TIER 2 – POWER TOOLS

Contents
1 Introduction ............................................................................................. 4
Definitions ......................................................................................... 5
Health and Safety Responsibilities .............................................................. 7
Working Alone .................................................................................... 7
Supervisor Responsibilities ................................................................... 7
All User Responsibilities ....................................................................... 7
Safety ..................................................................................................... 8
Personal Protective Equipment (PPE) ..................................................... 8
Eye and face protection .................................................................. 8
Clothing/ Entanglement Hazards ..................................................... 8
Ear protection ............................................................................... 8
Respiratory protection.................................................................... 8
Musculoskeletal Injuries ....................................................................... 9
Ergonomics................................................................................... 9
Lifting .......................................................................................... 9
Workplace Hazards ........................................................................... 10
Slips and Trips ............................................................................ 10
Mist/Fumes/Vapours .................................................................... 10
Dust .......................................................................................... 10
Electrical Safety .......................................................................... 11
Fire Safety.................................................................................. 11
Chemical Hazards ........................................................................ 12
Metal Work Fluids (MWFs) or Cutting Oils ....................................... 12
Emergency Preparedness ................................................................... 13
General Machinery Safety ........................................................................ 14
Conduct ........................................................................................... 14
Surroundings.................................................................................... 14
Safeguarding .................................................................................... 15
Barrier Guards ............................................................................ 15
Emergency Stop .......................................................................... 15
4.5 Safety Procedures ............................................................................. 16
Hazardous Areas ......................................................................... 16
 Machine Setup ............................................................................ 16
Machine Usage ............................................................................ 17
Machine Shutdown ...................................................................... 17
Specific Machinery Safety ........................................................................ 19
6. Quiz: ........................................................ Error! Bookmark not defined.
1 Introduction

This training builds on Tier-1 training which is a prerequisite. After completing this
training, you will have access to the power tools in the Light Fabrication Facility
(LFF) at the Myhal Centre for Engineering Innovation and Entrepreneurship (Myhal
Centre) and Arena (Myhal Centre LL0), which you will be able to operate upon
undergoing in-person training with the LFF staff. Do not use a tool unless you have
been trained to use it safely and know its limitations and hazards. Using a tool
without having completed the corresponding safety training will result in
losing the privilege to access the LFF.

The same general rules described to hand tools apply to power tools with
additional requirements that will be highlighted in the sections below. Unlike hand
tools, the power operated tools represent a much higher risk of injury upon
accidents occurring, given that:

• Once a machine is switched on it will continue to operate regardless of the

operator been injured, exacerbating the injury.
• Machines possess greater power and speed, and possess a much greater
capacity to cause significant injury when used incorrectly (loss of body parts
and long-term recovery)

All power tools considered here will generally have these common risks.

• Being struck by pieces of materials ejected from the machinery.

• Contact or entanglement with the machinery components or materials in
motion.
• Electrical hazards.
• Chemical hazards (from cutting fluids, lubricants, etc.).
• Burns, cuts and other injuries from materials or substances used/exhausted
by the machinery.
• High noise levels.
• Material Storage and handling (manual material handling, ergonomics).
• Safe access to/from machines (tripping hazards).

Most of the injury risks can be greatly reduced by following general power tool
safety protocols as outlined in Section 3 that apply to all power tools.

Always remember: NO amount of time saving is worth the risk of cutting off a
finger or worse. That will eventually happen if you take shortcuts and do not follow
the safety regulations. Be smart, be safe.

No matter how many safety measures are in place they will amount to nothing if
you are not paying your full attention when operating a power tool. Headphones,
use of mobile phones and horseplay are not acceptable in the Fabrication Facilities.
Food and beverage consumption is not allowed in the Fabrication Facilities.
 Definitions
Bit/Drill bit: cutting tool used to drill holes.

Blade click: an indication of a cracked blade is a rhythmic click as the cracked

portion of the blade passes through the wood.

Burrs: a rough raised edge of material remaining attached after cutting.

Chips: debris generated while cutting/drilling/debasing.

Chuck: a device for holding a workpiece in a lathe or a bit in a drill, typically having
three or four jaws that move radially in and out to grasp a piece within.

Emergency stop (Machine): Shuts off a machine. Functionally the same as the
stop button or an off switch, it has a large red mushroom shape that makes it
easier to shut off the machine in case of an accident.

Emergency stop (Facility): Shuts off all electricity in a fabrication facility

stopping all machinery. An emergency stop is to be activated only to cut power to a
machine where an accident occurred without having to approach each machine
itself. It is meant to be used only in emergencies.

Fraying: becoming worn at the edge, especially through constant rubbing.

Fumes: gas, smoke, or vapor that smells strongly or is dangerous to inhale.

Grain: longitudinal arrangement or pattern of fibers in wood, paper, etc.

Horseplay: fooling around, irresponsible behaviour.

Interlock: Safety mechanism that cuts power to a machine if the operator

attempted to perform certain unsafe actions. Altering, manipulating or disabling an
interlock is not allowed. Interlock are only used in very specific sets of
circumstances and does not protect from all risks.

Jig: a custom-made tool, frame or other device used to control or guide your work.

Key/Chuck Key: tool that allows tightening of the chuck securing the drill bit in
place.

Kickback: wood may get caught or jam and be flung back violently.

Lock-out/Tag-out (LOTO): when machines are secured to be inoperable while

repairs or adjustments are made.

MSDS (Material Safety Data Sheet): safety information about a product or

material’s chemical compounds, behaviour, health hazards, etc.

PPE (Personal Protective Equipment): protective garments or equipment

designed to protect the wearer’s body from injury.
Push stick: a safety device used to safely maneuver a workpiece

Sacrificial piece: piece of spare material that you don’t mind damaging, which is
temporarily placed on your workpiece to help facilitate some sort of task while
maintaining the integrity of your workpiece.

Saw blade: cutting tool typically composed of a number of teeth per inch (or cm).
The higher the density of teeth the less material is removed in a single movement
loop and the cleaner the cut (less tear-out).

Stock: the raw material from which a specified commodity can be manufactured.

Tail out: to guide a piece of material as it emerges from the other end of a saw

Work surface: surface where work is carried out. A clean and tidy work surface
helps to prevent accidents.

Tear-out: when material is ripped out instead of being cut cleanly, often as an
unwanted result of hasty cutting.

WHMIS (Workplace Hazardous Materials Information System): a Canadian

workplace hazard communication standard.

Workpiece: Material to be worked on.

MYMaker Site: Information hub for the Myhal Centre Fabrication Facilities: Link

https://utoronto.sharepoint.com/sites/fase-myhalfabrication/SitePages/Home.aspx
 Health and Safety Responsibilities

Working Alone
Working alone with power tools is not allowed. Working with them in the LFF is only
allowed when the Makerspace Facilitator and/or the Senior Facility Supervisor are
present.

At the Arena, there must be at least two students present at all times when
fabrication work is occurring. The Arena will not be supervised day to day by the
Fabrication Facility staff, but instead by Tier-2 trained users who will each assume
the roles of supervisors. For power tools to be used, at least one user present must
have Tier-2 training and will take on supervisory responsibilities as outlined in
Section 2.2.

Supervisor Responsibilities
• Inspect and correct any workplace hazards that may be present.
• Inform users about any remaining hazards. Implement appropriate precautions
and procedures to control the hazards that may be present.
• Ensure that users comply with their responsibilities and safety regulations.
• Ensure that only qualified users with the requisite training operate machines and
power tools and follow developed safe work procedures.
• Ensure all written procedures are readily available to users.
• Ensure that the machines and power tools are in good condition.
• Follow machine-specific Lock-out Tag-out (LOTO) procedures.
• Ensure that users are provided with and wear the appropriate personal
protective equipment (PPE).

All User Responsibilities

• Take care to protect your health and safety and that of others who may be
affected.
• Do the requisite training to work safely with machines and power tools.
• Be familiar with and comply with established safe work procedures.
• Follow safety regulations and use appropriate equipment and PPE.
• Inspect any equipment for defects prior to its use.
• Report health and safety hazards, accidents, incidents, or concerns, including
any unsafe machine practices or damaged equipment, to supervisors.
• Practice good housekeeping and hygiene.
• Refrain from horseplay or similar conduct.
• Do not work if you are impaired (ie. by alcohol, by injury).
• Where requested, assist supervisors in identifying situations with potential of
machine hazards and participate in the development of work procedures.
 Safety

Personal Protective Equipment (PPE)

Users must know which specific Personal Protective Equipment (PPE) is required for
their specific tasks and equipment being used and use them as appropriate.
Students in supervisory role should assist any users with their concerns.

Eye and face protection

• Always wear safety glasses when operating
power tools, to protect eyes from flying debris.
• Wear face protection when necessary, such as
to protect from sparks during metal work.

Clothing/ Entanglement Hazards

• Always wear closed-toe and slip-resistant shoes.
• No loose clothing – wear comfortable, close-
fitting clothing only.
• No loose hair, must be tied back, confined, or covered.
• No jewelry or accessories that may get caught in machinery.
• No gloves near machinery or moving parts where gloves can catch. Wear
gloves only when away from machinery and necessary for handling heat,
chemicals, wood (splinters), sharp materials, etc.
• Consider wearing long sleeves and long pants to help protect your body
from lacerations, abrasions, kickbacks, and other impact.

Ear protection
Wear earplugs or earmuffs when near loud machinery. If you have trouble
hearing someone speak from three feet away, the noise level from the
machine may be hazardous, stop work immediately and implement hazards
control protocols to prevent your injury and that of the people around you.

Respiratory protection
Wear dust masks when from dust particulates are been generated. Always
position snorkels near the source of fumes when casting, thermoforming,
working with foam, heavy soldering, or any other fabrication process that
generates fumes. Respirators can be used for additional respiratory protection
but not as a replacement of fume extractors. Face must be clean shaven to
ensure a proper fit and seal of respirators on your face.
 Musculoskeletal Injuries
Sprains and strains, also known as musculoskeletal injuries (MSIs) can develop as a
result of improper handling or lifting of objects (ie. awkward postures, repetitive
movement, overexertion). These injuries can affect people for the rest of their lives.

Ergonomics
• Avoid awkward body positioning and motions.
• Do not overreach, reach behind or high above you while using equipment.
• Reach only as high and far as is comfortable for you. Use a stool or ladder
when necessary.
• Do not stand for long periods of time. Wear appropriate shoes to relieve
stress on knees and back.
• Always keep proper footing and balance for a stable stance. A sudden slip
could cause you to move into the cutting tool or blade.

Lifting
• Lift and carry only what you can handle.
• Assess the following factors:
o Size, shape, and weight of object
o Whether you will need to bend, twist, or reach
o How long you will be doing the task
• Ask for help or speak to your supervisor if the object is tricky to lift.
• Use mechanical aids (i.e. hoists, dollies, hand carts) whenever possible,
especially for heavy loads.
• Wear appropriate gloves or other protective equipment when handling
objects with sharp objects.
• Practice good lifting techniques:
o Place feet apart for good balance.
o Bend knees to lift with your legs, not your back.
o Get a good grip. Use your hands, not just your fingers.
o Hold the object as close to your body as possible.
o Lift up straight, smoothly and slowly.
 Workplace Hazards

Slips and Trips

Slipping and tripping on dirty surfaces or clutter commonly results in injury in
the workshop. Good housekeeping and regular clean-up are often overlooked
but extremely important aspects of daily work.

• Keep floors, especially pathways and aisles, free of objects, sawdust, spills.
• Do not run extension cords where they may create a tripping hazard.
• Keep your work area, equipment, and surrounding environment clean,
during and after your work session.
• Do not accumulate scrap materials; deposit them in corresponding scrap
bins or garbage and recycling containers.
• Work in a well-lit environment.
• Wear non-slip footwear.

Mist/Fumes/Vapours
Where processes may produce mists, fumes, or vapours which may be
hazardous, local exhaust ventilation must be used to remove the hazardous
substances. Relevant PPE must always be worn as outlined in Section 3.1.

• Fume Extractors remove airborne pollutants using suction

and filtration systems. Tabletop fume extractors, and
overhead fume arms can be used. Soldering produces
harmful fumes that impose adverse effects on health, as
well as create layers of dirt on nearby equipment. Gluing
large surfaces, heating/melting plastic or foams are other
examples of situations where use of a fume extractor is
necessary.

Dust
Where processes may produce large amount of dust, a dust collection system
must be used. If the dust is localized the collection can be delayed until work
has finished. Power tools usually have vacuum ports so that most dust is
collected as it is generated.

• Portable dust collection systems remove dust or other

particles using vacuum suction. The particles are collected in
a container for disposal. Must be used only with compatible
materials (i.e. a wood dust collecting system should not be
used when working with metals because of the risk of sparks
starting a fire).
 Electrical Safety
Misuse or carelessness with electrical components and powered equipment
can cause wear, short circuits, and shocks. Always be careful when handling
them, and do not handle them beyond your scope.

• Inspect equipment, power cords, and electrical fittings for damage prior to
each use.
• Report any equipment defects to the supervisor immediately.
• Ensure equipment is switched OFF before connecting them to a power
supply and before making adjustments.
• Ensure that electrical equipment is properly grounded or double-insulated.
The ground equipment must have a 3-prong plug.
• Keep power cords clear of the equipment during use.
• Do not bypass the switch and operate the tools by connecting and
disconnecting the power cord.
• Do not carry electrical tools by the power cord.
• Do not tie power cords in knots.
• Do not plug several power cords into one outlet.
• Do not disconnect power supply by pulling or jerking cord from the outlet.
Disconnect by pulling the plug, not the cord.
• Do not use extension cords as permanent wiring.
• Do not allow carts and trolleys to pass over unprotected power cords.
Cords on the floor could be protected by placing planks alongside them.
• Do not use electrical wires and equipment that is wet, broken or not
working properly, report immediately, label as damaged/broken.

Fire Safety
Be informed about the fire evacuation procedures in your workplace, outlined
in Section 3.5.

• Know where fire extinguishers and alarms are located. Fire alarms are
usually located along the evacuation routes. Make sure you have the
appropriate fire extinguishers for the type of fires that might present in
your workplace.
• There are 5 types of fires:
o Class A. Caused by materials heated to their ignition temperature.
Will continue to burn as long as there is heat/Oxygen and fuel.
Examples: paper, rubber, some plastics.
o Class B. Flammable liquids with ignition temperatures below 100 °C.
Examples: alcohols, solvents, paints.
o Class C. Electrical fires. Short circuits, overloaded switchboards,
faulty equipment and damaged wiring can all cause electrical fires.
 o Class D. Combustible Metals and Metal
Alloys. Examples: Sodium, Calcium,
Magnesium, etc.
o Class F. Cooking oil fires. Examples:
cooking oils, animal and vegetable fats,
grease.
• Typical fire extinguishers are ABC, flammable
materials in Class D and F are not allowed in
the fabrication facilities.
• Keep all exits and passageways clear at all
times.
• All fire extinguishers and alarms should remain
accessible at all times, do not block, disable or remove them.
• If a fire occurs:
o Pull the closest fire alarm, your first responsibility is to
alert other occupants in the building that there is a fire
and they should evacuate.
o Follow the evacuation procedures.
o Do not attempt to extinguish the fire at least you have
been properly trained and have the appropriate
equipment.
o If you catch fire, drop to the ground and roll to smother
the flames.

Chemical Hazards
Flammable and combustible liquids include, but are not limited to, materials
such as gasoline, oils, some paints, lacquers, thinners, cleaners and solvents.
To determine if a material or product is flammable or combustible, review the
product Material Safety Data Sheet (MSDS) or read the manufacturers label.

• Users must undergo WHMIS (Workplace Hazardous Materials Information

System) training before using chemicals.
• Read the label manufacturer’s instructions for use, including the use of PPE.
• Chemicals and flammables should be stored in appropriate cabinets or
storage locations approved for that use, as appropriate.
• Do not store incompatibles chemicals together.
• Any cloth, paper, or material that has been saturated with flammable or
combustible liquids, even if it is only a small amount, should be stored or
disposed of appropriately in an approved metal can with a tight-fitting lid.
Saturated fabrics can easily ignite if exposed to an ignition source such as
radiant heat, flame, sparks or slag from hot work or an electrical arc.

Metal Work Fluids (MWFs) or Cutting Oils

Metalworking fluid (MWF) is the name given to a range of oils and other
liquids that are used to cool and/or lubricate metal workpieces when they are
 being machined, ground, milled, etc. MWFs reduce the heat and friction
between the cutting tool and the workpiece and help prevent burning and
smoking. Applying MWFs also helps improve the quality of the workpiece by
continuously removing the fines, chips, and swarfs.

• Be familiar with the MSDS for the types of MWFs they use.
• Choose MWFs with the least toxic materials whenever possible.
• Maintain especially good hygiene when working with MWFs such as always
washing your hands right after finishing working.
• Is a good idea to keep extra clothes on hand in case clothing becomes
soaked with oil.
• Keep your hands and forearms clean by regularly washing.

Emergency Preparedness
All users should be aware of the following in case of emergency.

• Location of the first aid station and eye wash station.

• Location of emergency phone numbers (near the First Aid
Station).
• Location of fire extinguishers and how and when they should
be used.
• Locations of fire alarms and fire exits. Eye wash station
• Evacuation plan for the building.
• Hallways, exits and stairs must be kept clear of clutter and
obstacles.
• Obtain first aid immediately for all injuries.
• Who the first aid trained staff are.
• All accidents must be reported to the fabrication facilities
supervisor. You can also report any accident through the
Environmental Health and Safety portal:
http://www.ehs.utoronto.ca/resources/wcbproc.htm
First aid station
 General Machinery Safety

Each workplace is different and has different hazards. It is imperative that you
understand and follow the safety rules, regulations, and SOPs (Standard Operating
Procedures) specific to the Myhal Fabrication Facilities tools. The SOPs indicating
safety features and their appropriate use is available to the user through the
MYMaker site and hardcopies are available at the LFF office. Staff at the Light
Fabrication Facility is available to address any doubts or concerns that might arise.

Supplementary to Tier-1 and Tier-2 Safety Training, appropriate in-person training

must be done for each specific power tool/ machine.

Conduct
• Stay alert, watch what you are doing, and use common sense.
• Ask the supervisor questions to clarify anything you don’t understand or are
unconfident about.
• Do not work in a hurry or while distracted. Put personal devices away.
• Do not let your laziness or ego get in the way of your safety and that of others.
• Do not distract others or engage in horseplay.
• Do not eat or drink in the machine shop or work areas.
• Do not work impaired (ie. by alcohol, by injury).
• Wash your hands and forearms (if exposed) regularly. Scrub with soap in the
dedicated workshop sink between jobs.

Surroundings
• Check for Workplace Hazards as described in Section 3.3.
• Check for adequate space for you and your work to move around.
• Check for people in your vicinity, and if necessary, alert them of task at hand.
• Check for activities happening around you.
• Check for obstructions along the path of operation. Make sure the tool or
workpiece will not hit a clamp, a vise, the workbench, a power cord, or other
protruding parts, as you move them around during your operation.
• Check where offcuts are being ejected and what will happen when you reach the
end of the operation. When necessary, ask someone to wait at the end of your
material to tail-out, or receive a loose off-cut.
 Safeguarding

Barrier Guards
In machinery, there are three main types of barrier guards that physically
prevent a worker from reaching around, over, under, and through the guard to
the danger area.

• Fixed Guard: a guard that is a permanent part of the machine, but is not
dependent upon moving parts of the machine to perform its guarding
function. Fixed barrier guards must be secured with at least one fastener
requiring a tool for removal.
• Interlocked Guard: guards that are connected to a mechanism that cuts
power to the machine when the guard is tripped or moved out of position.
• Self-adjusting Guard: a guard that adjusts automatically to the thickness
and movement of the tool or stock material.

Interlocked guard

Self adjusting

Fixed guard

Emergency Stop
Emergency or ‘E-Stop’s is a red mushroom shaped button.

• Emergency stop (Machine): Functionally the same as the

stop button or an off switch, but bigger in size. Note that
pressing stop does not put a brake on moving parts of the
machine, but rather simply shuts of power. For instance,
even after hitting the switch, a sanding belt, blade, or drill
press will continue to rotate until it slows to a stop.
• Emergency stop (Facility): Shuts off all electricity in the fabrication
facility, stopping all machinery. When an accident occurs, a facility
emergency stop can be pressed to cut power to all machines without
having to approach each machine. Only to be used in emergencies.
4.5 Safety Procedures
The following safety procedures apply to all power tools and machines. Remember
to always wear safety glasses and identify and wear other PPE that is appropriate
for the work you are doing (Section 3.1) and according to the equipment you are
using.

Hazardous Areas
Identify specific locations of potential hazards in the equipment
to be used:

• Point of Operation: the area where work is performed on

the material (e.g. edge of blade, tip of drill bit, face of
sander).
• Nip or Pinch Point: areas other than a point of operation
where a belt contacts a pulley, or where one or more
rotating parts come together, and it is possible for a part
of the body to get nipped or pinched by moving parts.
• Power Transmission: areas where power is transferred
from one part to another such as a drive shaft, belt,
pulleys, sprockets, gears, couplings or chains.

Machine Setup
• Follow good housekeeping procedures – keep the work area free of hazards
as described in Section 3.3.
• Ensure that workpiece has a shape that can be securely placed on guide
fences and work surfaces. Otherwise, you will not have good control over
the workpiece and a special jig must be used, consult with the supervisor
for assistance.
• Inspect material stock for nails, staples, or other impurities before use.
• Clamp down and secure all work pieces and jigs as necessary.
• Check for barrier guards that provide protection. Ensure all guards are
fitted, secure and functional. Do not operate if guards are missing or faulty.
• Ensure all parts are securely tightened and well tensioned.
• Check that any unsecured accessories like keys and adjusting wrenches are
removed from the machine and properly secured so they won’t fall as the
machine is operated.
• Asses the suitability of the tool to the task and material at hand.
• Ensure that all cutting tools and blades are clean, sharp, and in good
working order so that they will cut freely, not forced.
• Ensure switch is in the off position before connecting the tools to power.
• Ensure machine is off before making adjustments to the machine or to your
workpiece.
• Understand that the health and hazards can vary from material to material.
Make sure to read the MSDS for unfamiliar materials and that appropriate
precautions are taken.
• Know emergency procedures for shutting off machines.

Machine Usage
• Only one person may operate one machine at a time. If someone is
assisting you, communicate and coordinate clearly about your operations.
• Avoid awkward hand positions and motions. Do not overreach, pass hand
over active moving parts, cross arms, or reach behind or over your body.
• Keep body parts, scraps and tools clear from hazardous areas (Section
4.5.1).
• Keep hands out of the line of the point of operation. Use a “push stick” or
specific jig to keep hands safe during cutting procedures.
• Always use a push stick for pieces less than 30 cm (1 ft) in length, or for
the last 30 cm of a longer cut.
• Use good lighting so that the work piece, cutting blades, and machine
controls can be seen clearly. Position or shade lighting sources so that they
do not shine in the operator’s eyes or cause any glare and reflections.
• Stop the machine and report suspect machinery to the supervisor, such as
if you notice any of the following:
o power cord is fraying, damaged, more than comfortably warm
o strange sounds
o sparks
o excessive imbalance or wobbling
o faulty equipment
o misalignment
o a tingle in your fingers
• Do not walk around with a plugged-in tool.
• Do not leave a running tool unattended. Do not leave it until it has been
turned off, and it has slowed to a complete stop.
• Do not use in wet or damp conditions.
• Do not adjust, clean or measure, while the machine is running.
• Do not operate tools in an area containing explosive vapours or gases. Do
not clean tools with flammable or toxic solvents.

Machine Shutdown
• Use a push stick to remove the cut piece from between the fence and the
blade. Avoid putting your hands close to blades, bit or cutting tools, they
can be very hot and cause a severe burn.
• Store tools when they are not being used.
• Do not use compressed air to blow debris from machines or to clean dirt from
clothes.
• Wait until the machine has stopped entirely, then clear cuttings with a
vacuum, brush or rake.
• Do not try to free a jammed blade before turning the power off.
• Do not leave machines running unattended (unless they are designed and
intended to be operated while unattended). Do not leave a machine until
the power is turned off and the machine comes to a complete stop.
• Let the machine cool – metal parts such as drill bits, screws, blades, will be
hot enough to cause a burn if you touch it immediately after machining.
• Be careful of sharp metal burrs and wood splinters remaining on your
workpiece or work area.
• Do not handle metal cuttings by hand because they are very sharp.
• After finishing using the machine must be left clean, tidy and ready to be
used by the next student. Each user is responsible to clean all debris
generated during their operation of the machines.
 Specific Machinery Safety

In addition to General Machinery Safety (Section 4), use these safety guidelines along with the SOPs (Standard
Operating Procedures) for each specific machine to use each one correctly. Ask any questions or clarifications during
the requisite in-person training with a supervisor. The Light Fabrication Facility (MY435) is available to assist on any
safety concern that might arise at any point in time, an open honest communication between students and
Fabrication staff is fundamental to develop and maintain a healthy safety culture.

Remember: there is no amount of SOP, PPE or safety measures that can protect against careless, distracted or
irresponsible work. Working with power tools require your full attention and respect, they will allow you to create
wonderful projects, but they can similarly cause great harm when used irresponsibly.
Hand Drill
• Follow general machinery safety procedures (Section 4)

Setup

• Use a punch to mark the center of your hole and create a dimple.
• Select appropriate drill bit and torque setting for material.
• If drilling metal, lubricate drill bit.
• If drilling a large hole, consider drilling a pilot hole first.
• Center drill bit shank in the chuck and tighten securely.
• Secure workpiece with clamp/ drill vise to prevent slip/spin.
• Check that bit is centered by turning machine on for a moment.

Start

• Place the tip of the bit onto the material by centering it on the
dimple, before pulling the trigger.
• Start slowly, then speed up the drill as the hole gets deeper.
• Hold the drill steady with both hands and push into the material
with steady pressure in a steady angle.
• When making deep holes, withdraw and recommence frequently to
clear the cuttings.

Finish

• Give the bit time to cool down before touching it.

• Return drill bits and other tools to proper storage area.
• Remove burrs and chips around hole by sanding or grinding.
Drill Press
• Follow general machinery safety procedures (Section 4)

Setup

• Select appropriate drill bit and speed for material.

• If drilling metal, lubricate drill bit.
• If drilling a large hole, consider drilling a pilot hole first.
• Center drill bit shank in the chuck, and tighten securely using
chuck key, then remove the chuck key.
• Check that bit is centered by turning machine on for a moment
• Adjust depth stop to desired feed depth.
• While machine is off, peck the tip of the drill down into the work
piece to align it to the centers of the desired holes.
• Secure workpiece with clamp/ drill vise to prevent slip/spin.
• Adjust table height so the tip of the bit is close to workpiece.

Start

• Start the machine while the drill is off the workpiece.

• Let the machine reach maximum speed before feeding the drill.
• When making deep holes, withdraw and recommence frequently to
clear the cuttings.
• As the drill nears the bottom of the workpiece, before it breaks
through, reduce the drilling pressure to avoid damaged tools or
workpieces.

Finish

• Give the bit time to cool down before touching it.

• Return drill bits and other tools to proper storage area.
• Clean the table and the area surrounding the machine.
• Remove burrs and chips around hole by sanding or grinding.
Belt & Disc Sander (not for metal)
• Follow general machinery safety procedures (Section 4)

Setup

• If sanding small objects, hold securely with locking piers.

• Do not sand very small items that can get stuck between the edge
of the work table and the belt.
• Adjust the angle of the table to desired angle.
• Connect and start the dust extractor.

Start

• Start the machine. Let it reach full speed.

• Get a firm grip on the workpiece in your hands or by holding
material firmly against table.
• If holding the workpiece free-hand and not resting it on the table,
make sure to angle it down with the direction of rotation, never up
and against the direction of rotation.
• Disc sander: use the entire disc for larger material, or the portion
of the disc sander that is rotating downward for smaller material
(when disc is rotating counter clockwise, use the left portion).
• Slowly advance the workpiece towards the sander.
• Do not push the workpiece hard into the disc.
• Move the piece from left to right. Holding material in one place for
too long could melt, burn and damage the piece.
• Keep fingers clear of disc or belt while sanding.

Finish

• Follow machine shutdown basics in 4.5.4

Bench Grinder (metal only)
• Follow general machinery safety procedures (Section 4)

Setup

•
• Ensure that no flammable or combustible materials are nearby.
• Fill a bucket with cold water and keep it close.
• If grinding small objects, hold securely with locking piers.
• Do not sand very small items that can get stuck between the edge
of the tool rest and the grinding disc.

Start

• Stand to the side while starting the machine until it reaches

maximum speed, then stand directly in front of grinder.
• Firmly hold workpiece down onto the tool rest.
• If holding the workpiece free-hand without the tool rest, get a firm
grip and angle it down with the rotation of the wheel, never up and
against the rotation of the wheel.
• Slowly advance the workpiece towards the grinder.
• Move the piece back and forth across the grinder until the desired
amount is taken off. Holding metal against the grinder in one place
for too long could melt and damage the piece.
• Do not push workpiece hard into the wheel.
• Do not use the sides of the grinder, only the front.

Finish

• Dip the piece into the water pot to cool the metal after or during
grinding. Keep your face away from the pot to avoid getting hit by
hot steam
Scrollsaw
• Follow general machinery safety procedures (Section 4)

Setup

• Select correct blade and speed for the material.

• Check that blade is secured in the clamps and is tensioned
properly, and that teeth point downwards.
• If making an inside cut:
- Drill a starter hole in the workpiece that is big enough to fit the
blade through without the blade touching the sides of the hole.
- Release the blade and slot it through the hole in the workpiece.
- Secure the blade back onto the machine and properly tension it.
• If cutting small pieces, use a jig
• to hold it safely.
• Connect and start the dust extractor.

Start

• Take caution not to touch the blade.

• Firmly hold the workpiece down onto the table with both hands.
• While the blade is off the workpiece, start the saw. Let the saw
reaches its full power.
• Slowly advance the workpiece forward into the blade. Do not
forcefully push into or yank the fragile blade. Move only forwards,
not backwards, into the teeth of the blade. Make gradual turns.

Finish

• Make sure machine is fully turned off before loosening the blade.
• Be careful the blade can be hot.
Jigsaw
• Follow general machinery safety procedures (Section 4)

Setup

• Select correct blade and speed for the material.

• Never install or remove the blade while the saw is plugged in.
• Secure workpiece with clamp/vise to the table, as close as possible
to the cutting line without interfering with the cut.
• If cutting straight, set up a straight edge guide and clamp it to the
workpiece. Keep into account the distance between the edge of the
guide and the blade.

Start

• Firmly press the base flat onto the workpiece, and align the inner
side of the blade to the outer edge of the cutting line.
• Hold the jigsaw with both hands to maintain control of the saw.
• Start the saw with the blade off the workpiece and let the saw
reaches its full power before advancing forward into the material.
• Continue to keep the jigsaw pressed flat while cutting. Do not
insert or withdraw the blade from the material while machine is on.
• Do not force the saw. Cut at a steady pace that allows it to turn
with ease without the blade deflecting.
• Cut relief cuts or holes when cutting long stretches of material or
tight curves to prevent the blade from binding.

Finish

• Unplug the tool, and put it and all accessories to appropriate

storage area.
Plunge Track Saw – ONLY WITH SUPERVISION OF LFF STAFF
• Follow general machinery safety procedures (Section 4)

Setup

• Clamp workpiece securely down to table.

• If using a guide rail:
- place the guide rail on top of the workpiece, whenever possible,
on the side of the cut that will be saved.
- align it parallel to the cut line.
- clamp the rail down to your workpiece or table.
• Select correct blade and depth and speed for the material.
• Adjust bevel angle as required.
• Connect and start the dust extractor.

Start

• Start the saw while it is off the workpiece. Let it reach full speed.
• Plunge the saw slowly down, then advance forward. Never back
the saw up.
• When making rip cuts, plunge down with the saw behind the
workpiece, then advance the saw into the material.

Finish

• Unplug the tool, and put it and all accessories to appropriate

storage area.
Plunge Router – ONLY WITH SUPERVISION OF LFF STAFF
• Follow general machinery safety procedures (Section 4)

Setup

• Select the right router bit, speed, and depth for your purpose.
• Make sure the collet nut is securely tightened on the router bit.
• If cutting thick material, consider doing multiple passes.
• If using a guide rail:
- place guide rail on top of the workpiece, on the push-cutting side
of the router, and clamp in place.
• Connect and start the dust extractor.

Start

• Hold firmly in both hands using the handles.

• Start the router while it is off the workpiece. Let it reach full speed.
• Lower the router down to the right depth, then tighten in place.
• Advance the router forwards into the workpiece.
• Always move the router in the direction against the rotation of the
bit (push-cut), do not cut with the rotation (climb-cut).

Finish

• Unplug the tool, and put it and all accessories to appropriate

storage area.
Router Table – ONLY WITH SUPERVISION OF LFF STAFF
• Follow general machinery safety procedures (Section 4)

Setup

• Select the right router bit and speed for your purpose.
• Raise the router to its max height to remove any throat plates.
• Change bits, ensure they are securely tightened.
• Reinstall throat plates.
• Loosen the fence and adjust the distance as necessary. Align it to
be parallel to the path of the mitre gauge. Tighten.
• Loosen the fence faces and slide apart enough to clear the router
bit. Tighten.
• Lower and raise the router to desired height and lock.
• Install a featherboard as necessary.
• Do not cut small pieces – use a sled if necessary.
• Connect and start the dust extractor.

Start

• Start the router while it is off the workpiece. Let it reach full speed.
• Place the workpiece against the fence and hold it firmly against the
fence and table with both hands.
• Advance the workpiece while maintaining pressure against the
fence to ensure the edge remains in contact throughout the cut.
• Always move the workpiece in the direction against the rotation of
the bit (push-cut), do not cut with the rotation (climb-cut).

Finish

• Unplug the tool. Return tool and accessories to the appropriate

storage area.
Circular Mitre Saw – ONLY WITH SUPERVISION OF LFF STAFF
• Follow general machinery safety procedures (Section 4)

Setup

• Set the mitre angle, bevel angle, and depth limit as desired.
• Set the workpiece flat on the base of the mitre saw, and flat
against the back fence.
• Align the inner edge of the blade with the outer edge of your
cutline. While the machine is off, lower the blade down onto the
work piece to align.
• Secure the workpiece down with the hold down clamp or with your
hand. You must always keep hands outside of the no hand zone.
• Do not cut pieces that are not long enough to span the fence.
• Connect and start the dust extractor.

Start

• Start the saw at the top while it is off the workpiece. Let it reach
full speed.
• When chopping a small piece:
- bring the saw down into the workpiece.
• When cutting a wide piece:
- pull the saw out towards you
- bring the saw down to the workpiece.
- once it reaches the bottom of its depth, advance the saw forward
to cut across the width of the piece.
• Never pull the saw through the cut, always chop down or push.

Finish

• Remove and return all accessories to appropriate storage area.

Table Saw – ONLY WITH SUPERVISION OF LFF STAFF
• Follow general machinery safety procedures (Section 4)

Setup

• Be extremely careful. Tablesaws are the most dangerous tool in

the shop. Ensure all safety guards and mechanisms are in place.
• Set the bevel angle as desired, and blade height as appropriate.
• Align the inner face of the blade with the outer edge of the cutline
and adjust the fence to the appropriate width.
• Use a push shoe when feeding a narrow workpiece.
• Do not cut material that is too small or irregularly shaped.
• Stand slightly to the side and not directly behind the blade.
• Connect and start the dust extractor.

Start

• Start the saw while it is off the workpiece. Let it reach full speed.
• Ensure you have good control of your workpiece. Hold it flat down
on the table with hands or push shoes, and flat against the fence
or miter gauge (never use both together).
• Advance the workpiece forward evenly, all the way past the blade.
• Never move the workpiece backwards. If it gets jammed, while
keeping your hands firmly securing the workpiece, use your knee
to turn off the machine and bring it to a full stop.
• Make sure someone “tails out” when cutting long material.
• Never cut freehand.
• While the table saw is running, don’t do anything else (cleaning
etc) but cutting

Finish

• Remove and return all accessories to appropriate storage area.

Compact Metal Bender (Pipe Bender), Metal Roller
• Follow general machinery safety procedures (Section 4)

Metal Bender

• Select the dies and attachments for your particular bend, and
insert them into the appropriate locations.
• Ensure the bender is disengaged before fitting the attachments.
• Orient the handle up and on the right side.
• Insert stock into the bender and position it.
• Do not attempt to bend very small items that do not fit securely.
• If the workpiece is long, it should be held by two people.
• Move handle clockwise to bend workpiece.
• Return all dies and attachments to proper storage area.

Roller

• Raise and lower the back roller to adjust the type of curve desired.
• To insert and remove cylindrical workpieces, loosen the roller
retainer pins then pull the top roller out towards you to release.
• Insert workpiece between the upper and lower rollers, then loosen
and tighten the thickness adjustment bolts until it fits snugly.
• Remove the workpiece, then rotate the thickness adjustment bolts
clockwise ¼ turn to create additional pressure.
• Insert workpiece again, then turn the hand crank to create curve.
• Do multiple passes with gradual reductions in the curve radius
rather than attempting to immediately make a tight curve.
Metal Brake and Sheer
• Follow general machinery safety procedures (Section 4)

Setup

• Mark a line along the width of the workpiece for the bend/ cut.

Brake

• Position the workpiece under the finger receiver.

• Gently lower the finger receiver to hover above the workpiece until
to help position it along the marked line.
• Hold the workpiece steady while keeping your fingers away from
the finger receiver.
• Activate the brake with an even and stead pressure.
• Do not attempt to bend very small items that do not fit securely.

Shear

• Set the correct gap for the shearing blades for the material.
• Position the workpiece against a side guide block, and align the cut
mark with the shear blade.
• Adjust the holddown bar so that it firmly holds the workpiece in
place.
• Activate the shear with an even and steady pressure.
• Keep hands off the shearing blades.
Foam Cutter
• Follow general machinery safety procedures (Section 4)

Setup

• Wear a respirator for comfort.

• Wear heat resistant protective gloves.
• Ensure that no flammable or combustible materials are nearby.
• Ensure that the wire is tensioned adequately.
• Ensure that the wire is at a right angle with the work surface.
• Select the appropriate temperature for the type of material. Foam
should not smoke.
• Do not cut workpieces that are too small without using a jig.
• Position and start the fume extractor.

Start

• Take caution not to touch the hot wire.

• Hold the workpiece securely with both hands and move it through
the wire with a light pressure and even speed.
• Do not forcefully push into or pull the foam through the wire. Let
the wire do the cutting by melting the foam. If the wire is bending,
you are applying too much pressure and the cutting surface will
have a poor finishing.

Finish

• Once the machine is off, clean the wire of foam residue by gently
wiping with a cloth or paper towel.
Vacuum Former – ONLY WITH SUPERVISION OF LFF STAFF
• Follow general machinery safety procedures (Section 4)

Setup

• Wear a respirator for comfort.

• Wear heat resistant protective gloves.
• Ensure that no flammable or combustible materials are nearby.
• Select the appropriate material and thickness for the form job.
Remove any protective film on plastic stock.
• Select the appropriate temperature for the type of material.
• Apply release agents on the tops and sides of your mold(s).
• Place your mold(s) on the center of the work area. Place thin
spacers under the molds to aid air flow.
• Molds should have adequate clearance around all sides.
• Position and start the fume extractor.

Start

• Take caution not to touch the heating elements or hot metal

components.
• Turn on and warm up the oven.
• Open the frame and place the plastic stock inside, then tighten.
• Bring the frame and plastic close to the oven for heating.
• Once the plastic is heated, turn on the vacuum. Swiftly and
steadily press the frame and plastic into the mold.
• Once the plastic has molded successfully, turn the vacuum off.

Finish

• Be careful not to touch hot plastic, machine parts, or mold. Allow

adequate time for cooling, then loosen frame and remove plastic
from mold.
Soldering
• Follow general machinery safety procedures (Section 4)

Setup

• Ensure that no flammable or combustible materials are nearby.

• Select the appropriate temperature for the type of solder.
• Select the appropriate iron and tip size for your job.
• Hold wires and components to be heated with tweezers, clamps, or
helping hands.
• Wet the cleaning sponge.
• Use rosin-free and lead-free solder whenever possible. Rosin and
Lead can cause serious chronic health effects.
• Never solder a live circuit.
• Position and start the fume extractor.

Start

• Take caution to never touch the element of the soldering iron.

• Always return the soldering iron to its stand when not in use.
Never put it down on the workbench.
• Do not get your face too close to the iron, the solder can “spit”.
• Regularly clean the tip by scraping it on the wet sponge or metal
sponge to remove old solder until shiny.

Finish

• Turn off the solder iron, unplug it, and wait for it to cool for a few
minutes before putting it away in storage.
• Let soldered surfaces cool for a few minutes before touching.
• Always do a visual quality assessment of the soldered joints.
Dremel
• Follow general machinery safety procedures (Section 4)

Setup

• Select appropriate accessories for the intended function (grinding,

sanding, wire brushing, polishing, carving). Ensure that arbor size
properly fits the collet/ chuck.
• Only make adjustments while the machine is unplugged.
• Securely clamp your workpiece down.

Start

• Hold the tool firmly in your hand(s).

• Start the tool while it is off the workpiece.
• Move the dremel in the same direction as the chips are thrown.
• Do not use excessing pressure and force the tool, let the tool do
the cutting.

Finish

• Unplug the tool, remove and clean accessories. Store all used tools
in the appropriate area.