Schools’ Health and Safety Handbook
Section9.3: Code of Practice for Secondary Design and Technology
Risk Assessment WW01: Circular Sawing Machine
February 2007
Risk Assessment WW01: Circular Sawing Machine
ESTABLISHMENT
SCHOOLS TEACHING SECONDARY DESIGN AND
TECHNOLOGY
DEPARTMENT
DESIGN AND TECHNOLOGY
WORK ACTIVITY
USE OF CIRCULAR SAWING MACHINE
HAZARDS

WHO MIGHT BE
HARMED?
(EMPLOYEES)
The work piece may become jammed in the
circular saw
 The work piece may kick back
 Hands or fingers may come into contact with the
saw blade causing serious cuts or amputations
 Any electrical faults may cause electric shock
 Wood dust may be inhaled which may cause
serious lung diseases over a period of time
 The noise from the machine may cause
permanent hearing damage over a period of time
 Accidental starting of the machine can present a
serious hazard
 Unauthorised use of the machine can present a
serious hazard
Design and Technology Teachers
Design and Technology Teaching Assistants
Design and Technology Assistants
WHO MIGHT BE
HARMED?
(NONEMPLOYEES)
Children
Visitors
Contractors
IS ANYONE AT
SPECIAL RISK?
Persons working alone
Inexperienced teachers
Persons who have not been trained and certificated
within the past five years.
Persons who use the equipment infrequently
Unauthorised users, for example, site manager,
caretakers, teachers who have not been trained in its
use
Switchgear
 The machine must be provided with a means of
isolation using a fused switch-disconnector on or
adjacent to the machine
 The fused switch-disconnector must be controlled
by a starter incorporating overload protection and
no-volt release
RISK CONTROL
MEASURES
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Schools’ Health and Safety Handbook
Section9.3: Code of Practice for Secondary Design and Technology
Risk Assessment WW01: Circular Sawing Machine
February 2007


It must be possible to lock the machine off when it
is not in use to prevent unauthorised use. A
locking device may be incorporated in the
machine.
The key must not be left in the lock when the
machine is unattended.
Emergency Switchgear
 The machine should be provided with a
conveniently positioned red, mushroom headed,
emergency stop switch, on a yellow background, or
other suitable control device that can bring the
machine to rest within 10 seconds and is labelled
with an emergency stop sign
Cabling
 Cabling should be armoured to protect it from
damage.
Space and Floor Area
 There must be sufficient space around the saw
bench so that the timber can be handled safely.
The DfES Guidance should be followed.
 There should be sufficient space around the
machine to prevent the operator being knocked by
passers by.
 This area should be clearly marked with yellow
tape or paint.
 The machine must be secured to the floor. Bench
mounted machines must be secured to the bench.
 The floor of the work area must be level and nonslip.
 The floor must be kept free of loose material such
as wood shavings and saw dust which could make
it slippery.
 The floor should be cleaned at least once daily
using a method that does not produce large
quantities of dust such as a vacuum cleaner fitted
with a fine dust filter of mesh size not greater than
0.1 microns.
Guarding
 The motor, drive belts and wheels should be
guarded by the main frame of the machine
 The part of the saw blade below the table should
be guarded by the main frame of the machine, or
for open framed machines by a fixed guard that
requires a tool for removal.
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Schools’ Health and Safety Handbook
Section9.3: Code of Practice for Secondary Design and Technology
Risk Assessment WW01: Circular Sawing Machine
February 2007

Projecting ends of saw spindles should be
guarded.
The Riving Knife
 The riving knife should be securely fixed below the
surface of the table.
 It should be set so that gap between the knife and
the saw blade at table level is the minimum
practicable and at any rate not greater than 8 mm
or less than 3 mm.
 The riving knife should be thicker than the plate of
the saw but thinner than the saw kerf.
 The riving knife should extend upwards from the
table surface to a point not more than 25 mm
below the top of the saw blade, or to a minimum
height of 225 mm if the diameter of the saw blade
is 600 mm or greater.
The Crown Guard
 The crown guard for the exposed part of the saw
blade should be rigid and easily adjustable, but not
easily deflected.
 The crown guard should extend from the top of the
riving knife to a point above and as close as
practicable to the work piece.
 The crown guard should extend down each side of
the saw blade, and the adjustment should ensure
that the roots are covered at all times
Control of Noise
 Circular sawing machines can produce noise
levels of around 100 dB(A). A noise assessment of
personal daily exposures should be carried out by
a competent person.
 Hearing protection must be worn when using the
circular sawing machine.
 A sign should be displayed near the machine
indicating that hearing protection must be worn.
 Hearing protection should be stored near the
machine, be properly maintained, correctly worn
and be repaired and replaced when required.
Personal Protective Equipment (PPE)
 Eye protection should be worn when using the
circular sawing machine.
 A “wear eye protection” sign should be displayed
on or near the machine.
 It should be stored near the machine.
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Schools’ Health and Safety Handbook
Section9.3: Code of Practice for Secondary Design and Technology
Risk Assessment WW01: Circular Sawing Machine
February 2007

All PPE must be cleaned maintained and replaced
when necessary.
Hair and Clothing
 Substantial, non-slip, flat healed shoes which
cover the whole of the foot, should be worn when
using this equipment. Trainers do not give
adequate protection
 Loose clothing must be secured and long hair tied
back.
 Dangling jewellery must not be worn
 Gloves and bandages should not be worn
Ripping Fence
 The ripping fence, if used, should be accurately
adjusted not to extend more than 50 mm beyond
the tips of the saw teeth, in the direction of feed.
Single Spindle Speed Machines
 For machines with a single working spindle speed,
saw blades with a diameter below 60 % of the
largest diameter the machine is designed to use
should not be used.
Machines with More then One Spindle Speed
 For machines with more than one working spindle
speed, saw blades with a diameter below 60% of
the largest diameter the machine is designed to
use at the fastest speed should not be used.
Blade Diameter Notice
 A notice specifying the smallest diameter saw
blade that can be used on the machine should be
clearly displayed on the machine.
Use of Circular Sawing Machine
 The circular sawing machine may only be used by
competent, trained employees who have been
trained in accordance with the Health and Safety
Training Standards in Design and Technology
published by the Design and Technology
Association (DATA). They must hold documentary
evidence that they have completed this training
successfully within the past five years.
 The machine must NOT be used by pupils
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Schools’ Health and Safety Handbook
Section9.3: Code of Practice for Secondary Design and Technology
Risk Assessment WW01: Circular Sawing Machine
February 2007
Control of Wood Dusts
 Circular sawing machines produce significant
quantities of dust and must be fitted with an
interlocked dust extraction system. This will extract
beneath the table and at the crown guard.
 The dust extraction system must be fully tested
annually by a competent engineer and a written
report must be produced an the recommendations
in it must be followed.
 Copies of reports must be kept for at least 5 years.
It is advised that they are kept in a clearly labelled
ring binder.
 They must be kept available for inspection by
visiting health and safety advisers and subject
advisers.
 The dust extraction equipment must be emptied
regularly to maximise its efficiency. When doing
this care must be taken to ensure that the wood
dust is disposed of safely and is not allowed to
escape into the air where it may be inhaled.
Push Sticks
 Push sticks or a correctly designed push block
should be used for making any cut of less than
300 mm and for feeding the last 300 mm of longer
cuts.
Long Lengths of Timber/Take off Tables
 Long lengths of timber must be appropriately
supported during cutting.
 If an assistant helps with drawing off, a suitable
extension table must be provided to a minimum
distance of 1200 mm between the up running part
of the saw blade and the further edge of the
extension table.
Saw Blades
 Saw blades must be kept sharp and be of the
correct profile and properly set.
 Saw blades must conform to BS EN 847-1.
 Saw blades which have been subjected to
overheating should be discarded.
 Saw blades must have the correct number of teeth
to minimise the risk of kicking back.
 Tungsten carbide tipped saw blades must be
inspected regularly for chipped teeth and small
cracks between the tips and body of the blade.
They must be discarded or repaired as appropriate
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Schools’ Health and Safety Handbook
Section9.3: Code of Practice for Secondary Design and Technology
Risk Assessment WW01: Circular Sawing Machine
February 2007
following the inspection.
Safety Rules
 Safety rules for the use of the machine should be
displayed near the machine where they can easily
be referred to
Servicing and Maintenance
 The circular sawing machine must be included in a
planned programme of servicing and maintenance
which should include electrical safety checks.
 Records of servicing and maintenance must be
kept and be available for inspection by health and
safety advisers, subject advisers/consultants and
other authorised persons.
Manufacturer’s Instructions
 A copy of the manufacturer’s instruction book
should be kept by the machine and a spare copy
in the departmental office.
FURTHER ACTION
REQUIRED TO
CONTROL RISK
ACTION BY
PERSON
ACTION BY DATE
DATE REVISION
OF ASSESSMENT
DUE
ASSESSED BY
DATE
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