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DL79 Auditing Health & Safetyin a Secondary SchoolDesign and TechnologyDepartment

September 2009

DL79

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eptember2009

E m e r g e n c ys t o p

AuditingHealth&

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fetyinaSecondarySchoolDesignand

TechnologyDepartment

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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:[email protected]

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
mailto:[email protected]://www.cleapss.org.uk/mailto:[email protected]://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 it

This 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 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

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

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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-ROMand 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 demandsof 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-ROMand can be customised by individual departments for their

own use.

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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-ROMand 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.

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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 thatthe 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.

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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 purposes300 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.

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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 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 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 ofcookers.

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 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 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 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 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.

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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. Theyshould 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.

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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 drillingmachine). 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.

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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 areaThe 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.

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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 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

roomsshould 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 placerestrictions 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.

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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 afused 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.

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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 by-

passed. 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 Equipmentprovides 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 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 checkingand maintenance of all machines, with appropriate records kept.

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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 bestored in outside, well-ventilated storage rooms.

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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 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 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

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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)

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School:

Checklist for textiles rooms



Room clean and tidy





Shut off valve for gas and water supply accessible,

working and labelled






Sufficient electric socket outlets for portable equipment

location, condition

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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School:

Checklist for resistant materials rooms



Room clean and tidy





Shut off valve for gas and water supply accessible,

working and labelled






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 and

working

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)

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School:

Checklist for graphics rooms / areas



Room clean and tidy











Work benches / tables spaced out appropriately

Sufficient electric socket outlets for portable equipment location, condition

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)

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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)

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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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School:

Checklist for machines (includes plastics equipment)


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 inplaceand

working

Evidence ofmaintenanceprogramme

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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 itdoes 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 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, 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.

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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 electricjig saw

- portable electriccircular saw

- portable electricbiscuit cutter

- portable electricplaner

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.







Band saw

Circular saw

Bench mountedjig saw

Radial arm saw

Chop saw

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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.







Combinedplaner /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.







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 are

required to use

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

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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 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

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 permanentlyconnected 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 notre-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.

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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 inuse 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.

FENCE should project a maximum of 50 mm beyond front of

saw blade.

CROWN GUARD

RIVING KNIFE

Take off table

(shown in lowered position) 1.2 metres

needed between rear of saw blade and

rear edge of table.

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.

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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.

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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 used

for a power hacksaw or horizontal grinder provided

that they are lower than the table of the saw.

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.

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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 AROUNDPLANER / 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.

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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.

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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

WOOD TURNING LATHE

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ADVISED SPACE AROUND 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.

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 hollowmandrel.

Power feed / lead screw should be

guarded. Alternatively disconnect it except

when needed and then carry out a specific

risk assessment.

ADVISED SPACEAROUND A

METAL-TURNINGLATHE

VERTICAL MILLING MACHINE

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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.

GRINDING AND POLISHING MACHINES

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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.

1000

600600

ADVISED SPACE AROUND HIGH SPEED GRINDER

HORIZONTAL SLOW SPEED GRINDER

ADVISED SPACE AROUND

A 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 guarded

on both sidesof the mop.

ADVISED SPACE AROUND

A BUFFING MACHINE

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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.

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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.

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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

750

On four-place benches the outer 50 mm ofspace can be shared with the adjacent

bench. The pale (blue) area denotes the

workspace and the darker (blue) areas

indicate potential overlap space.

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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 othersituations 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.

DL079

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