AROUND A SANDING MACHINE

DRILLING MACHINES
Must have: a foot switch and be fitted with a drill chuck guard.

PEDESTAL DRILLING MACHINE

Drill chuck guard. This must be used at all times. A foot switch must be fitted.
ADVISED SPACE AROUND A DRILLING MACHINE

MORTISING MACHINE
Must have: interlocked or fixed cover over augur chuck. Relatively few hazards. Auger bits should be kept sharp. Bench mounted machines should be bolted to the bench.

Interlocked or fixed cover needed over auger chuck.

ADVISED SPACE AROUND A MORTISING MACHINE

1500

1500

1000

WOOD TURNING LATHE

Relatively few hazards. A foot switch is highly recommended. LEV if the risk assessment shows that it is required. A guard over work piece not required. Turning tools should be stored safely. Only used by one person at a time. ADVISED SPACE AROUND WOOD TURNING LATHE May be set at an angle to the wall to give better working space.

METAL-TURNING CENTRE LATHE

Must have: a chuck guard. A cover is needed for the end of the hollow mandrel. Power feed / lead screw should be guarded. Alternatively disconnect it except when needed and then carry out a specific risk assessment.

ADVISED SPACE AROUND A METAL-TURNING LATHE

VERTICAL MILLING MACHINE

Must have: cutter guard. Draw bolt must have a bolted cover. Draw bolt cover. Cutter guard.

SPACE REQUIRED AROUND A MILLING MACHINE A better type of milling machine guard

This type of guard fully encloses the work and the cutting tool and is fitted with an interlock switch that will prevent the machine from starting unless the guard is closed.

GRINDING AND POLISHING MACHINES

Must have: (on high speed grinder) new grinding wheels fitted by a trained specialist. Key switch is highly desirable. Ensure eye shields and grinding wheels are in good condition In use, the tool rest should be within 3 mm of the front edge of the grinding wheel. Useful to be in the workshop but away from other machines. Normally used for sharpening of cutting tools. Special grinding wheels needed for grinding mild steel and tungsten tipped tools.

DOUBLE ENDED HIGH SPEED GRINDER

Tool rest.

600

600

1000

ADVISED SPACE AROUND HIGH SPEED GRINDER

HORIZONTAL SLOW SPEED GRINDER

ADVISED SPACE AROUND A HORIZONTAL, SLOW SPEED GRINDER

BUFFING AND POLISHING MACHINES

Must have: guards on the mop spindle on both sides of the mop. LEV fitted if the risk assessment indicates it is required. Eye shields and polishing mops should be in good condition. ADVISED SPACE AROUND A BUFFING MACHINE

Eye shield. The mop spindle must be guarded on both sides of the mop.

METAL SAWING MACHINES

These machines should not be used by pupils. Both power hacksaws and metal cutting bandsaws are difficult to guard effectively. All of these machines are best located in a store room.

RECIPROCATING POWER HACKSAW

METAL CUTTING BANDSAW

METAL CHOP SAW

These are becoming more common. They can be fitted with an abrasive wheel or a saw blade.

HOT METAL EQUIPMENT

Must have: LEV. Extraction should be at a low level, i.e. fumes must not be drawn across the face of the operator. Fumes must be vented to the atmosphere. Older systems with overhead extraction hoods may not comply with current regulations. Anti glare screens not required for this equipment. Modern equipment comes with its individual gas safety system. However a gas safety system for the whole room can also be used.

SINGLE BRAZING HEARTH

ADVISED SPACE AROUND A SINGLE BRAZING HEARTH

DUAL BRAZING HEARTH AND CHIP FORGE

ADVISED SPACE AROUND A CHIP FORGE

This is an effective space-saving piece of equipment but beware of too many pupils trying to use it simultaneously.

CRUCIBLE FURNACE
A tray of sand is needed to rest the mould on for pouring. Adequate space is needed for pouring molten metal. Condition of crucible should be checked before each use. The area around the crucible should be kept clear. ADVISED SPACE AROUND A CRUCIBLE FURNACE

For a crucible that has to be lifted out, 1000 mm is required on both sides as well as 1200 mm to the front.

Spacing around work areas

WORKSHOP BENCHES Sufficient space is required around all work benches. On the adjacent diagram the pale (white) area denotes the workspace for that side of the bench. The darker (blue) areas denote space that should be kept clear for circulation.

750

750

750

On four-place benches the outer 50 mm of space can be shared with the adjacent bench. The pale (blue) area denotes the workspace and the darker (blue) areas indicate potential overlap space.

750

WORK AREAS IN FOOD TECHNOLOGY ROOMS

The diagram gives spacing for cookers and sinks. Allow a minimum of 1750 mm clear space between peninsular units or other situations involving parallel workbenches. There should always be a work surface on both sides of any cooker, at the same height as the hob of the cooker. The height of work surfaces used for food preparation should not be greater than 850 mm. As in the previous diagram the pale (blue) area denotes work space and the darker (blue) denotes potential overlap space with neighbouring work stations.

SEWING MACHINES
Space sewing machines as in the diagram. The bench should be at least 850 mm deep. Socket outlets for power should be positioned on the wall not less than 150 mm above the surface of the bench. Sufficient socket outlets should be provided to allow for each machine to have its own switched outlet. Multi-way adaptors and four way distribution blocks should not be used.