Department of Human Resources
Helping managers to manage

Safety In Design Technology
Helping Managers to Manage
General
Secondary Schools
Primary Schools
Information
CLEAPSS (Consortium of Local Education Authorities for the Provision of Science
Services)
Helpline 01895 251496
Risk Assessments
Class Sizes for Practical Subjects
Lone Working
Training
Accidents
First Aid
Fire
Emergency Procedures
Housekeeping and Cleaning
Monitoring
Hazardous Substances
Local Exhaust Ventilation (LEV)
Compressed Air Systems/Pressure Systems
Woodworking Machinery Run Down Times
Date for run down time requirement
Type of Machine
Lighting
Heating
Gas Safety
Electrical – Installations, Appliances, Fixed Equipment, Isolation, Controls
Electrical Installations.
Fixed Installation
Portable Appliances
Fixed Electrical Equipment (Machine Tools)
Work Area Isolation Points
Kilns
Lifting Equipment
Abrasive Wheels
Maintenance
Personal Protective Equipment (PPE)
Workshop Safety Notes
Workshop Safety Notes (Personnel)
Introduction of Pupils to Machines
How to use model (or general) risk assessments - Summary
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Occupational Safety Unit Page 2 of 25 Issued March 2005

Safety in Craft Design & Technology
Helping Managers to Manage
The standard for guidance in school workshops is the British Standards Institution publication
‘Health and Safety in Workshops of Schools and Similar Establishments (BS 4163: 2000).
Implementation of BS4163:2000 is not a legal requirement but does provide a means of demonstrating that reasonably practicable steps have been taken to minimise risks. Equally, compliance with a British Standard does not of itself confer immunity from legal obligations.
BS4163 sets out systems of working which are drawn from current recommendations but they do not preclude the need for competent, experienced staff to exercise care and good judgement in safeguarding against accidents. It forms the basis of a code of good practice, which should be applied in all school workshops.
BS4163 is supplemented by CLEAPSS guidance, including, ‘Model Risk Assessments for
Design and Technology in Secondary Schools’.
Health and safety guidance for science and technology in primary schools is provided by the
Association of Science Educa tion (ASE) publication, ‘Be Safe’ - ISBN 086357324X and
CLEAPSS guidance.
All DT staff in secondary schools should be aware of the information in BS 4163:2000 and any additional advice in circulation from CLEAPSS, the DfES and the LEA. Copies of BS4163 have been supplied to secondary schools in the past but if not available, further copies can be obtained from HMSO Booksellers – Blackwells Bookshop in Leeds (Tel: 0113 243 2446) priced £22 (at February 2005) or DATA priced £19.50 (see appendix 2).
All Science and Design and Technology staff in primary schools should be aware of the information in Be Safe. All primary schools should be in possession of a copy. If this is not the case, further copies can be obtained from ASE priced £10. See contact details in
Appendix 2, later in this guidance. CLEAPSS termly publication ‘Primary Science and
Technology’ is supplied to Bradford primary schools and offers guidance, advice and support.
The PST index and all newsletters can be viewed on the CLEAPSS website primary section.
The newsletter also gives password details to the members only section of the site.
The Co-ordinator of Design and Technology should ensure that all such information is readily available to all members of their department. It should be ensured that all new members of the DT Department are also made aware immediately on taking up post.
The Occupational Safety Unit website offers further information and guidance on a range of Health and Safety issues www.bradford.gov.uk/hands/ .
Occupational Safety Unit Page 3 of 25 Issued March 2005

Safety in Craft Design & Technology
Helping Managers to Manage
Bradford Metropolitan District Council is a member of CLEAPSS who provide a range of advice, guidance, position statements and support material on science and DT processes, equipment and activities. This also includes Model Risk Assessments (supplied previously on
CD ROM to all Bradford Secondary Schools). It is essential that secondary schools are in possession, and take account of CLEAPSS information.
The CD ROM can be repurchased at very reasonable cost (£12 for CD) from CLEAPSS
(01895 251496). Updates can be found on the CLEAPSS website. Your Science Department will have further details of CLEAPSS if required. Updates and further information can be obtained from the members area of the CLEAPSS website www.cleapss.org.uk
.
The CLEAPSS helpline can be contacted for specialist over the phone advice for Science and
DT issues.
Risk assessment of significant hazards in ANY workplace is a requirement of the
Management of Health and Safety at Work Regulations 1999. This requires managers to identify hazards and ensure that control measures are put in place and maintained. Risk assessments should be undertaken of DT activities whether they take place in the classroom, workshop, prep room or off site. Further general guidance on risk assessment can be found in the HSE publication ‘5 Steps to Risk Assessment’ at www.hse.gov.uk/pubns/indg163.pdf
or on the Occupational Safety Unit website www.bradford.gov.uk/hands/ which also includes a training pack.
As previously explained Model Risk Assessments have been provided to Bradford secondary schools from CLEAPSS for work with Resistant Materials, Compliant Materials, and Food Technology and Be Safe publication for primary schools. The majority of groundwork has already been done with the hazards and risks identified and suitable control measures specified. School specific adaptation of these or other generic type assessments are necessary for two reasons:-
1. to cope with problems arising from the local premises or equipment and
2. to cope with different pupil groups (behaviour, special needs, abilities). For this reason it is important to regularly review control measures to cater for new groups or those with individual requirements.
Further CLEAPSS guidance on how to implement these or similar model risk assessments is provided in Appendix 1 of this guidance, which also gives an index of the CLEAPSS
Model Risk Assessments.
Occupational Safety Unit Page 4 of 25 Issued March 2005

Safety in Craft Design & Technology
Helping Managers to Manage
It is recognised that difficulties may arise in determining the right class size and this is exacerbated by the fact that there is no statutory limitations on class size in any subject in
England and Wales, although in Scotland it is law that no practical class (including science) may exceed 20.
The levels should be determined by risk assessment and factors to consider should include the room size and layout, intrinsic risk of the activity, supervision requirements, age and experience of pupils, special needs pupils, behavioural problems, expertise and experience of teachers and available technician support. Guidance is available from
CLEAPSS position statement PS9.
Consideration should be given to situations that present significant risk due to a person working alone. This may be controlled by arranging times of such activities to when there are others present, ensuring emergency communication is in place, or using an alternative process. Further guidance on Lone Working can be found on the Occupational Safety website. Lone working in workshops can also affect cleaning staff who may clean the area after other staff have left for the day.
Staff should be sufficiently trained and be conversant with all the equipment and materials in the workshop. This is particularly important for new staff and should form part of the induction process.
Only authorised, trained persons should be allowed to operate hazardous machinery. Any staff who operate woodworking machinery must have appropriate training. ‘Safe use of
Circular and Band Saws’
training can be arranged with various external providers including
Keighley College by contacting Andy Quinn 01535 618615.
The certificated training can be delivered at your own school with your machinery or at the providers workshops.
Training records should be maintained.
Occupational Safety Unit Page 5 of 25 Issued March 2005

Safety in Craft Design & Technology
Helping Managers to Manage
All Design and Technology staff should be thoroughly acquainted with the procedure to follow in the event of an accident in the department. All accidents must be entered in the school ‘Accident Book’ and where appropriate, reported to Occupational Safety Unit in the prescribed manner.
All staff should be made aware of the schools procedures for ensuring this.
The names of qualified First Aiders and the location of First Aid supplies should be displayed in each area.
A first aid container equipped and maintained in accordance with the Health and Safety
(First Aid) Regulations 1981, should be readily available in each Art and Design and
Technology area. Suitable eye irrigation arrangements should be in place and at least one person holding a current First Aid at Work certificate or who has been trained in emergency aid, should always be available when Art and Design and Technology rooms are in use. Refer also to the First Aid Guidance and training details on the Occupational
Safety Unit website.
Pupils and staff must be familiar with the fire alarm procedures and evacuation drill. Fire procedures notices should be displayed indicating actions to take in the event of fire. The full school fire risk assessment should cover the control of fire hazards in the workshops.
Staff should be trained in the use of appropriate fire fighting equipment, which must be available and maintained. The Occupational Safety Unit website has a fire training package and other guidance.
Fire risks from individual activities should be considered in the risk assessment with relevant controls implemented.
Pupils and staff should be clear about department safety rules and the steps to take in any emergency. Arrangements must be in place to ensure that any processes and activities are left in a safe condition on evacuation eg. open flame/hot process work.
It is important to maintain good standards of housekeeping. Work areas must be kept free of clutter, as they are often a cause of slips and trips and also a potential fire risk.
Regular monitoring should be in place to keep all areas clean and tidy.
Displays of pupils work must be sited carefully with consideration given to the emergency means of escape, fire spread and general staff and pupil circulation.
Clay and materials such as plaster and wood dust create particular problems and dry sweeping of ceramic studios and woodworking areas should be avoided.
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Safety in Craft Design & Technology
Helping Managers to Manage
Damp sweeping and specialist vacuum cleaners with specialised filters should be employed.
Wet clays should be cleaned up before drying out and creating dust.
Cleaning activities also require assessment for PPE requirements as dust may be disturbed during such activities and the use of face masks required in certain circumstances.
Routine monitoring of health and safety standards, systems and procedures should be undertaken. A department monitoring checklist is provided in Appendix 3 and on the
Occupational Safety Unit website to help in this purpose.
User inspections prior to use should be carried out, particularly of electrical equipment.
Occupational Safety Unit Page 7 of 25 Issued March 2005

Safety in Craft Design & Technology
Helping Managers to Manage
Using chemicals o r other hazardous substances at work can put people’s health at risk so the law requires employers to control exposure to hazardous substances to prevent ill health. They have to protect both employees and others who may be exposed, by complying with the Control of Substances Hazardous to Health Regulations 2002
(COSHH). This requires the assessment and control of risks. Hazardous substances could include adhesives, dyes, inks, paints and varnish, plaster, clay and also includes dust and fumes.
Chemicals are classified as, irritant, toxic, corrosive, flammable and highly flammable. It is essential to use up to date information on hazards associated with chemicals.
CLEAPSS guidance offers further information and the substance suppliers hazard data sheets should be obtained and consulted.
Guidance on COSHH (including training package) can be found on the Occupational
Safety Unit website.
It is also a requirement of COSHH that any LEV system provided for the control of vapors, dusts, etc are inspected by a competent person within every 14 month period.
(see LEV section in this guidance).
Further advice on LEV can be obtained from Asset Management and CLEAPSS guidance.
Whilst asbestos is not regulated by COSHH (it has its own regulations) it is a hazardous substance. It is essential that asbestos containing materials are not used. Fire blankets, mats, ropes, gloves, wools, fillers, cement, and brake materials, should be asbestos free.
Some existing materials in schools (eg fume cupboard linings, work surfaces, oven door seals) may contain asbestos. If the presence of asbestos is suspected, this can be checked on the schools Asbestos Register.
Contact the Councils Asbestos Unit (01274 433562) for further advice.
Some dust and fumes can present serious health risks both to staff and pupils, specific legal limits apply and these must not be exceeded. COSHH Regulations requires that LEV must be provided if a risk assessment shows that it is required, to keep within these stipulated legal limits.
To assist schools CLEAPSS model risk assessments identify the equipment and processes that will require LEV.
LEV refers to a system that traps an airborne contaminant close to its source and removes it safely from the environment; they can be individual systems or a series of hoods and ducting.
It would be very difficult to argue that in any secondary school workshop the level of risk is so low that no precautions are necessary. Therefore all workshops would be expected to have some LEV installation.
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Safety in Craft Design & Technology
Helping Managers to Manage
Note. LEV systems must be thoroughly examined by a competent person at least every 14 months and records kept for at least 5 years as required by COSHH. LEV should also be checked for operation every time it is used.
CLEAPSS guidance L225 - LEV in Design and Technology (March 2003) is an essential publication for all schools. Position Statement PS62 supplements this in giving lists of suppliers and testers of LEV systems. These documents along with many others can be found on the CLEAPSS CD ROM.
In some circumstances additional protection afforded by personal protective equipment
(PPE) such as respiratory protection, may need to be employed, e.g. when cleaning up, removing dust bags from LEV, etc.
Regular cleaning using a dustless method (e.g. industrial vacuum cleaner) is needed to reduce background dust levels and prevent fire. Dry sweeping must be avoided. This should be communicated to the cleaner in charge and monitored.
The Pressure Systems Safety Regulations 2000 apply to mobile and fixed pressure systems. Compressed air systems should have a scheme of examination drawn up by a competent person in accordance with the above regulations.
The system should then be examined by a competent person in accordance with the scheme. BS4163 offers further information in relation to air receivers.
Secondary school science and Design and Technology departments may also have pressure cookers, autoclaves and model steam engines which all come under the above regulations.
Please contact your competent person/insurance company for further advice.
CLEAPSS Guide L214a Examining Autoclaves, Pressure Cookers and Model Steam
Engines gives Guidance for Employers. This can be found on the Science CD ROM.
Preparation of a scheme of examination and performance of the examinations are normally contracted to Insurance Companies with specialist engineers. If your school insures through the Councils Insurance Scheme, further details can be obtained from the
Insurance Section in Britannia House (01274 432779 or 432780).
Certain types of woodworking machines (see list below) had until the 5 th December 2003 to comply with additional requirements of the Provision and Use of Work Equipment Regulations
98 (PUWER). Other types have a later date to comply.
These requirements are for machines to have a run down time of 10 seconds or less where there is a risk of contact whilst it runs down.
In order to achieve this it may be necessary for retrospective braking to be fitted by a competent person. Newer machines should already comply with these requirements.
Potentially there may be some conflict with electronic braking and the workshops emergency stop system. Where these are fitted and electronic braking is fitted on the same circuit , the operation of the workshop emergency stop button will remove power from the machine and will therefore deactivate the braking, making it ineffective.
Please discuss the issue with Terry Adey, Asset Management Electrical Surveyor 01274
431946 or your competent person, before proceeding with any work.
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Helping Managers to Manage
What to do now.

Establish if you have any of the machines listed below.

Establish if they have a rundown time of 10 seconds or less when stopped by conventional OR emergency stop systems. (Many schools equipment may have already been checked on workshop surveys, (of which schools would have a copy) by
Terry Adey, CBMDC Asset Management Electrical Surveyor).

Ensure that a record of compliance is kept in the department/school.

Where retrospective fitting is required and cannot be fitted within the timescale below then the machines must not be used after the specified date and should be isolated.

Risk assess other machines not listed to identify if braking required.

Where machines do not comply, ensure that measures are taken to retrofit braking noting the timescales below.
5 December 2003
5 December 2005
5 December 2008
Circular Saw Benches, dimension saws, powered and hand fed cross cut saws, single end and double end tenoning machines, and combined machines incorporating a circular saw and/or tenoning attachment.
Narrow band saws, re-saws, vertical spindle moulding machines
(unless fitted with a manual or foot operated brake), hand fed routing machines, thicknessing machines, planning/thicknessing machines and surface planning machines.
All other machines not listed but where risk assessment shows braking to be necessary.
Further information on woodworking machinery safety, including retrofitting of braking above, can also be found on the HSE website at www.hse.gov.uk/pubns/woodindx.htm
Sufficient lighting should be provided in work areas. Emergency lighting should be provided where appropriate. Sudden changes of intensity of illumination within work areas/entrances/exits should be avoided. There should be subdued lighting in forging, brazing and welding areas to enable colour changes in heated metals to be easily observed.
BS4163 recommends that at least 500lux should be provided for normal bench and machine work (taking into consideration the stroboscopic effect of fluorescent lighting units).
Lighting units in storage areas should be physically protected against damage.
Supplementary lighting should be provided for machine tools and equipment if the main room lighting is not sufficient.
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Helping Managers to Manage
Work areas should be maintained at a temperature comfortable to work in when appropriate protective clothing is worn. Temperatures specified by the Education Premises
Regulations can be found on Occupational Safety Unit website.
Food preparation should not be carried out in close proximity to fan-assisted heating units where there is the potential for food contamination from airborne dust. Fan-assisted heating should be avoided where dust-producing activities are carried out e.g. work with wood dust or clay.
Gas-powered equipment must be subject to regular maintenance, inspection and testing.
This should be undertaken by a CORGI registered gas engineer. No person, other than an engineer qualified to the relevant level, as identified on his/her CORGI registration card, should carry out work on any part of a gas appliance or gas system.
Design and Technology work areas with gas equipment should have a means of isolating the gas supply to the room which is lockable in the off position. The means of isolation should be in a readily accessible position and should be clearly marked, but should not be readily accessible to students. It should be situated as near as practicable to the point where the gas supply enters the building. The means of isolation should be a manual valve or a failsafe electrically operated solenoid valve that may form part of an emergency system within the room.
Gas Escape notices, should be displayed in work areas. The Education Department Gas
Policy contains a gas escape notice.
A notice should also be displayed to indicate the location of the turn off point.
The Education Department Gas Safety Policy can be found on the Occupational Safety
Unit website.
Electrical systems and equipment should be maintained as required by the Electricity at
Work Regulations (EAW). Any work on electrical systems installations or equipment must only be carried out by a competent person (as defined by the EAW). For further advice contact Asset Management Electrical Surveyors (01274 431770).
This means the mains electrical wiring system. Inspections and tests on it should be carried out at least every 5 years. This is arranged for schools by Asset Management
This means equipment with a flex and a plug. The equipment should be inspected and tested in accordance with the portable appliance testing regime. Mains powered portable equipment (indoors or outdoors) should be supplied via a Residual Current Device (RCD) or protected socket outlet. The correct working of these devices should be verified using the test button. Cordless, battery-operated tools should be used if possible.
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Each piece of fixed electrically powered equipment should be able to be individually isolated from the main supply. Emergency stop switches should be provided at all fixed machines, and be easily actuated by the user.
The basic requirements in relation to stop and start controls and emergency controls are detailed below.
Stop and start controls
Must be separate and easily identifiable
Stop controls must always override any start controls
Start controls should be recessed so that a positive action is required to operate the machine
Stop controls should stand proud of the machine control panel
No machine should be able to operate without the voluntary action of a start control – No
Volt starters should be fitted to prevent this occurring.
Once a machine has been stopped it must only be able to be restarted by voluntary actuation of a start control.
Emergency stops
Unless it will not reduce any risk arising to any greater extent than the normal stop device every machine must be fitted with an emergency stop.
Emergency stops should not be used as the normal stop control.
They must be readily accessible and easily actuated when necessary, easily identifiable and distinct. Buttons should be of the large red mushroom type; foot and knee stops should be red and not shrouded in any way.
The position of emergency stops will depend upon the machine risk assessment. It should be as close as possible to the machine operator so they do not have to reach or stretch to operate it. Ideally, to give quicker operation foot stops should be able to be operated by sliding the foot as this takes less time than having to lift and use downward force. Terry
Adey in Asset Management has a specification and supplier if required. They should be tested daily for satisfactory operation.
In each workshop it should be possible to disconnect and isolate all electrical circuits supplying fixed equipment and socket outlets. The isolator should be easily accessible, clearly labelled “main switch” and be lockable in the off position. It should not control lighting, space heating and sockets specific for cleaning purposes.
All Design and Technology workshops should have emergency stop circuits, lockable in the off position and the stop buttons to be clearly labelled. This system should be tested daily for satisfactory operation.
There has been confusion in the past regarding the provision and installation of electric kilns in schools. Kilns have often been ordered prior to a suitable site being identified. The
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Helping Managers to Manage provision of a safe site and suitable electrical installation has then caused considerable expenditure and delay afterwards.
A suitable safe location for a kiln should be found prior to purchase.
Advice and guidance can be sought from the Electrical Surveyors, Asset Management
Support Service. Tel: 01274 431771.
Further guidance regarding kilns can be found on the Occupational Safety Unit website and CLEAPSS CD ROM.
The Lifting Operations and Lifting Equipment Regulations 1998 (LOLER) apply to any equipment used for lifting and lowering loads (e.g. vehicle hoists, jacks, pulley blocks etc.)
Briefly these regulations require the following:
 that lifting operations are planned, supervised and carried out by competent persons;
 that lifting equipment is strong enough, stable and suitable for the purpose;
 the safe working load is indicated on the equipment;
 that a test certificate is provided by the supplier;
 that thorough examinations are carried out by a competent person. These are usually 12 monthly for lifting machines and 6 monthly for equipment such as chains, slings and eyebolts, etc. Examinations are usually contracted to insurance companies with specialist engineers.
Although the Abrasive Wheels Regulations 1970 have been superseded by the Provision and Use of Work equipment Regulations 1998 (PUWER), the sections regarding training of persons to mount abrasive wheels, on guarding of wheels, and measures to prevent wheels over speeding, are still recognised as good practice guidelines.
There is no substitute for thorough practical training in all aspects of the mounting and use of abrasive wheels and only those who have undertaken relevant training should perform these duties.
Training courses are offered by many organisations. Further information can be obtained from the British Abrasives Federation or CLEAPSS.
Locally, Keighley College (01535 618615) offer Abrasive Wheels Training.
An appropriate regular systematic maintenance programme must be in place for machinery tools and any other work equipment. Each item of equipment is subject to
PUWER (Provision and Use of Work Equipment Regulations) 1998.
This requires that all work equipment is maintained in safe efficient working order.
Only competent persons should carry out maintenance and repairs of machines.
Only a suitably qualified and competent person should carry out repairs and maintenance of gas, electrical and air systems.
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Due to specific legal duties and levels of risk, particular attention should be paid to the following categories of equipment:-
Fixed Electrical Equipment Woodworking Machinery
Metalworking Machinery
Food Technology Equipment
Personal Protective Equipment
Local Exhaust Ventilation (LEV)
Welding Equipment
Portable Electrical Tools and Appliances
Gas Appliances
Lifting Equipment
Pressure Systems LPG Installations and Equipment
With regard to the complexity of PUWER and other specific legislation, it is strongly recommended that schools employ the services of an independent competent person or organisation to ensure compliance in respect of the above. It is the schools responsibility to arrange for inspections testing and repairs.
Many schools continue to use H&S Williamson who previously provided the YPO maintenance contract. If you wish to discuss/arrange machinery maintenance H&S
Williamson can be contacted by phone on 01924 407803, Fax 01924 408658, or mobile
07778483557.
Risk assessments will identify the need for PPE for pupils and staff. This could include overalls, face masks, goggles and gloves. Any PPE provided should be stored, cleaned, and maintained appropriately to ensure its efficiency.
The teacher in charge of the lesson must ensure that pupils wear the required PPE and monitor its use.
The recommendations in BS 4163 (2000) should be applied in all school workshops together with the following:-
All workshops to have emergency stop circuits, tested daily and recorded, lockable in the off position and the stop buttons to be clearly labelled.
Power supplies must be locked off when the workshop is unsupervised.
All fixed machinery should have emergency stop controls (see the individual specification).
Where applicable, all guards which have to be moved to adjust machinery to have interlocking protective switches. (see CLEAPSS detailed sheets on individual machines).
Installation or modification of machinery and equipment must comply with relevant legislation, including PUWER, Electricity at Work Regulations, COSHH.
Installation and modification must only be undertaken by competent persons.
Further advice and guidance can be obtained from Terry Adey (Electrical Surveyor) in
Asset Management Support on 01274 431946.
No unauthorised person or unsupervised pupil to use any equipment.
In the case of the Design and Technology teacher being absent, whenever possible the teaching group should be transferred to a general teaching room.
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Under no circumstances should practical work be undertaken with staff who do not have appropriate training and qualifications.
It is the duty of staff to:-
 See that all machinery and equipment is serviceable and clear of obstruction before pupils enter the workshop.
 Be sufficiently trained and conversant with all workshop equipment and materials.

Pay attention to the wearing of suitable protective clothing / adequate footwear

equipment, for the process in hand.
 Prevent pupils entering a workshop without supervision.
 Demonstrate correct processes and safety procedure.
 Be satisfied that pupils can complete an operation safely before they begin that operation.

Keep equipment and materials in good condition.
 Store equipment and materials safely.
 Keep floors and equipment clear of obstruction.
 Use equipment safely.

Check emergency stop buttons daily.

Teach safety regulations and practices.

Prevent more than one person working at each machine.
 Prevent unauthorised persons using any equipment.
 Switch and lock off the power when leaving the workshop unsupervised.
 Keep safety notes readily available and up-to-date.
 Record all significant injuries (see Accidents section).

Only use equipment and machinery for authorised purposes and duties.
Pupils shall :-
 not use any equipment or material until they have been sufficiently instructed and trained on its safe use and feel competent to use it safely.
 not operate any fixed machinery unless they have been authorised and trained to use it and a member of staff is in the workshop.
 not operate any portable equipment unless they have been authorised to use it and are under the supervision of staff.
 not adjust or clean any machinery unless the isolator is in the off position.
 not operate any machinery which is not adequately guarded.
 not behave in any manner likely to cause an accident.
 wear suitable clothing / adequate footwear
 report all accidents or injuries to the teacher.

report defects to a member of staff
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Safe, appropriate clothing including footwear must be worn. Ties, sleeves, apron strings, jewellery, footwear and long hair can put machine operator at risk and will require appropriate controls.
The teacher should demonstrate the functions of a machine by working through its checklist.
Before a pupil uses a machine for the first time the teacher must be satisfied that the pupil is aware of the following:-
 Where the isolator is
 How to switch machine on and off
 Emergency actions/procedures
 The function of the machine – what will happen when the controls are used

That the machine must be used only as the teacher has demonstrated. The pupil must not ‘experiment’
 The isolator is to be in the off position except when the operation is being carried out. All cleaning, adjusting and setting up shall be done with the isolator in the off position

All other pupils shall keep away from the operator
Only one person may use a machine at a time (even the double ended polishing machines). If any help is required the teacher must give it.
Clear and precise instructions appropriate to the individual machine should always be brought to the attention of all pupils staff and technicians (including new colleagues and students on teaching practice).
The pupils should be taught how to deal with swarf and waste products safely eg. turnings, drillings, offcuts from the guillotine. These can be very dangerous and must be placed in a suitable bin and not left to litter machines or floor.
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Appendix 1
Helping Managers to Manage
The following index is from ‘CLEAPSS Model Risk Assessments For Design And
Technology In Secondary Schools’. The full texts can be found on the CLEAPSS CD
ROM. CD ROM also offers position statements on a range of issues.
( Note : There has been some new pages issued and several pages have been revised since the first issue in 2000. The date in the contents list below identifies material that is new or has been revised. The footer on each page shows the date of issue or revision.
Unless indicated, pages in part 1 were issued in 2000; pages in parts 2 and 3 were issued in 2001.)
*
It is possible to update the Model Risk Assessments from the CD ROM via the
CLEAPSS website.
Foreword 1
Acknowledgements 2
General introduction 3
Health & Safety Law 3
The Management Regulations (2001; page 5 only) 4
The COSHH Regulations (2001; page 6 only) 6
Personal Protective Equipment Regulations 8
The Noise at Work Regulations 8
The Manual Handling Regulations 9
The Provision and Use of Work Equipment Regulations 9
The Electricity at Work Regulations 11
Food Safety Regulations 12
Immediate Remedial Measures & First Aid 13
Model Risk Assessments in Design and Technology 14
Part 1: Work with Resistant Materials 15
1.001 Adhesives: Acrylic cement (2001) 17
1.002 Adhesives: Cyanoacrylate 19
1.003 Adhesives: Hot-Melt types (For Glue guns) 21
1.004 Adhesives Activities: Glue Guns 23
1.005 Adhesives: Reactive resins, Epoxy, Polyester (2002) 25
1.006 Adhesives: Reactive resins, Formaldehyde 27
1.007 Adhesives: Solvent-based, Rubber solution, Polymer cements, Cellulosics (2001) 29
1.008 Adhesives: Solvent-based, Repositionable 31
1.009 Adhesives: Water-based, PVA, Rubber latex 33
1.010 Chemicals for P C Boards: Preparation of etch-resistant track layouts (2001) 35
1.011 Chemicals for Printed Circuit Boards: Etching (2001) 37
1.012 Electricity and Electronics Work 39
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Helping Managers to Manage
1.013 Heat Treatment: Brazing, Silver-soldering, Fumes and fluxes 41
1.014 Heat Processes: Brazing, Silver soldering 43
1.015 Heat Treatment: Casting, Fumes and sand 45
1.016 Heat Processes: Casting 47
1.017 Heat Treatment: Forging, Fumes 49
1.018 Heat Processes: Forging 51
1.019 Heat Treatment: Soft soldering, Fumes and fluxes 53
1.020 Heat Processes: Soldering Irons 55
1.021 Heat Treatment: Welding (Electric arc), Fumes 57
1.022 Heat Processes, Welding: Electric arc (2001) 59
1.023 Heat Treatment: Welding (Oxy-acetylene), Fumes 61
1.024 Heat Treatment: Use of Oxygen 63
1.025 Heat Processes, Welding: Oxy-acetylene (2002) 65
1.026 Lapidary Equipment: Cutters and Grinders 67
1.027 Metal Working: Grinding dust 69
1.028 Metal-Working Machines: Grinding, Tool & Surface 71
1.029 Metal Working: Cutting oils (2002) 73
1.030 Metal-Working Machines: Guillotines, (Shears and notchers) 75
1.031 Metal-Working Machines: Drilling machines 77
1.032 Metal-Working Machines: Lathes, Mills and Power saws (2002) 79
1.033 Metal Working: Polishing materials and Polishing dust 81
1.034 Metal-Working Machines: Linishing and Polishing 83
1.035 Metal Working, Portable Tools: Grinders and Drills 85
1.036 Motor Vehicle Engineering: Asbestos 87
1.037 Motor Vehicle Engineering, Batteries: Electrolyte and fumes (2001) 89
1.038 Motor Vehicle Engineering: Demonstration Engines 91
1.039 Motor Vehicle Engineering: Engine fuels, Engine oils 93
1.040 Motor Vehicle Engineering: Exhaust fumes (2001) 95
1.041 Motor Vehicle Engineering: Lifting and holding equipment 97
1.042 Plastics: Hazards of materials 99
1.043 Plastics: Glass-Reinforced Plastic, Resin casting, Fumes and Chemicals
1.044 Plastics: Machine Abrading, Fumes and dust 103
1.045 Plastics Machines: Abrading & Trimming Equipment (2002) 105
1.046 Plastics Machines: Injection-Moulding Equipment 107
1.047 Plastics: Hot-Wire cutting, Fumes 109
1.048 Plastics: Polishing Dusts 111
1.049 Plastics Machines: Polishers 113
1.050 Plastics Machines: Sheet Benders 115
1.051 Plastics Machines: Vacuum- and Pressure-forming Equipment 117
1.052 Surface finishes: Acid Treatments (Pickling & Sample etching) (2001) 119
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Helping Managers to Manage
1.053 Surface finishes: Enamelling Materials 121
1.054 Surface finishes: Enamelling Kilns 123
1.055 Surface finishes: Solvent-based paints (Aerosols) (2002) 125
1.056 Surface finishes: Solvent-based paints (Liquids) (2002) 127
1.057 Surface finishes: Varnishes and Wood polishes (2002) 129
1.058 Wood working: Dust (2002) 131
1.059 Wood working, Hand Tools: Chisels and Gouges (2002) 133
1.060 Wood working, Portable tools: Saws, Drills and Routers (2002) 135
1.061 Wood working, Portable tools: Sanders, Planers (2002) 137
1.062 Wood-working Machines: Sanders, Disc and Belt 139
1.063 Wood-working Machines: Saws - Circular, Band and Radial arm (2002)
1.064 Wood-working Machines: Planing and Thicknessing (2001) 143
1.065 Wood-working Machines: Turning and Mortising 145
1.066 Cutting and Shaping Resistant Materials by Hand (2002) 146A
1.067 Bench-mounted Jig saws, Scroll saws and Fret saws (2002) 146C
1.068 Cutting Compliant Materials (2002) 146E
1.069 Using CNC Machines to Cut and Shape Materials (2002) 146G
1.070 Using Compressed Air and Pneumatics Equipment (2002) 146I
1.071 Using Air Brushes and Paint Sprays (2002) 146K
Part 2: Work with Compliant Materials: (ie, textiles and some plastics)
Introduction to Part 2 147
2.001 Adhesives used with Compliant Materials 149
2.002 Cleaning fabrics 151
2.003 Cleaning agents: Bleaches 153
2.004 Cleaning agents: Detergents 155
2.005 Cleaning agents: Solvents 157
2.006 Dyes & Mordants 159
2.007 Paints & Inks used with Textiles 161
2.008 Fabric Identification: Activities 163
2.009 Fabric Identification: Chemicals 165
2.010 Flammable Substances: Liquids 167
2.011 Flammable Substances: Non-liquids 169
2.012 Cutting Compliant Materials 171
2.013 Ironing 173
2.014 Knitting Machines 175
2.015 Sewing Equipment: General-purpose machines 177
2.016 Sewing Equipment: Overlockers 179
2.017 Sewing Equipment: Small items 181
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2.018 Wear Tests on Textiles 183
Appendix 1: Results of burning tests on fabrics 185
Appendix 2: Results of chemical tests on fabrics 186
Helping Managers to Manage
Part 3: Work in Food Technology
Introduction to Part 3 187
3.001 Handling Food 191
3.002 Food Purchase and Selection 193
3.003 Food Tasting and Eating 195
3.004 Food: Chemical Tests 197
3.005 Food Preparation: Using Conventional Ovens 199
3.006 Food Preparation: Cooking and Reheating, Food Poisoning 201
3.007 Food Preparation: Defrosting Foods 203
3.008 Food Preparation: Using Knives 205
3.009 Food Preparation: Processing 207
3.010 Portable Food Processors, Mixers & Powered Tools 209
3.011 Food Preparation: Using Enzymes 211
3.012 Food Preparation: Using Microorganisms 213
3.013 Mixing, Liquidising and Mincing 215
3.014 Food Storage: Dry Foods 217
3.015 Food Storage: High Temperatures 219
3.016 Food Storage: Low Temperatures 221
3.017 Freezing Food: Refrigerator, Freezer 223
3.018 Heating Food: Kettle, Urn & Hob 225
3.019 Frying and Grilling Food 227
3.020 Toasting Food 229
3.021 Heating Food with Microwaves 231
3.022 Pressure Cookers 233
3.023 Cleaning Agents for food handling areas: General 235
3.024 Cleaning Agents for food handling areas: Bleaches 237
3.025 Cleaning Agents for food handling areas: Descalers 239
3.026 Cleaning Agents for food handling areas: Detergents 241
3.027 Cleaning Agents for food handling areas: Disinfectants 243
3.028 Cleaning Agents for food handling areas: Oven Cleaners 245
3.029 Cleaning Agents for food handling areas: Sink & Drain Cleaners 247
3.030 Pest Control 249
3.031 Waste Disposal 251
Appendix 3: Major Causes of Food Poisoning 253
Appendix 4: Details of Suggested Food Tests 255
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Helping Managers to Manage
The model risk assessments supplied as these sheets are not an end in themselves; merely possessing them does not meet the various regulations which call for risk assessments. Model risk assessments are starting points which Design and Technology departments must adapt to their local circumstances and use in preparing activities for their pupils or students. One way of doing this is to consider the following questions.
Answer once for the whole department:-

What is the proposed activity?

Is it to be done by teachers, technicians or pupils/students?

Do all staff have the necessary skills and experience to do and supervise this activity? If not, the activity must be restricted to those with the skills until training has taken place.

Does it use equipment listed in these assessments? If so, find the sheet(s).

Does it use chemicals, eg, adhesives, finishes or cleaning materials? If so, find the sheet(s).

If no sheets are available and you consider the activity could be hazardous, telephone the CLEAPSS Helpline (01895 251496) for advice.

Do any rooms have layout/space/equipment problems?

Do the sheets list Control Measures which your facilities cannot provide? (For example, is local exhaust ventilation essential but yours is inadequate or broken?)

Can you avoid the problem perhaps by restricting the work to very small groups or by working outside?
Record the sheet numbers and your conclusions in a place where all staff will be aware of them.
Answer for each lesson:-

Is this an activity I can supervise? If not, see the department arrangements.

Does this activity require preparation which the technician can do or must I do it?

Is my class ready for this activity?

Are the class members mature enough to follow my instructions or should I defer it until later in the year or later in the course?

Is the class too large for all to do this activity at once? If so, how large a group should it be?

Are there pupils in this class whose presence would make this activity unsafe for all?
Note your conclusions in your lesson plans.
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Safety in Craft Design & Technology
Appendix 2
Helping Managers to Manage
The Design and Technology Association (DATA)
Tel: 01789 470007; Fax: 01789 841955
E-mail: DATA@data.org.uk
http://www.data.org.uk
The Consortium of Local Education Authorities for the Provision of Science
Services (CLEAPSS)
Tel: 01895 251496; Fax 01895 8134372; www.cleapss.org.uk
The Association for Science Education (ASE)
Tel: 01707 267411; Fax 01707 266532
E-mail: ase@asehq.telme.com
www.
ase .org.uk
/
The National Association for Advisors and Inspectors in Design and technology
(NAAIDT) www.naaidt.org.uk
CBMDC Asset Management Electrical Surveyors, Flockton House
Tel 01274 431770
CBMDC Occupational Safety Team
City Exchange, Hall Ings, Bradford. BD1 5SG
Tel 01274 431oo7. Fax 01274 431178 www.bradford.gov.uk/hands/
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Appendix 3
Helping Managers to Manage
The following health and safety checklist should be regularly completed (minimum yearly) with findings documented and action taken to rectify any issues.
Design & Technology
Departments’ policy and procedures up to date
Findings/action required
Relevant, up to date guidance, standards, model risk assessments available. Have all the appropriate staff been made aware of them? Eg CLEAPSS CD ROM, BS4163.
Evidence of using guidance to annotate lesson plans/schemes of work?
Evidence of adaptation of general assessments to local circumstances?
Off site visits risk assessed?
Technicians’ activities risk assessed?
Organisation and delegation of duties clear?
Evidence of previous monitoring and follow up actions taken?
Evidence of appropriate staff qualifications/training?
Staff trained/authorised and competent to use high-risk machinery/tools? Eg Circular Saw.
Inspections/ tests carried out by “competent persons” and records kept?

Electrical system

Fixed electrical equipment

Portable electrical tools/equipment

Woodworking machinery

Metal working machinery

Abrasive wheels

Welding equipment

Personal protective equipment

Gas appliances

Local exhaust ventilation Inspection (COSHH 14 monthly)

Lifting equipment

Pressure Systems

LPG Installations/equipment

Kilns
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Helping Managers to Manage
General maintenance regularly carried out and records kept?
Good standards of housekeeping, hygiene and cleanliness?
LEV fitted to relevant machinery?
General levels of ventilation adequate?
First aid provision adequate (equipment and people)?
Fire doors operational, clearly marked, free from obstructions?
Fire fighting equipment readily available and maintained?
Emergency arrangements in place (e.g. accidents, leaks)?
Suitable PPE provided and worn?
Work areas – suitable conditions in respect of:

Ventilation

Security

Lighting

Heating

Surfaces

Noise

Water supply/drainage/sinks
Room isolating gas taps/controls clearly marked, accessible and in working order?
Work area emergency switching systems in place/working?
Power isolators locked off when room unsupervised?
Individual machines fitted with suitable stop/start controls? and emergency stops?
Does machinery/ equipment comply with PUWER – evidence?

Suitability

Guarding

Stability

Lighting

Markings

Health and safety warnings

Braking
– run down times
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Helping Managers to Manage
Storage arrangements adequate for:

Food

Flammables

Oxygen/acetylene

Chemicals/ hazardous substances

Plastics

Portable equipment

PPE

Art studios
Do staff carry out pre-use checks of all equipment? e.g. gas hoses, RCDs, electrical leads etc.
Health and safety notices clearly displayed?
Students receive appropriate H & S instructions before equipment is operated or before heavy items lifted/handled?
Code of conduct in place? Standards of behaviour specified?
Emergency Stops tested daily?
Consider the following specific processes/areas – any issues?

Woodworking

Metalworking

Motor vehicle work

Moulding / heat processes

Ceramics

Printing

Textiles

Photography

Food technology
School: _______________________________________________________
Department/area: ______________________________
Checklist completed by: ________________________
Date: _____________________
Occupational Safety Unit Page 25 of 25 Issued March 2005