Producing forged parts by hand forging — Planning and preparation

Introduction

This aiMOOC is the Planning and preparation module of Producing forged parts by hand forging. It is designed for vocational learners in blacksmithing, artistic metalwork, heritage craft and small-batch forged work.

Selected jurisdiction: United Kingdom — operational scope: England. Workplace-safety references use the Health and Safety Executive framework that applies in Great Britain and is valid for workplaces in England. Apprenticeship references are explicitly England-specific through Skills England. Fire-safety references are England-specific. British Standards Institution references are UK standards references. This module does not merge or imply equivalence with training, law, certification or job titles in any other country.

Safety and authority note: Hot forging involves severe burn, fire, fume, noise, impact, manual-handling and equipment hazards. You must not carry out hazardous forge work unsupervised. Your employer's or training provider's current risk assessments, safe systems of work, equipment instructions, supervision arrangements and emergency procedures take precedence over this learning resource. Official rules and competent workplace instructions always take precedence.

Current-information check: Legal, training and standards claims in this module were checked against HSE, GOV.UK, Skills England and BSI information available on 1 September 2026. Rules and standards can change; verify the current official version before applying them in practice.

The image shows hot hand forging at an anvil. Study the relationship between workpiece, hammer, anvil face and hot-work zone. In a real forge, the safe arrangement depends on the workshop risk assessment and supervision plan.

MOOCwiki Metadata

Field	Entry
Exact title	Producing forged parts by hand forging — Planning and preparation
Parent learning area	Producing forged parts by hand forging
Module	Planning and preparation
Target language	English
Jurisdiction	United Kingdom — operational scope England
Intended learners	Vocational learners in blacksmithing and artistic metalwork
Learning level	Introductory to intermediate vocational planning, with supervised workshop transfer
Review status	Open educational resource prepared for expert review
Course-text licence	CC BY-SA 4.0; third-party media retain the licence or terms stated at their source
Safety status	Planning resource only; no permission for unsupervised hazardous work

Learning Outcomes

By the end of this module, you should be able to explain how a professional blacksmith plans a hand-forged job before lighting the forge; interpret a drawing, sample or specification; select known material and suitable stock section; estimate forging allowance; select and inspect suitable hand tools and workholding; identify significant hazards and choose controls using the hierarchy of control; produce a logical job sequence with supervisor hold points; define measurable quality criteria; plan material and energy use responsibly; and record the plan so another competent person can review it.

Occupational Context in England

Skills England describes the blacksmith occupation as designing, shaping and joining metal components by hot forging and other metalworking processes for small-batch or bespoke production and heritage metalwork conservation. Its current Blacksmith apprenticeship standard is ST0378 version 1.1, status Approved for delivery, at Level 3, with a typical duration of 48 months. The standard includes health and safety, technical interpretation, drawing and design, hot forging, tools and equipment, quality, finishing and fitting.

This aiMOOC is not an apprenticeship standard, qualification, certificate or licence to practise. Completing it does not confer automatic credit, certification or occupational equivalence in the UK or any other country.

Skills England: Blacksmith ST0378 version 1.1

Planning Mindset: From Drawing to Safe Work Sequence

Professional preparation begins before any metal is heated. A useful planning chain is:

JOB REQUIREMENT
      ↓
DRAWING / SAMPLE / SPECIFICATION
      ↓
MATERIAL ID + STOCK SIZE + FORGING ALLOWANCE
      ↓
PROCESS SEQUENCE + TOOLS + WORKHOLDING
      ↓
HAZARDS + CONTROLS + SUPERVISOR HOLD POINTS
      ↓
QUALITY CHECKS + FINISH + RECORDS

A competent plan answers four questions: What must be made? What material and stock are required? How will it be made safely and efficiently? How will you know it is correct?

Reading the Job Requirement

Start with the information you have: a drawing, client brief, historic sample, template, photograph, repair specification or verbal instruction. Identify critical dimensions, tolerances, symmetry, surface requirements, interfaces with other parts, finish, quantity and whether the item has a safety-critical function.

For artistic metalwork, appearance is a technical requirement. A repeated scroll may need consistent rhythm, taper, spacing and texture even when no tight engineering tolerance is stated. For a heritage repair, the brief may require faithful reproduction of section, tool marks and construction method. For any load-bearing, guarding, structural or life-safety application, do not substitute an informal workshop judgement for the specified engineering, building-control or competent-person requirements.

Datums, Templates and Jigs

A datum is a reference point, line or surface from which measurements are taken. A working template helps compare bends, scrolls or profiles during manufacture. A jig locates or supports work so repeated components can be made consistently.

Templates are especially useful for decorative work because they convert a drawing into a practical visual reference. Mark the template with orientation, centre lines, critical dimensions and any no-go zones. Do not use a template as a substitute for measuring where a drawing specifies numerical tolerances.

This annotated anvil image uses common English terms including face, step, horn, hardy hole and pritchel hole. Workshop terminology can vary, so use the terminology established by your training provider and employer.

Materials and Stock Selection

For introductory hand-forging plans, vocational workshops commonly use low-carbon steel of known specification because it is comparatively forgiving to forge. The important planning principle is not the label “mild steel” by itself; it is that the material is identified, appropriate for the job and supplied or verified through a controlled route.

Planning question	Good vocational practice
What is the material?	Record the grade or supplier identification where available. Do not assume unknown scrap is suitable.
What section is required?	Choose round, square, flat or other stock that supports the final geometry and minimises unnecessary drawing-out or waste.
Is the surface contaminated or coated?	Treat paint, plating, oil, unknown residues and contaminated stock as a stop point until the COSHH assessment and workplace procedure allow work to proceed.
Does the job require tool steel or another alloy?	Use the specified material and separate heat-treatment competence. Do not infer heat-treatment practice from a low-carbon-steel exercise.
Is recycled material proposed?	Use it only when identity, condition and suitability are known. Reuse is not sustainable if it creates unsafe fumes, unpredictable properties or repeated rejects.

Forging Allowance and Volume Thinking

Hot forging redistributes metal. For planning, treat material volume as approximately conserved before allowing for trimming, oxidation scale and any process-specific loss. A useful relationship is:

Initial stock volume ≈ final forged volume + justified process allowance

For constant-section bar:

Required stock length = required metal volume ÷ stock cross-sectional area

Worked planning example: A non-load-bearing decorative test piece is to have 100 mm of unchanged 10 mm square shank plus a 30 mm long square pyramidal taper. The unchanged shank volume is 100 × 100 = 10,000 mm³. The ideal taper volume is one third of base area × length, so 100 × 30 ÷ 3 = 1,000 mm³. Total ideal metal volume is about 11,000 mm³. Dividing by the 100 mm² stock area gives 110 mm of original bar. A workshop may add a justified trimming or process allowance based on its own method and previous samples. There is no universal percentage that replaces a trial, drawing review and instructor approval.

The calculation is a planning estimate, not permission to forge the part independently.

Tools, Equipment and Workholding

A hand-forging job plan should name only the tools actually required. Typical categories include the forge or hearth, anvil, suitable hand hammer, matched tongs, leg vice, hot-cutting or forming tools where authorised, punches and drifts where required, bending forks, fullers or swages, wire brush, rule, dividers, square, gauges, working templates and safe hot-work holding or cooling arrangements.

Tool-selection rule: choose by function, stock size, access and control, not by habit. Tongs should match the stock section and hold the work securely without requiring excessive grip force. A hammer should have a suitable mass and face for the task and user. Hardy tools, punches, chisels and other striking tools must be suitable for the operation and in serviceable condition.

Pre-use Inspection

Before work starts, follow the workshop inspection system. Remove defective equipment from service and report it. Typical hand-tool checks include a secure hammer head, sound handle, undamaged tong reins and jaws, correct tong fit, no dangerous mushrooming or cracking on struck tools, stable anvil and vice, clear work area, serviceable guards and controls on any powered equipment, and current inspection status where required.

HSE states that PUWER requires work equipment to be suitable, maintained in a safe condition and used only by people who have received adequate information, instruction and training. Inspection depth and frequency should be based on risk assessment and manufacturer guidance.

HSE: PUWER overview HSE: Inspection of work equipment

Workshop Layout and Preparation

The safest layout is site-specific, but planning should prevent people, hot work, stock and tools from competing for the same space.

MATERIAL RACK → CUT / PREP AREA → FORGE OR HEARTH → ANVIL / VICE → HOT HOLD / CONTROLLED COOLING → QUALITY CHECK
                         ↑                 ↓
                ventilation / LEV   clear working radius
                         ↓                 ↓
                 emergency route ← KEEP WALKWAYS CLEAR → tool storage

This is a planning diagram, not a prescribed forge layout. Follow the actual workshop risk assessment, fire strategy, ventilation design and instructor direction.

When reviewing a workshop image, look for safe access, tool storage, stable equipment, stock control, housekeeping, hot-work separation, ventilation and unobstructed emergency routes. Do not copy a photographed layout without a local risk assessment.

Risk Management and Safety Duties in England

HSE's risk-management sequence is to identify hazards, assess risks, control risks, record findings and review controls. In vocational work, learners should participate in this process but should not assume the employer's legal duty.

HSE: Steps needed to manage risk

Core Hazards in Hand Forging

Hazard	Why it matters	Planning controls to consider
Hot metal, scale and radiant heat	Contact burns, flying hot scale, heat stress and ignition	Defined hot-work zone, suitable workholding, barriers or separation where needed, controlled hot-metal communication, process-compatible PPE, breaks and heat-stress controls
Hammering and struck tools	Impact injuries, flying particles, hand injuries and tool failure	Serviceable tools, matched workholding, clear striking zone, trained technique, eye and face protection selected from risk assessment
Noise	Repeated hammering and powered equipment can create harmful exposure	Assess exposure, reduce noise at source and by organisation, provide suitable hearing protection where residual risk remains, provide information and health surveillance where required
Fume, dust and gases	Combustion products, coatings, scale, grinding dust and process fume can harm health	Identify material and contaminants, prevent exposure at source, use suitable ventilation or LEV where required, keep control systems maintained and follow COSHH assessment
Fuel and fire	LPG, solid fuel, flammable liquids and hot work can create fire or explosion risk	Apply DSEAR and fire-risk controls as relevant, inspect fuel systems through authorised procedures, separate combustibles, maintain emergency arrangements and never improvise fuel handling
Manual handling	Bar stock, anvils, tooling and awkward components can cause crush or musculoskeletal injuries	Avoid hazardous handling where reasonably practicable, use mechanical aids, reduce load and carrying distance, assess task, load, environment and individual capability
Heat stress	Heavy work close to radiant heat can overload the body's cooling system	Assess work rate, radiant heat, ventilation, PPE burden, exposure duration, hydration and rest arrangements
Powered equipment	Grinders, drills, power hammers and presses add entanglement, ejection, crushing and stored-energy hazards	Use only when trained and authorised, with guarding, isolation, inspection and safe systems of work under PUWER

Hierarchy of Control

Do not start with PPE. Prefer elimination or substitution where practicable, then engineering controls, then administrative controls, with PPE used for remaining risk. Examples for planning include selecting clean known stock instead of coated unknown scrap, using correct workholding rather than hand proximity to the work, using enclosure or LEV for relevant fume and dust, arranging the work sequence to reduce unnecessary exposure, and then selecting compatible PPE for residual hazards.

Key Current Legal and Official References

England workplace safety scope: The Health and Safety at Work etc. Act 1974 and associated regulations create duties for employers and workers. The list below is a learning map, not an exhaustive legal register.

Area	Current official reference used in this module	Planning implication
Work equipment	Provision and Use of Work Equipment Regulations 1998	Suitable equipment, maintenance, safeguards, information, instruction and training
Hazardous substances	Control of Substances Hazardous to Health Regulations 2002 as amended	Identify hazardous substances and process-generated fume or dust; prevent or adequately control exposure
Noise	Control of Noise at Work Regulations 2005	Assess, reduce exposure, provide hearing protection where needed and apply health surveillance where required
PPE	Personal Protective Equipment at Work Regulations 1992 as amended by the 2022 Regulations	Suitable PPE follows risk assessment; employers' duties extend to relevant limb b workers
Manual handling	Manual Handling Operations Regulations 1992	Avoid hazardous handling where reasonably practicable, assess what remains, reduce risk
Dangerous substances	Dangerous Substances and Explosive Atmospheres Regulations 2002	Control fire and explosion risks from dangerous substances such as LPG and other flammables
Workplace fire safety	Regulatory Reform Fire Safety Order 2005 as applied in England	The responsible person must assess fire risk and maintain suitable precautions

Official pages: HSE: COSHH basics HSE: Noise at work HSE: PPE regulations from 2022 HSE: Manual handling at work HSE: DSEAR GOV.UK: Workplace fire safety in England HSE: Heat stress HSE: Local exhaust ventilation

PPE and British Standards

BSI is the UK's National Standards Body. A product standard does not replace risk assessment, correct fit, compatibility, user training or manufacturer instructions. For a forge, PPE selection must match the actual hazards and process.

As checked on 1 September 2026, BSI lists BS EN ISO 16321-1:2022+A1:2025 as current for general occupational eye and face protection, including hazards such as impact, optical radiation, molten metals, heat and hot solids. BSI lists BS EN ISO 20345:2022+A1:2024 as current for safety footwear. BSI lists BS EN ISO 11612:2015 as current but under review for protective clothing against heat and flame; verify its current status before specification.

BSI: UK's National Standards Body BSI: BS EN ISO 16321-1 BSI: BS EN ISO 20345 BSI: BS EN ISO 11612

Important: Do not choose gloves, eye protection, footwear, hearing protection or clothing by a generic list alone. Some PPE can introduce additional risks if incompatible with a task or machine. Use the workplace PPE assessment and supervision.

Step-by-Step Demonstration: Planning a Forged Wall Hook

This demonstration is a planning exercise for a non-load-bearing decorative wall hook. Any live forging is instructor-led and supervised. The example intentionally stops short of giving independent forge-lighting, fuel-adjustment or high-risk machine instructions.

Job brief: Read the drawing and confirm that the hook is decorative, non-load-bearing, made from known low-carbon steel, and has defined overall length, fixing detail and finish.
Datums: Mark the main datum, centre line and critical dimensions on a full-size paper or steel template.
Stock selection: Choose the specified section from identified stock and record the material source or workshop identification.
Forging allowance: Estimate blank length from finished volume, trimming needs and a previous approved sample; record the assumption and have it checked.
Process sequence: Write a high-level sequence such as prepare stock, form taper, form hook curve, form fixing end, set alignment, brush or descale as specified, inspect and finish.
Tool selection: Select only the required serviceable hammer, matched tongs, anvil tools, measuring tools, template and workholding; list powered equipment only if authorised and necessary.
Risk controls: Check the job against hot-metal, impact, scale, noise, fume, fuel, manual-handling, heat-stress and housekeeping hazards.
Work area: Confirm clear walkways, safe working radius, ventilation or LEV status where relevant, hot-work segregation and emergency access.
Communication: Agree the workshop's hot-metal warning convention, instructor commands, who may enter the striking zone and how the learner signals a stop.
Supervisor hold point: Present the drawing, stock, tool list, risk controls and sequence to the instructor before any forge is lit or hot work begins.
Supervised observation: During the instructor-led forge demonstration, compare the developing form with the template between operations and note where the planned sequence needs adjustment.
Quality record: After the work is safe to handle under workshop instruction, check dimensions, alignment, taper, surface condition and finish; record deviations and improvements for the next job.

Demonstration Media

International practitioner technique reference — not UK legal or certification guidance. Observe how tools are arranged, how stock is controlled and how a simple hook develops through a sequence. Apply only the techniques authorised by your instructor.

Tool-selection reference — international practitioner source. Focus on why the task needs suitable tongs, hand tools and a deliberate setup. The video's safety choices do not replace your England workplace rules.

Tongs as a workholding concept — international practitioner source. This video shows the craft importance of tongs; do not reproduce toolmaking without competent supervision and the workshop's risk controls.

Authentic Planning Examples

Job	What planning must capture	Typical quality focus
Pair of decorative gate scrolls	Full-size template, matching stock, bend sequence, orientation, repeatability and finish	Pair symmetry, smooth curvature, consistent taper, no unintended flats or twists
Fireplace tool handle	Grip length, balance, section transitions, hanging feature, tool attachment and finish	Comfortable proportions, straightness, controlled texture and sound joint preparation
Replacement heritage latch component	Sample measurement, conservation brief, material identification, original tool marks and fitting sequence	Visual fidelity, fit, reversible or approved intervention where required, record of work
Workshop tongs	Target stock section to be held, jaw form, reins, rivet or boss geometry and trial fit	Secure grip, jaw alignment, comfortable reins and fit for intended stock

None of these examples authorises you to work on safety-critical, heritage-protected or structural components without the required competent supervision, specification and approvals.

Common Errors and Corrections

Common planning error	Why it causes problems	Better approach
Starting from a picture without dimensions	Scale and fit become guesses	Establish datums, critical dimensions and a full-size template where useful
Using unknown scrap because it is available	Composition, coatings and prior damage may be unknown	Use identified material that meets the job requirement
Choosing tongs after the stock is hot	Poor fit can reduce control	Match and test workholding cold before hot work
Treating PPE as the first control	Exposure remains at source	Apply the hierarchy of control and use PPE for residual risk
Planning only the forging operations	Measuring, movement, hot holding, cooling, finishing and housekeeping are missed	Plan the complete job from stock receipt to final inspection
No supervisor hold point	Errors or unsafe assumptions reach the hot-work stage	Build in a formal check before hazardous operations
Using colour as an absolute temperature measurement	Apparent colour changes with alloy, lighting and perception	Follow the workshop's material and temperature-control method
Copying another forge's layout	Different ventilation, fire arrangements and traffic routes change risk	Use the local risk assessment and equipment instructions

Quality Criteria

Quality begins in the plan. Define what will be checked and how.

Criterion	Evidence
Dimensional accuracy	Measurements from stated datums meet the drawing or approved tolerance
Profile and symmetry	Curves, scrolls or repeated parts agree with the working template and design intent
Section control	Tapers and transitions are deliberate, smooth and not unintentionally thinned
Alignment	The part is straight, square or intentionally offset as specified, without accidental twist
Surface integrity	No unacceptable cracks, laps, cold shuts, sharp burrs or heavy unintended hammer marks
Functional fit	Interfaces, holes, hooks, joints or mating surfaces fit the intended component
Finish	Scale removal, texture and protective finish match the specification
Traceability	Material, process notes, inspections and deviations are recorded where the workplace system requires them

Sustainability and Resource Efficiency

Sustainable forging is not just about using scrap. A strong plan reduces rework, unnecessary heating, wasted stock and consumables.

Choose the nearest suitable stock section so less metal has to be displaced. Nest cuts to use bar efficiently. Keep usable offcuts identified and segregated. Avoid heating more material than the job requires. Plan the sequence to reduce unnecessary reheating, while never compromising safe control or material requirements. Maintain forges, burners, blowers, doors, refractory and extraction systems so energy and control systems perform as intended. Segregate recyclable metal from contaminated waste. Manage oils, paints, solvents, scale and other wastes through the workplace environmental and COSHH procedures.

For fuel choices, do not make a blanket claim that solid fuel, LPG, electricity or induction is always “greener”. Compare the actual energy source, efficiency, production scale, maintenance, ventilation demand and local emissions. Use life-cycle or site data where decisions matter.

Inclusive and Professional Workshop Practice

Good planning includes the person doing the work. PPE must fit the individual. Controls should account for reach, stature, strength, mobility, hearing, vision, fatigue and communication needs. Mechanical aids, adjustable supports, alternative workholding, task rotation or revised stock lengths can improve control without lowering the quality standard.

Instructions should be available in a form the learner can use: clear drawings, large print where needed, visual demonstrations, plain technical language and agreed communication signals. In England's apprenticeship context, Skills England also recognises British Sign Language qualifications as an alternative to English qualifications for apprentices whose primary language is BSL under the applicable rules. That training-rule reference does not change workplace safety duties.

A professional forge culture makes it normal to report a damaged tool, unclear drawing, unsafe condition or uncertainty before work continues.

Glossary

Term	Meaning in this module
Anvil	The main hardened work surface used to support hand-forged metal.
Beak or horn	The projecting anvil feature used for supporting curves and forming work.
Billet	A piece of metal stock prepared as the starting material for forging.
Datum	A reference point, line or surface from which measurements are taken.
Draw out	To lengthen metal by reducing its cross-section under forging.
Fuller	A tool or operation used to localise deformation and spread or draw metal.
Forge or hearth	Equipment or the working fire used to heat metal for forging.
Forging allowance	Extra or redistributed stock planned to achieve final volume, trimming and process needs.
Hardy hole	The square hole in an anvil used for suitable bottom tools.
Heat	In shop language, one working cycle in which a workpiece is heated and worked before reheating is required.
Jig	A device that locates, guides or supports work to improve repeatability.
Leg vice	A blacksmith's vice designed to withstand heavy hammering loads through a supporting leg.
Pritchel hole	A round anvil hole commonly used to provide clearance for punching.
Scale	Oxide that forms on hot steel and may flake from the workpiece.
Set down	A forging operation that creates a defined change in thickness or shoulder.
Stock	Raw material supplied in a known section such as round, square or flat bar.
Swage	A shaped tool or die used to form or finish a particular section or profile.
Template	A full-size or scaled reference used to check shape, profile or position.
Tongs	Forging workholding tools whose jaws are matched to the workpiece.
Upset	To increase cross-section by shortening and gathering material.
Working drawing	A technical drawing containing enough information to plan and make the component.

Reflection

Before moving to supervised workshop practice, consider these questions in your learning journal: Which part of your plan has the greatest safety consequence if it is wrong? Where could a full-size template reduce rework? Which control removes or reduces a hazard at source instead of relying on PPE? What information would another competent blacksmith need to review your job card without asking you to explain it verbally?

Interactive Tasks

Quiz: Test Your Knowledge

What should happen before any hazardous forge operation begins? (The approved plan and controls should pass the supervisor hold point) (!The stock should be heated first so the plan can be adjusted later) (!The learner should copy another worker without checking the job) (!The learner should choose PPE after the first heat)

Why is known material identity important when planning a forged part? (It supports predictable properties and appropriate hazard controls) (!It guarantees that every steel needs the same forging process) (!It removes the need for drawings and dimensions) (!It makes supervision unnecessary)

What is a datum used for? (A consistent reference for measurement) (!A fuel setting for a forge) (!A type of hearing protector) (!A method for storing tongs)

Which control approach should be considered before relying on PPE? (Reduce or remove the hazard at source) (!Add more PPE without changing the process) (!Work faster to shorten exposure) (!Ignore short tasks because they are always low risk)

What is the main purpose of matched tongs? (To hold the selected stock securely and controllably) (!To replace all measuring tools) (!To cool the workpiece faster) (!To increase the forge temperature)

What does forging allowance help you plan? (The amount of starting stock needed for the intended final form) (!The legal noise limit for a workshop) (!The colour of the protective finish) (!The apprenticeship funding band)

What does PUWER require for work equipment used at work? (It should be suitable safe maintained and used by trained people) (!It should be used until it fails and then inspected) (!It should be modified by any learner who finds it inconvenient) (!It should be used without guards for short operations)

Which statement best describes a working template? (It is a practical reference for checking shape or profile) (!It replaces every numerical tolerance) (!It proves the material grade) (!It certifies the finished product)

Why should unknown coated scrap be treated as a stop point? (Heating it may create uncontrolled material and fume hazards) (!All recycled steel is illegal to forge) (!Coatings always improve forgeability) (!Unknown stock is automatically tool steel)

What is the status of this aiMOOC after completion? (It is learning evidence but not a qualification or licence to practise) (!It is automatic Level 3 apprenticeship certification) (!It gives automatic occupational equivalence in every country) (!It replaces workplace training and supervision)

Memory Game

Forging allowance	Planned stock provision for final volume trimming and process needs
Datum	Reference used for consistent measurement
Hold point	Planned stop for competent review before hazardous work continues
Tongs	Workholding tool matched to the stock section
Scale	Oxide flakes formed on hot steel
Template	Practical reference used to compare shape or profile

Drag and Drop

Match the correct terms.	Topic
Confirm drawing requirements	Before selecting stock
Use known material	Material control
Match tongs to stock	Workholding
Inspect equipment	Pre-use condition
Use a supervisor hold point	Before hazardous operation

...

Crossword Puzzle

Allowance	What planning term means extra or redistributed stock for the intended forged result?
Datum	What reference is used for consistent measurement?
Tongs	What hand tool grips hot stock during forging?
Anvil	What main work surface supports hammer forging?
Scale	What oxide can flake from heated steel?
Template	What reference helps check a repeated profile or curve?

LearningApps

Cloze Text

Open-Ended Tasks

Easy

Annotated anvil study: Create a labelled image or sketch of an anvil and explain how three features support a planned hand-forging operation without carrying out hot work.
Job card draft: Produce a one-page planning card for a simple decorative hook with drawing reference, material, stock section, tools, hazards, controls, hold point and quality checks.
Material identification poster: Create an illustrated poster showing why known clean stock is preferred to unknown coated scrap for supervised forging.
Risk spotting image: Use a forge photograph supplied by your tutor and mark potential issues involving access, tool storage, hot zones, ventilation and housekeeping; do not infer that the photographed workshop is compliant or non-compliant without context.

Standard

Blacksmith interview: Interview a practising blacksmith, tutor or workshop technician about how they plan stock allowance, tool selection and supervisor checks; summarise where workplace practice differs by job type.
Supervised hook plan: Develop a complete plan and full-size template for a non-load-bearing decorative hook, then obtain instructor approval before any live workshop activity.
Safety communication video: Produce a ninety-second English video that demonstrates hot-metal communication, clear work zones and stop signals using cold props only.
Forge visit review: With an organised class visit and responsible staff, map the flow of stock, hot work, tool storage, emergency access and quality checking in a working forge without entering restricted areas.

Advanced

Competing process plans: Create two possible supervised process sequences for the same forged component and justify which better controls risk, material use, quality and rework.
Cold mock-up experiment: Use wire, modelling material or other tutor-approved cold media to test how different operation sequences affect final geometry; record observations and use them to revise the hot-work plan.
Ergonomic layout proposal: Produce a scaled layout or CAD proposal for an inclusive training-forge workstation that considers reach, handling aids, working radius, ventilation interfaces and emergency routes, then have a competent person critique it.
Expert review dossier: Prepare a review pack containing drawing, calculation, material traceability, tool list, risk-control summary, quality criteria, sustainability notes and source checks; ask a qualified vocational or industry expert to annotate it.

Learning Assessment

Planning transfer assessment: Given a new forged component drawing, justify stock section, allowance method, tool set and supervisor hold points, and explain how your choices affect quality and risk.
Hazard-control reasoning: Analyse a forge scenario with noise, coated stock and awkward handling, then propose controls in hierarchy order and defend why PPE is not the only answer.
Quality diagnosis: Compare two sample components or images and identify which planning decisions could have caused misalignment, inconsistent taper or poor repeatability.
Sustainability decision: Evaluate whether reusing an unidentified offcut is genuinely resource-efficient when material identity, coating and rework risk are considered.
Regulatory application: Match a realistic workplace issue to the relevant HSE area such as PUWER, COSHH, noise, manual handling or DSEAR, and explain what a learner should report or verify rather than attempting to discharge the employer's duty.
Professional communication: Present your job plan to a mock supervisor and respond to a change in drawing, material availability or risk controls without losing traceability.

Evidence of Learning

Evidence type	What strong evidence looks like
Knowledge	Accurate use of practitioner terminology; understanding of stock selection, forging allowance, workflow, risk-control hierarchy, quality and sustainability
Skills	Clear interpretation of drawings, basic volume calculations, template preparation, cold tool-fit checks, risk spotting and preparation of a coherent job sequence
Products	Job card, full-size template, risk-control summary, tool list, stock calculation, quality checklist and reflection record
Professional behaviours	Stops when information is unclear, reports defects, follows supervision, communicates hot-work boundaries and records changes
Transfer	Can adapt the same planning method to a new decorative, repair or small-batch forging job without assuming that another country's rules are equivalent

Expert Review Checklist

For expert review, verify the occupational terminology against current blacksmith practice in England; confirm the current Skills England ST0378 version and status; re-check HSE pages and the workshop's legal register; verify the BSI standards status before any procurement specification; confirm that the media links remain available; review the worked allowance calculation; and check that all suggested workshop transfer remains supervised and compatible with local risk assessments.

OERs on the Topic

Useful official and open references checked for this module include: HSE risk management HSE PUWER HSE COSHH HSE noise at work HSE manual handling HSE DSEAR HSE heat stress HSE local exhaust ventilation Skills England Blacksmith apprenticeship standard BSI as the UK's National Standards Body

Media note: Wikimedia Commons files embedded in this aiMOOC use the licence information on their individual Commons file pages. YouTube embeds remain external content under their own terms. The course text does not relicense third-party media.

This image of a traditional forge can support a discussion about fuel, air supply, combustion, ventilation and fire planning. It is not a model layout for an England workplace.

Linked Learning Areas

Producing forged parts by hand forging

The essential learning areas connect technical interpretation, material science, workshop mathematics, craft process planning, occupational safety, quality, sustainability and professional communication. These links support transfer from planning to later supervised hand-forging modules.