G79 Auditing Health & Safety in a Secondary School Design...

G79 Auditing Health & Safetyin a Secondary SchoolDesign and TechnologyDepartmentSeptember 2009

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Contents1. Introduction: about this guide and how to use it .............................................................. 1

2. Department documentation............................................................................................. 3

3. Requirements for teaching rooms ................................................................................... 6

3.1 Teaching room / workshop........................................................................................ 6

3.2 Food technology area ............................................................................................... 7

3.3 Textiles area.............................................................................................................. 8

3.4 Resistant materials area. .......................................................................................... 8

3.5 Graphics area.......................................................................................................... 10

3.6 Systems and control area........................................................................................ 11

4. Preparation and store rooms......................................................................................... 12

5. Fixed and portable machines ........................................................................................ 13

5.1 Fixed workshop machines check ............................................................................ 13

5.2 Portable mains electric and air powered tools check (including soldering irons)..... 14

6. Heat treatment and welding equipment......................................................................... 15

Appendix 1 Example H&S Audit Forms .................................................................................. 16

Appendix 2 Health & safety training audit for design and technology ..................................... 24

Appendix 3 Key safety points for machinery and space around machinery............................ 28

© 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 foruse in their own establishments.

CLEAPSSBrunel Science Park

Kingston LaneUxbridgeUB8 3PQ

Tel: 01895 251496Fax: 01895 814372

E-mail: [email protected] Site: www.cleapss.org.uk

mailto:[email protected]

http://www.cleapss.org.uk/

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Auditing health and safety in a secondary schooldesign and technology department

1. Introduction: about this guide and how to use itThis guide will help a design and technology department to ensure that its equipment is appropriatelyinstalled 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 andsafety 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 ofrisk 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 andrisks which result from using equipment and rooms. The audit will pinpoint where action is needed toreduce 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 thatemployees are provided with adequate training”, which needs to be “repeated periodically whereappropriate”. An audit and record of staff training can be used to check on new training needs and toensure that refresher training has been carried out where needed.

It should be noted that the employer has the ultimate responsibility for implementing and ensuringappropriate health and safety measures. For maintained schools the employer will be the localauthority. For other state schools, including voluntary aided, foundation and academies, andindependent schools, the employer will be the governors, owner or trustees. In any event, the employermay set their own guidelines which must be followed.

For the effective management of health and safety in a design and technology department, there is alsoa need to produce or have easy access to a range of documents. A list of such documents is given insection 2.

The various audit documents in this guide are based on the recommendations contained within BritishStandard 4163:2007, Health and Safety for Design and Technology in Schools and SimilarEstablishments. Although published by British Standards, this document is a code of practice ratherthan a specification. It is, however, based on legal requirements and the audit documents in this guidewill 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 departmentsand why.

• Section 3 outlines the what CLEAPSS believes, drawing fully on BS 4163:2007, is required forhealthy 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 healthyand safe practice in D&T preparation and storage rooms.

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• 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 spacerequired 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-ROMand web site in a customisable form for users to download and use. See the section of the web siteentitled D&T Resource.

Although implications from the British Standard 4163 have been carried over into this guide, design andtechnology staff may find it useful to refer to it when conducting a health and safety audit in theirdepartment. British Standard 4163:2007, Health and Safety for Design and Technology in Schools andSimilar Establishments. ISBN 978 0 580 50452 5 Published by BSI, 389 Chiswick High Road, LondonW4 4AL. Tel: 020 8996 9001.

The following CLEAPSS documents are free to staff in member schools. At the time of writing, all localauthorities in England and Wales subscribe to CLEAPSS and therefore all local authority maintainedschools are members. The great majority of independent schools and colleges are also members. Thedocuments are available on the CLEAPSS Design and Technology CD-ROM and on the secure part ofthe 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

http://www.cleapss.org.uk/

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2. Department documentationHeath and safety policy

Employers are required by law to have a health and safety policy. In practice, in schools this generallymeans the school has its own policy and this will frequently form part of the staff handbook. It is usefulfor a design and technology department to also have its own health and safety policy and this shouldreflect 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 onthe CLEAPSS web site. A customisable version is also provided that can be adapted to meet thespecific 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, invarious regulations to do with chemicals and their hazards. A department that did not maintain achemical stocklist as described would have to produce one or more smaller lists to satisfy the demandsof the DSEA (Dangerous Substances and Explosive Atmospheres) Regulations 2002, or the RegulatoryReform (Fire Safety) Order 2005. In addition, a central chemical stocklist could be given to the staff thatprovide first aid to avoid loss of time in an emergency.

The chemicals stocklist will also support risk assessment procedures in the department. The outcomesof the risk assessment process - chemical hazards and the relevant control measures - are best notedon the department schemes of work.

CLEAPSS has drafted a basic chemical stocklist for D&T that can be downloaded from the CLEAPSSweb site and the CLEAPSS D&T CD-ROM and can be customised by individual departments for theirown use.

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Risk assessments

The employer is required to provide risk assessments for all activities that involve any hazard anddepartment staff need to have easy access to these risk assessments. In practice, educationalemployers provide model risk assessments, such as the CLEAPSS Model Risk Assessments forTechnology, which are available on both the CLEAPSS D&T CD-ROM and web site. Employees arerequired to consult such model risk assessments and adjust them to meet the specific needs of localcircumstances. The significant outcomes of any adjustments need also to be written down and wesuggest 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 usingequipment and machines.

It is important to recognise that risk assessments also need to be consulted and, if necessary, adjustedfor activities that teachers and technicians do as part of daily work. This will include less frequent taskssuch 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 thatgaps can be identified and a suitable training plan be set up where needed. For using many D&Tmachines 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 oftraining certificates.

Design and technology room rules for pupils

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

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Records of equipment checks and maintenance

Equipment must be maintained in safe and effective working order. A documented maintenance checkand 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 thatthe equipment is in good order and functioning correctly. Such certificates should be held of thefollowing:

• Annual (technically every 14 months) checks of LEV equipment (dust & fume extraction and, wherefitted, extraction from laser cutters).

• Annual checks of gas equipment, including gas cookers, heat treatment equipment and gas weldingequipment 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 usuallyarranged by the employer but, in the case of local authority schools, this may be delegated to individualschools.

Portable electrical equipment has to be maintained in good condition. In most schools this is facilitatedby a programme of inspection and test. The frequency and logistics of this will be determined by theemployer, whose systems must be followed. Most have a policy that requires inspection and testingannually. However, HSE guidance suggests that different types of equipment and the way it is usedshould determine the frequency and detail of any inspection and/or test regime.

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3. Requirements for teaching rooms3.1 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 withsuitable filters rather than by brushing. There are further special requirements for the cleaning ofrooms used for food technology.

• Appropriate heating and ventilation. The temperature of the room should be maintained at acomfortable level throughout the year. This includes keeping the room cool in summer through theuse of blinds, opening windows or suitable cooling systems. Food technology rooms may requirespecial consideration for heating and ventilation.

• Light levels, natural and/or artificial, should be sufficient. For general teaching purposes300 lux of light are needed and 500 lux are needed where visually demanding work, such as finework with fabrics, is done. Up to 1000 lux may be required for finer work in workshops and intextiles rooms. Adjustable task lighting may also be required for some machines. (by way ofillustration, 300 lux is roughly the light level in a well-lit room at night, 500 lux is the level needed foroffice 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 alltimes This is essential in workshops and other rooms where machines are used, such as graphicsrooms, rooms used for systems and control work and preparation rooms where machines arelocated. If such a system is in a food technology room then equipment such as fridges and freezersmust be on separate circuits so that they cannot be inadvertently switched off. In workshops it isgood practice to turn off the power at the end of the school day or at the end of the last lesson ofthe day. An electrical shut off system that is in a room that can be locked, such as an office or storeroom 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 outletsockets 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 theoff position is clearly indicated. Ideally, these valves should be situated so that they are not easilyinterfered with by pupils. In workshops it is good practice for the gas valve to be shut at the end ofthe school day or at the end of the last lesson of the day or if the equipment is not to be used. Thesame 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 tosecure these, normally one or more lockable cupboards or a store room.

• Hazard / warning signs. Suitable warning signs to indicate hazards such as guards over movingparts, and to indicate safe exits should be displayed. Home-made signs are acceptable but wherethey exist, pictogram signs conforming to BS 5378, part 1, should be used.

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• First aid. Provision of first aid materials may depend on the requirements of the employer. There isno requirement for a first aid box in every room but it may be a good idea to have any equipmentand 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 theemployers fire risk assessment. Where provided any fire-fighting equipment should be accessibleand should be checked every 12 months

• A room of sufficient size. In England and Wales there are no legal limits on class size and henceon the size of the room. However, overcrowding can lead to accidents. For both workshops andfood rooms a good rule of thumb is to allow four square metres for each pupil in the largest classgroup and an additional 20 square metres for fixed equipment and furniture. For a class of 20 pupilsthis 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. Floorcoverings should be in good condition with no gaps and with no obvious dirt traps. There should beno gap between the base units of cupboards and the floor.

• Sealed worktops. There should be effective seals between worktops and adjacent walls and injoins in the work surfaces.

• Electric sockets for portable equipment. There should be sufficient electric socket outlets forstaff and pupils to have easy access when using any portable electrical equipment. Outlets shouldnot be near to sinks and it should not be necessary to trail leads across walkways or the hobs ofcookers.

• Fixed appliances. Fixed equipment such as cookers, washing machines and tumble dryers shouldbe properly connected to the electrical supply. Ideally laundry machines should be connectedthrough a fused spur switch rather than using a plug and socket. Whatever is used, the socket orfused 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 chainshould be long enough to allow the cooker to be moved out for cleaning, but prevent the flexible gaspipe from being strained. The chain should be securely fixed at both ends. Hooks or clips should notbe used.

• Fridges / freezers. It is essential that fridges & freezers are kept clean in in good condition, andthat correct temperatures are maintained.

• Storage of pupils’ ingredients. Appropriate arrangements must be made for the storage ofuncooked food and other ingredients brought in by pupils before the lesson, and for the storage ofcooked 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. Safetyinterlocks must be working.

• Pressure cookers. Pressure cookers are subject to the Pressure Vessel Regulations and must bechecked regularly by a competent person (see CLEAPSS guide L214 Examining Autoclaves,Pressure Cookers and Model Steam Engines).

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3.3 Textiles area

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

• Electrical sockets for portable equipment. There should be sufficient socket outlets, convenientlysited for the number of electrical items used. Multi way adaptors and four way distribution boardsshould 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 tothe power supply.

• Sewing machines. These must be maintained in good order, and located so that there is sufficientspace around them. There should be a minimum of 500 mm between adjacent machines. Chairsshould be of the correct height and there should be good levels of lighting. Sewing machines shouldbe serviced every 12 months.

• Irons and ironing boards. These should be located in a safe position and near to an electricsocket 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 minimumof 750 mm of space around any work bench is needed. Adjacent work benches, therefore, need1500 mm of space between them. See Appendix 1.

• Machinery. There should be sufficient clear space around fixed machines. Use the guidelines inappendix 3. It is an advantage, but not a legal requirement, to mark safe working areas around eachmachine. All fixed machines should be connected through a suitable isolating switch. This shouldnormally 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 shouldbe wired in with fixed wiring. Supply cables should be enclosed in suitable fixed or flexibleconduit. Steel conduit is far more robust than plastic.

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• Electrical sockets for portable equipment. There should be sufficient electrical sockets forportable electrical equipment. Socket outlets that are used for small portable machines or forportable power tools should be controlled by the emergency stop system. Sockets for use withcomputers 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 forsemi-permanent installations.

(Note that BS4163 does not require the use of 110 volts systems for workshops but someemployers may insist on this. There is also no national requirement for soldering irons to operate onvoltages 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 areused 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. Stopbuttons should not be obstructed by machines, furniture or other items. Stop buttons should be redin colour on a yellow background. Stop buttons should be labelled with a pictogram sign thatconforms to BS 5378 part 1.

Emergency stop

• Local exhaust ventilation. LEV is required for any woodworking machine that produces fine dustor sawdust, which might, depending on the risk assessment, include wood turning lathes andmortising machines. LEV is also needed for heat treatment areas and must be arranged to extractfumes at a low level. Overhead hoods no longer comply with regulations.

• Air compressor. These must be maintained in good working order. Under the Pressure SystemsSafety Regulations 2000 pressure vessels, where the pressure multiplied by the internal volume ofthe pressure vessel exceeds 250 bar litres, have to have a written scheme of examination. Theyshould be inspected regularly in accordance with that written scheme (often every 12 months) by acompetent 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. Wherelow voltage systems in trunking are available, the system must be in good condition and it should befed via an isolating transformer.

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• Person protective equipment (PPE). All items of PPE should be stored carefully and easilyavailable to users. Suitable eye protection should be provided in sufficient numbers for themaximum 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 forhand 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 safemovement.

• Electrical sockets for portable equipment. There should be sufficient socket outlets for portableelectrical equipment. Socket outlets that are used for small portable machines or for portable powertools should be controlled by the emergency stop system. Sockets for use with computers should beon a separate circuit so that data is not lost if the power is turned off. Extension leads should nottrail across walkways. Extension leads should not be used for semi-permanent installations.

• Machines used for making graphics models (e.g. bandsaw, sanding machine, bench drillingmachine). These should be connected as described in section 3.4 above. The machines should besecured to a bench or table and the electrical supply cable protected as described in section 3.4above See also requirements for machines given in section 5.

• Emergency electrical stop system. All workshops and other teaching rooms where machines areused 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. Stopbuttons should not be obstructed by machines, furniture or other items. Stop buttons should be redin colour on a yellow background. Stop buttons should be labelled with a pictogram sign thatconforms to BS 5378 part 1.

• Local exhaust ventilation. LEV is required for any woodworking machine that produces fine dustor sawdust and for air brush systems where hazardous materials are used.

• Air compressor. These must be maintained in good working order. Under the Pressure SystemsSafety Regulations 2000 pressure vessels, where the pressure multiplied by the internal volume ofthe pressure vessel exceeds 250 bar litres, have to have a written scheme of examination. Theyshould be inspected regularly in accordance with that written scheme (often every 12 months) by acompetent person. A written record of the outcomes of any inspection, and any required action,should be kept in the department.

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• Low voltage power supply. In this situation, low voltage is defined as less than 25 volts. Wherelow voltage systems in trunking are available, the system must be in good condition and it should befed via an isolating transformer.

• Person protective equipment (PPE). All items of PPE should be stored carefully and easilyavailable to users. Suitable eye protection should be provided in sufficient numbers for themaximum 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 forhand washing.

3.6 Systems and control area

The requirements in 3.5 apply to systems and control areas, as appropriate. In addition, the followingare also required:

• Fixed machines. These should be connected through a switched dis-connector, and have supplycables fixed down and protected.

• Etch tank. These must be maintained in good order, correctly connected to power and waste, withprotective equipment to hand (eye protection and gloves). Etch tanks should ideally be set into abench top, but where this cannot be done they should be fixed to the bench. The lid should belockable.

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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 couldbe 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. Preparationrooms should be included in the cleaning schedule.

• Appropriate heating and ventilation. The temperature of the room should be maintained at acomfortable level throughout the year. This includes keeping the room cool in summer through theuse 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 accesshigh level storage. Staff should be trained in the safe use of ladders. The employer may placerestrictions on the height at which items can be stored. Ideally nothing should be stored above headheight.

• Hazardous and/or highly flammable materials. Correct storage for substances in these groups isnecessary. Liquids that are classified HIGHLY FLAMMABLE and EXTREMELY FLAMMABLEshould be stored in an appropriate metal flammables cupboard. These are yellow in colour with theflammable 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 tomaterials such as spray adhesives and spray paints.

• Food materials. These should be stored correctly and at correct temperature? Opened packets ofdry foods such as flour, rice etc., should be stored in plastic containers fitted with lids. Care shouldbe taken to see that lids or tops of containers are kept tightly closed and food products that need tobe 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 bestored upright and secured so that they cannot fall over. Normally gases such as oxygen, acetyleneand 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 combustiblematerials and having direct access to the outside of the building. Cylinders of liquefied petroleumgas (LPG) used to provide a gas supply for soldering torches should be stored and used in thesame way. Some employers required small cylinders of butane, used for miniature solderingtorches, to be stored outside in well-ventilated store rooms. No gas cylinders of any type should bestored 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 beevidence of the annual (actually 14 monthly) check.

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5. Fixed and portable machines5.1 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 afused switched disconnector or a lever-operated isolating switch. No fixed machine should beconnected using a 13 amp plug. There should be easy access to isolators ie access should not beimpeded by the machine, furniture, materials, or pupils’ work.

• No-volt and overload starter. All machines should be fitted with a no-volt and overload pushbutton starter. This will normally have a green button that is used to start the machine and a redstop button. When the power is turned off the machine should not restart until the green button ispressed. A simple ON / OFF switch is not sufficient. Machines should ideally be fitted with a latchingstop button ie a button that requires a deliberate action to release. Examples of latching stopbuttons 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 acceptablealternative. Some schools may choose to fit key switches to all machines but there is norequirement to do so.

• Emergency stop switch (often referred to as emergency stop buttons). Machines that aredesigned to be used from more than one position, such as planer / thicknesser machines, should befitted with stop button switches that can easily be accessed for from all working positions. BS 4163states that drilling machines should be fitted with a foot-operated emergency stop device so that themachine can be stopped without the operator having to let go of the spindle feed or work piece. Aknee-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 convenientlylocated mushroom-headed stop button or other suitable control device should be fitted to mostother workshop machines. In some circumstances the usual stop button will comply with this but inmany schools all machines are fitted with foot operated switches. Foot operated switches shouldcontrol a single machine only, and should be positioned so that they are easily accessible and arenot a trip hazard. Emergency stop switches should not be used as the usual way of stopping themachine.

• Stopping times. A check should be made to ensure those machines which are required to come torest within 10 seconds after switching off do so. (Currently, this includes circular saws and similarwood-sawing machines, band saws, and wood planing machines.)

• Electrical conduit. All supply cables for fixed machines, including those that work on a 240 voltsupply, should be enclosed within suitable fixed or flexible conduit. Steel, rather than plastic, ispreferred 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.

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• Drive guards. All drive belts and gear systems must be fully enclosed. Such guards should befitted with an electrical interlock so that the power to the motor will shut off when the guard isopened. Some alternative systems are acceptable. These include access doors or guards fitted witha key-operated lock. The key should be kept in a safe place. Another alternative is to fix the guardin place with machine screws or bolts which are kept tight and which require a tool to undo. Knurledscrews or thumb screws are not acceptable. Guards may be required for lead screws and feedshafts (where fitted) of metal turning centre lathes where there is a risk of entanglement. On metalturning centre lathes the hole in the change wheel guard that allows long work pieces to be passedthrough the hollow mandrel should be fitted with a cover plate held with machine screws. Thescrews 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 workpiece where necessary. Examples of cutter guards include the crown guard on a circular saw, thebridge guard of an overhand planing machine, chuck guards on drilling machines, mortisingmachines and metal turning lathes, guards for the blades on powered fret sawing machines, guardson horizontal and vertical milling machines, and eye shields on grinding machines. Crown guardson circular sawing machines should be set to cover the root of the saw teeth. Work or cutter guardsdo 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 by-passed. Wood turning lathes are not required to have guards. All guards must be maintained ingood 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, withappropriate records kept. The CLEAPSS guide L254 Health and Safety Maintenance of D&TWorkshop Equipment provides guidance on maintenance and the frequency of checks.

5.2 Portable mains electric and air powered tools check (includingsoldering irons)

• General condition. All portable tools should be maintained in good condition, which can be verifiedby a quick visual check each time the tool is used.

• Electrical safety check. Each time portable electrical equipment is used a quick visual checkshould confirm that the body of the equipment, the plug and cable are not damaged. The plugshould have shielded pins to the live and neutral connections. An electrical inspection and testshould be regularly carried out (often known colloquially as the PAT test). As a minimum this shouldbe every 12 months and may be required more frequently for equipment which might becomeelectrically damaged during use.

• Work holding or cutter guards. Where fitted guards for the cutter or work piece should be in goodcondition.

• LEV. If LEV is required it should be in place and working correctly. If dust collection bags are fittedthey should be in good condition.

• Maintenance. In addition to the general checks, there should be a regular programme of checkingand maintenance of all machines, with appropriate records kept.

15

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 valveshould 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. Notethat overhead hoods may not comply with the COSHH Regulations because the fumes may bedrawn across the face of the operator.

• Piped welding gas supply. This should be in good order, with all shut off valves working. Thesystem should be checked every 12 months by a suitably qualified person to ensure that it is ingood condition with no leaks.

• Gas cylinders. These should be secured upright and stored correctly with flash back arrestorsfitted on welding equipment. It is essential that gas cylinder are stored correctly. There should be anotice to indicate the presence of flammable gases under pressure. The local fire brigade should beinformed.

• Gas welding equipment. This must be checked annually – regulators, hoses, blowpipe, etc. This isan essential requirement.

• Electric arc welding. This should have a power supply that is capable of supplying the requiredinput current and be provided with an independent work piece earth, which should be checked forconductivity to earth every 12 months. Suitable screens, to prevent the glare of the arc affectingthose not involved with welding, should be in place. A face shield and/or goggles, with correct filterdensity, should be provided.

• Other flammable gases. Containers of gases such as liquefied petroleum gas or small butanecylinders should be stored as outlined in section 4 above. Some employers may require these to bestored in outside, well-ventilated storage rooms.

16

Appendix 1 Example H&S Audit Forms

Health and Safety Audit of Design and TechnologyPlease 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 Yes No Comments

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 activitiesin 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

………………………………………………………………………………………………………………………

………………………………………………………………………………………………………………………

………………………………………………………………………………………………………………………

………………………………………………………………………………………………………………………

………………………………………………………………………………………………………………………

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School:

Checklist for food technology rooms

Room name or number:


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 / equipmentwithin 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 inteaching 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 connectedto power supply

Safety chain fitted to gas cookers

Fridges and freezers in good condition and working atappropriate temperatures

Suitable arrangements in place for storing raw andcooked foods, and ingredients

Portable food mixers / processors in good order, safetyinterlocks working

Pressure cookers inspected regularly

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

………………………………………………………………………………………………………………………

………………………………………………………………………………………………………………………

………………………………………………………………………………………………………………………

18


School:

Checklist for textiles rooms



Room clean and tidy












Fixed appliances in good condition, correctly connectedto power supply

Sewing machines in good order, located appropriately

Irons and ironing boards in good order, locatedappropriately

Wax pots, if used, are located in appropriate positions

Further comments on this room if needed and action required

………………………………………………………………………………………………………………………

………………………………………………………………………………………………………………………

………………………………………………………………………………………………………………………

………………………………………………………………………………………………………………………

………………………………………………………………………………………………………………………

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………………………………………………………………………………………………………………………

………………………………………………………………………………………………………………………

19


School:

Checklist for resistant materials rooms



Room clean and tidy











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 of12 monthly check

If fitted, evidence of air compressor check

If fitted, low voltage power supplies in good order andworking

PPE in place and used

Work and/or consumable materials are stored correctly &not causing obstructions

Appropriate hand washing facilities provided

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

………………………………………………………………………………………………………………………

………………………………………………………………………………………………………………………

………………………………………………………………………………………………………………………

20


School:

Checklist for graphics rooms / areas



Room clean and tidy











Work benches / tables spaced out appropriately


If provided, machines connected through switcheddisconnector, fixed down, supply cable protected




If fitted low voltage power supplies in good order andworking

PPE in place and used



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

………………………………………………………………………………………………………………………

………………………………………………………………………………………………………………………

21


School:

Checklist for systems and control rooms



Room clean and tidy











Work benches / tables spaced out appropriately

Sufficient electric socket outlets for portable equipment

If provided, machines connected through switcheddisconnector, fixed down, supply cable protected




If fitted, low voltage power supplies in good order andworking

Etch tanks correctly installed and in good order withlockable lid

Appropriate PPE in place and used.



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

………………………………………………………………………………………………………………………

22


School:

Checklist for preparation and store rooms



Appropriate security (including lockable door)

Room clean and tidy

Heating/ventilation as required


Appropriate storage of bulky/heavy materials storedsafely and materials stored at height. Suitable laddersavailable

Hazardous / flammable / highly flammable materialsstored correctly and labelled

Food materials stored correctly and at correcttemperature

If applicable, gas cylinders stored correctly

If LEV system is fitted, is it working correctly, evidence of12 monthly check

Further comments on this room if needed and action required

………………………………………………………………………………………………………………………

………………………………………………………………………………………………………………………

………………………………………………………………………………………………………………………

………………………………………………………………………………………………………………………

………………………………………………………………………………………………………………………

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………………………………………………………………………………………………………………………

………………………………………………………………………………………………………………………

………………………………………………………………………………………………………………………

………………………………………………………………………………………………………………………

23


School:

Checklist for machines (includes plastics equipment)Room name or number:MachineMake / model / typee.g. Startrite 325 band saw

Machine ingood generalorder & fixeddown

Isolator inplace &working?

Key switchwhererequired.

NVOL inplace &working?Stoppingtime OK?

Conduit ingoodcondition

Drive guards inplace withinterlock orfixing device &in good order

Work holding orcutter guards inplace withinterlock whererequired?

LEV inplaceandworking

Evidence ofmaintenanceprogramme

24

Appendix 2 Health & safety training audit for design and technology

Audit of staff health and safety training needs for teachers and technicians in secondaryschools. 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 andsafety training for design and technology teachers and technicians. This training is competency basedand 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 forteachers and technicians working in resistant materials. All those receiving training need to cover thecore element, but the content can be modified to suit previous experience. The content of the units areoutlined below. This form is designed to identify your training needs in all the areas, but completion of itdoes not imply that the necessary training will be provided immediately.

DATA Core element training. Consists of three modules, essential for all teachers and techniciansworking in design and technology and introduced in 2004. Only those who were trained after this datewill have experienced them. Please complete the form below.

Module Tick this column if youhave done the module

If you have had training,put the year in whichtraining took place inthis column

Tick this column if youcan produce writtenevidence, of the training,e.g. a training certificate

Module 1Developing a culture ofhealth and safety

Module 2Risk Assessment

Module 3Health & safetyawareness

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

Module Tick this column if youhave had H&S trainingin this area of D&T

If you have had training,put the year in whichtraining took place inthis column

Tick here if you canproduce writtenevidence 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 thefollowing 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 yourtraining needs for this equipment.

Additional notes

Training – training is defined as being shown how to use the equipment by another competent personand 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 orthree times a month; rarely is defined as once or twice a term.

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Resistant materials specialist training

Equipment Tick if theequipmentis in yourschool

Tick if you arerequired to usethis equipment aspart of your job

Frequency of use:F= frequent;O = occasionally;R = rarely

Tick if you haveever had formaltraining to usethis equipment

The year ofany formaltraining

Can you produce writtenevidence, of the training,e.g. a training certificate

Drilling machine

Off hand grinder

Disc / belt sander

Polishing /buffing machine

Power hacksaw

Mortising machine

Plasticsequipment

Brazingequipment

Portablepower 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 radialarm saw and chop saw. Please complete the form below to identify your training needs for thisequipment.







Band saw

Circular saw

Bench mountedjig saw

Radial arm saw

Chop saw

27

Planer / thicknesser separate overhand planer and thicknesser. This unit includes combined andindividual machines. Please complete the form below to identify your training needs for this equipment.







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 machinesand equipment listed below. Please complete the form below to identify your training needs for thisequipment.







Wood turninglathe

Metal turninglathe

Verticalmilling machine

Horizontalmilling machine

Castingequipment

Welding – gas,arc, MIG, TIG

(Specify type ofwelding)

Anything else? Please list below any other equipment in your school not included above that you arerequired to use

Equipment Do you use it? Frequency Training? Date? Certificate?

28

Appendix 3 Key safety points for machinery, and space aroundmachinery and work areas in workshops, foodtechnology and textiles rooms

Common workshop machines and equipment

BAND SAW

Must have: key switch, LEV and must stop within10 seconds of being switched off.

When in use the top guide and blade guard must be as closeas possible to the top surface of the material being cut,normally 5 to 10 mm.

BLADE GUARD

TOP GUIDE

1500 1000

1000

ADVISED SPACE AROUND A BAND SAW

Guard should coverblade.

Foot should rest onthe work piece.

BENCH JIG SAW

Must have: guard for blade, NVOL*.

LEV should be provided. The machine should be bolted to thebench or to a suitable stand. It should be permanentlyconnected to the electrical supply through an isolating switchor a fused spur switch. The supply cable should be enclosed inconduit.

On this type of machine the guard is not very robust and caneasily be broken. The foot is often not used correctly. LEVarrangements are often inadequate.

*NVOL - No-volt and overload push button starter. Themachine is started by pushing a green button. If the electricalsupply is interrupted - e.g. power cut, the machine should notre-start unless the green button is pressed. If too much currentis drawn the machine should stop.

29

Take off table(shown in lowered position) 1.2 metresneeded between rear of saw blade andrear edge of table.

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 usercannot be distracted. A push stick should be used. When inuse the crown guard must be as close as practicable to the topsurface of the material being cut – normally 5 to10 mm andshould cover the root of the saw teeth.

FENCE – should project a maximum of 50 mm beyond front ofsaw 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 maybecome more common as vocational courses are introduced.It can be argued that it is safer to cut large sheets of timber onthis type of machine than on a circular saw.

Should be located in an area where user cannot be distracted.

30

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

3000

1000

1500

ADVISED SPACE AROUND RADIAL ARM SAW

Note Some of the space on each side might be usedfor a power hacksaw or horizontal grinder providedthat they are lower than the table of the saw.

31

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 usercannot be distracted.

COMBINEDOVERHAND PLANER/ THICKNESSER

THICKNESSER

Kickback fingers shouldbe provided. If none areprovided then only onepiece of timber should befed in at a time.

THICKNESSER ONFLOOR STAND

ADVISED SPACE AROUNDPLANER / THICKNESSER

32

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 assmall as possible usually 3 mm to 5 mm.

ADVISED SPACE AROUND A SANDING MACHINE

33

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

1000

15001500

34

WOOD TURNING LATHE

ADVISED SPACE AROUND WOODTURNING 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.

May be set at an angle to the wall to give better workingspace.

METAL-TURNING CENTRE LATHE

Must have: a chuck guard.A cover is needed for the end of the hollowmandrel.

Power feed / lead screw should beguarded. Alternatively disconnect it exceptwhen needed and then carry out a specificrisk assessment.

ADVISED SPACEAROUND A

METAL-TURNINGLATHE

35

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 tooland is fitted with an interlock switch that will prevent the

machine from starting unless the guardis closed.

36

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 conditionIn 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 andtungsten tipped tools.

DOUBLE ENDED HIGH SPEED GRINDER

Tool rest.

1 0 0 0

6 0 06 0 0

ADVISED SPACE AROUND HIGH SPEED GRINDER

HORIZONTAL SLOW SPEED GRINDER

ADVISED SPACE AROUNDA HORIZONTAL, SLOW SPEED GRINDER

BUFFING AND POLISHING MACHINESMust 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.

Eye shield.

The mopspindle mustbe guardedon both sidesof the mop.

ADVISED SPACE AROUNDA BUFFING MACHINE

37

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 thesemachines 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.

38

HOT METAL EQUIPMENTMust have: LEV. Extraction should be at a low level, i.e. fumes must not be drawn across the face ofthe 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 wholeroom 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 butbeware of too many pupils trying to use it simultaneously.

CRUCIBLE FURNACEA 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 onboth sides as well as 1200 mm to the front.

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Spacing around work areas

WORKSHOP BENCHES

Sufficient space is required around all workbenches. On the adjacent diagram the pale(white) area denotes the workspace for thatside of the bench. The darker (blue) areasdenote space that should be kept clear forcirculation.

750 750

750

750

On four-place benches the outer 50 mm ofspace can be shared with the adjacentbench. The pale (blue) area denotes theworkspace and the darker (blue) areasindicate potential overlap space.

40

WORK AREAS IN FOODTECHNOLOGY ROOMS

The diagram gives spacing for cookers andsinks. Allow a minimum of 1750 mm clearspace between peninsular units or othersituations involving parallel workbenches.

There should always be a work surface onboth sides of any cooker, at the sameheight as the hob of the cooker.

The height of work surfaces used for foodpreparation should not be greater than850 mm.

As in the previous diagram the pale (blue)area denotes work space and the darker(blue) denotes potential overlap space withneighbouring work stations.

SEWING MACHINES

Space sewing machines as in the diagram.The bench should be at least 850 mmdeep. Socket outlets for power should bepositioned on the wall not less than150 mm above the surface of the bench.Sufficient socket outlets should be providedto allow for each machine to have its ownswitched outlet. Multi-way adaptors andfour way distribution blocks should not beused.

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