Structure and organisation of the training workplace — Safe practice

Introduction

Structure and organisation of the training workplace — Safe practice is the safe-practice module of Structure and organisation of the training workplace. It is designed for vocational learners in blacksmithing and artistic metalwork.

Jurisdiction: England, United Kingdom. This course uses workplace-safety law and vocational terminology applicable in England. Health and Safety Executive (HSE) guidance often covers Great Britain; here it is applied only within the England context. The apprenticeship information refers specifically to the apprenticeship system in England. No automatic equivalence is claimed with qualifications, certificates, job titles, laws or training pathways in Scotland, Wales, Northern Ireland or any other country.

Safety priority: official law, current HSE guidance, your employer or training provider's risk assessments and safe systems of work, the manufacturer's instructions, equipment markings, and the directions of your competent supervisor or instructor take precedence over this learning resource. Never start, set up, adjust, clear, repair, isolate or operate hazardous forge, welding, grinding, cutting, press or power-hammer equipment without the training, authorisation and supervision required by your workplace. If you are unsure, stop and ask.

This module does not teach you to carry out hazardous hot-forging or machine operations alone. Its practical demonstration is a supervised pre-use workstation safety check and handover, which you can practise without heating metal or energising machinery.

Visual reading: The photograph shows hot metal at an anvil. Treat it as a hazard-recognition image, not as a model of PPE or workshop procedure. On a real training site, the local risk assessment and supervisor determine the safe system. Wikimedia Commons file, CC BY-SA 2.0.

Learning outcomes

By the end of this module, you should be able to explain how a forge or artistic-metalwork training workplace is organised; distinguish a hazard from risk; recognise common hot-work, machinery, fume, noise, vibration, manual-handling, fire and housekeeping hazards; select controls using the hierarchy of controls; explain the roles of supervisors, learners and employers; carry out a supervised pre-use safety check; identify situations that require you to stop and report; judge the quality of a safe workstation handover; and connect safe practice with resource efficiency and responsible waste management.

Vocational context in England

Skills England lists the current Blacksmith occupational standard ST0378, version 1.1 as an approved-for-delivery Level 3 apprenticeship standard in the Creative and design route. The occupational profile covers designing, shaping and joining metal by hot forging and other metalworking processes for small-batch, bespoke and heritage work. It includes architectural ironwork, public art, gates, railings, domestic objects and tools. The standard also expects knowledge of health and safety, hazard recognition, risk assessment, waste disposal, equipment inspection, PPE, noise, fumes and manual-handling risks.

The standard gives a typical apprenticeship duration of 48 months, excluding the assessment period. That is a description of the current apprenticeship pathway in England; it is not a statement of equivalence with training elsewhere. Employers set entry requirements, and workplace competence is developed and checked over time. A certificate or course attendance by itself must never be treated as permission to use a particular machine when the employer's competence and authorisation arrangements require more.

Official vocational source: Skills England — Blacksmith ST0378 v1.1.

Core Concepts of Safe Practice

Hazard, risk and control

A hazard is something with the potential to cause harm. In a forge, examples include hot stock, a rotating grinder, welding fume, a suspended load, an LPG supply, sharp offcuts and excessive noise. Risk considers how likely harm is and how serious it could be, taking account of who may be affected and the controls already in place.

Under the Management of Health and Safety at Work Regulations 1999, employers must identify hazards, assess risk and eliminate hazards where possible or otherwise control the risk. HSE presents risk assessment as a practical process that should lead to action, not merely paperwork.

Risk-management question	Forge example
What can cause harm?	Hot steel is being carried from the forge to an anvil across a shared route.
Who could be harmed?	The smith, another learner, a tutor, a visitor or a person entering the route.
What controls are stronger than PPE?	Redesign the route, separate pedestrians, define a hot-metal zone, reduce crossing points and organise communication.
What residual controls may still be needed?	Task-specific PPE, supervision, warning arrangements and a safe system of work.
When should the assessment be reviewed?	After changes in layout, equipment, materials, people, incidents or evidence that controls are not working.

Official source: HSE — Managing risks and risk assessment at work.

The hierarchy of controls

HSE's current PPE guidance uses the hierarchy of controls in this order, from most to least effective: elimination, substitution, engineering controls, administrative controls, PPE. PPE is the last line of defence, not the first answer to every hazard.

More reliable control	Application in a blacksmithing or metalwork training shop
Elimination	Remove an unnecessary hazardous step, for example redesign a job so a learner does not need to carry hot stock through a shared walkway.
Substitution	Replace a more hazardous product or process with a less hazardous one where technically suitable and approved.
Engineering controls	Guards, enclosures, separation, local exhaust ventilation, screens and mechanical handling aids control risk at or near the source.
Administrative controls	Authorisation, training, supervision, zoning, maintenance schedules, inspection, signage and safe systems of work organise how work is done.
PPE	Eye, face, hearing, foot, body, hand or respiratory protection selected from the task-specific risk assessment protects the individual against residual risk.

Do not use this hierarchy mechanically. The employer must assess the actual task, people, equipment, substances and environment. Several controls are often required together.

Official source: HSE — Managing risk using PPE.

Structure and Organisation of the Training Workplace

Roles, authority and communication

A safe training workplace makes authority and communication visible. The employer or training provider is responsible for organising work so risks are managed. A competent supervisor or instructor interprets the task, checks that controls are in place, decides what a learner may do, monitors performance and stops work when necessary. A learner or apprentice follows instruction and the safe system of work, uses controls correctly, reports defects and near misses, asks when uncertain and does not exceed their authorisation.

A learner who is under 18 may require more supervision because of inexperience, maturity and familiarity with workplace risk. HSE states that young people need clear and sufficient instruction, training and supervision. This module therefore assumes supervised hazardous work for all learners, with the degree of supervision set by risk assessment, competence and workplace policy.

Official source: HSE — Young people at work.

Typical zones in a training forge

The exact layout varies, but safe organisation usually separates incompatible activities and keeps material flow predictable. A training forge may include receiving and stock storage; cold preparation and marking out; forge and hot-work stations; anvils and hand-tool areas; power-hammer or press zones; welding or thermal-cutting bays; grinding and finishing areas; dedicated cooling or quarantine areas; scrap and waste segregation; tool storage; first-aid and emergency arrangements; and welfare facilities.

A useful planning principle is to avoid unnecessary crossing between people routes, hot-metal routes, spark or fume zones and machine danger zones.

Example material-flow diagram for discussion only
Delivery and identified stock	→	Cold preparation	→	Authorised hot work	→	Cooling and controlled handover
Known material and coating status	→	Cutting or marking in the correct zone	→	Forge, anvil or approved joining process	→	Inspection, finishing, storage or scrap

This diagram is not a site plan. Your training provider's marked routes, fire arrangements, extraction layout and restricted areas take precedence.

Anvil station and hand-tool area

The anvil station is a working envelope, not merely an anvil. You need stable footing, adequate clearance for the workpiece and hammer swing, correctly placed tools, a controlled route for hot stock and a defined place for items that are cooling. Do not leave hot material where another person may assume it is cold.

Tool identification: This nineteenth-century London-pattern anvil illustrates the face, horn and body form. It is a historical object, not a specification for a modern training workstation. Wikimedia Commons file, CC BY-SA 3.0.

A hand hammer should be suitable for the task and in serviceable condition. Check for defects according to workplace instruction, including loose or damaged handles and unsafe striking faces. Tongs must grip the intended section securely enough for the approved task. Never improvise a poor grip on hot material because the correct tong is unavailable; stop and obtain the right tool.

Hazard annotation: Hot stock can remain dangerous even when its colour changes. The picture is a close-up of striking work, not a licence to copy the technique. Wikimedia Commons file, CC0 1.0.

Forge and hot-work zone

The forge zone contains intense heat and, depending on equipment and fuel, may involve combustion products, fuel systems and fire or explosion hazards. Gas-fired forge systems may involve LPG or another fuel; solid-fuel forges involve hot fuel, ash, sparks and combustion products. Only authorised people should light, adjust, shut down or maintain equipment under the site's procedure and the manufacturer's instructions.

The Dangerous Substances and Explosive Atmospheres Regulations 2002, known as DSEAR, require employers to control risks from dangerous substances such as flammable gases, solvents and combustible dusts. Learners must not alter gas installations, bypass flame-safety devices or troubleshoot fuel systems unless specifically trained, competent and authorised.

Media source country: Malta. This image is used only to recognise the general elements of a traditional solid-fuel forge. It does not represent English legal requirements or a model training layout. Wikimedia Commons file, CC BY-SA 4.0.

Official source: HSE — DSEAR.

Power hammers, presses and rotating machinery

Power hammers, presses, grinders, drills and other powered equipment create crushing, drawing-in, entanglement, impact, ejection and unexpected-start hazards. Under PUWER 1998, work equipment must be suitable, maintained and used only by people who have received adequate information, instruction and training. HSE also identifies guarding, emergency stopping and suitable isolation from energy sources as core safeguards.

A learner must never defeat a guard or interlock, reach into a danger zone, clear a jam, mount an abrasive wheel, or perform maintenance because the task looks quick. Machine-specific training and authorisation are required. Long hair, loose clothing, jewellery and unsuitable gloves can create entanglement hazards around rotating machinery; the task-specific safe system must define what is permitted.

Official source: HSE — PUWER overview.

Abrasive wheels and grinding areas

Grinding creates high-speed ejection hazards, sparks, noise, dust and possible wheel failure. HSE publication HSG17 Safety in the use of abrasive wheels covers training needs, wheel characteristics, mounting, guards, portable grinders and protective equipment. A training workshop should restrict wheel mounting, adjustment and use to people who are trained and authorised for the specific equipment.

Media source country: Romania. This is a hazard-recognition image showing the spark plume from an angle grinder. It is not a demonstration of safe technique or UK legal compliance. Wikimedia Commons file, CC BY 2.0.

Official source: HSE — HSG17 Safety in the use of abrasive wheels.

Welding, thermal cutting and fume

Where welding is part of the training or production task, it requires specific controls. HSE states that all welding fume can cause lung cancer and that controls are required even for small amounts of welding. Appropriate controls can include a lower-fume process or alternative joining method, local exhaust ventilation, suitable RPE where needed, good general ventilation, maintenance and training.

Do not assume that opening a door or wearing a disposable mask is automatically adequate. The employer's COSHH assessment determines the control strategy. Local exhaust ventilation must capture contamination effectively at source and be maintained and examined as required. Learners should know the normal indicator or simple user check specified for their LEV and report failure immediately; specialist testing is for a competent person.

Official sources: HSE — Welding fume: protect your workers and HSE — LEV frequently asked questions.

Substances, coatings and unknown materials

COSHH applies to substances hazardous to health, including many fumes, dusts, vapours, mists and chemicals. In artistic metalwork, risk can come from welding fume, grinding dust, degreasers, paints, patination chemicals, fluxes, adhesives and contamination on old or reclaimed metal.

A crucial rule is: do not heat, grind, weld or chemically treat unknown or unidentified coated stock. Galvanised, painted, plated or contaminated material can release hazardous substances when processed. Quarantine the item, identify the material and coating using reliable information, consult the relevant safety data and COSHH assessment, and obtain supervisor approval before work proceeds.

Official source: HSE — COSHH basics.

Manual handling and material storage

Bar stock, plate, gates, jigs and finished architectural work can be long, awkward, heavy, sharp or hot. HSE's approach is to avoid hazardous manual handling so far as reasonably practicable; assess handling that cannot be avoided; and reduce risk as low as reasonably practicable. There is no single safe lifting weight in law.

Good organisation reduces handling risk: place commonly used stock at sensible heights, reduce carry distances, use suitable mechanical aids where the assessment calls for them, plan team handling where appropriate and keep racks stable and accessible. Never improvise a lift of a large gate or long bar because production is behind schedule.

Official source: HSE — Manual handling at work.

Noise and vibration

Hammering, grinding, power hammers and other metalworking operations can create harmful noise. Under the Control of Noise at Work Regulations 2005, HSE identifies 80 dB(A) daily or weekly average exposure as the lower exposure action value for employer risk assessment, information and training; 85 dB(A) as the level at which hearing protection and hearing-protection zones are required; and 87 dB(A) as the exposure limit value after taking hearing protection into account.

These are employer exposure-management values, not a reason for a learner to decide safety from a phone app. Noise assessment, control at source, exposure time, hearing protection selection and health surveillance are workplace responsibilities.

Hand-arm vibration from powered tools is controlled under the Control of Vibration at Work Regulations 2005. HSE gives an exposure action value of 2.5 m/s² A(8) and an exposure limit value of 5.0 m/s² A(8). The employer must assess exposure and reduce risk; learners should report tingling, numbness or abnormal tool vibration through the workplace process rather than trying to self-diagnose.

Official sources: HSE — Noise Regulations and HSE — Hand-arm vibration Regulations.

PPE and practitioner judgement

PPE is selected after stronger controls have been considered. The correct combination depends on the task. A forge risk assessment may identify eye or face protection, hearing protection, safety footwear and suitable protective clothing; grinding or welding can require additional task-specific protection. RPE must be selected and managed for the contaminant, exposure, wearer and work conditions.

Do not turn a generic list into a universal uniform. Gloves are a clear example: they may protect against some hazards but can create entanglement risk around rotating machinery, and not every glove protects against heat, cuts or chemicals. Use only the glove type and method required by the task-specific assessment, and never assume that a glove makes hot metal safe to grasp.

HSE requires PPE to be properly assessed, maintained, stored and used correctly, with information, instruction and training. Current BSI examples relevant to procurement include BS EN ISO 16321-1:2022+A1:2025 for general occupational eye and face protection and BS EN ISO 20345:2022+A1:2024 for safety footwear. A standards mark does not make an item automatically suitable for a specific forge task; the risk assessment and required performance class still matter.

Official sources: HSE — PPE overview, BSI — BS EN ISO 16321-1 and BSI — BS EN ISO 20345.

Authentic Workshop Examples

Decorative scroll commission

A learner is helping prepare repeated elements for a decorative railing. The main organisational problem is not only the forge temperature: it is the repeated movement of long hot stock between the forge, anvil and cooling area while other learners work nearby. A strong control plan separates the hot-metal route, defines where cooling pieces are placed, keeps spectators outside the working envelope, ensures the correct tongs are ready before heating, and assigns supervision before work begins.

Gate fabrication project

A gate project combines long-stock handling, fabrication, possible welding and grinding, and final movement of a large workpiece. The team should plan material flow, mechanical handling, welding-fume controls, screens or separation, grinding zones and the safe storage of partially completed work. A good plan also identifies who is authorised to use each machine and how a defect is reported and isolated.

Heritage repair with unknown coating

An old railing arrives with several layers of paint and corrosion. It would be unsafe to assume the coating is harmless because the object is old. The correct safe-practice response is to stop before heat, grinding or welding is applied, identify the material and coating, obtain the relevant COSHH information and method, and proceed only after competent approval. Heritage value does not override exposure control.

Shared training forge at changeover

One group finishes while another is ready to start. Hot offcuts remain near the anvil, a grinder guard is damaged and the LEV indicator is abnormal. A professional handover does not hide these problems to save time. The area is made safe, defects are reported, affected equipment is taken out of service according to site procedure, and the next group receives a clear status briefing before work starts.

Tools, Materials and Main Risk Controls

Tool, equipment or material	Typical hazards	Control priorities in a training workplace
Hand hammers and struck tools	Impact, flying scale, damaged handles or faces	Serviceable tools, correct tool for the task, clear working envelope, eye or face protection as assessed, training and supervision
Tongs	Loss of grip, hot-stock movement, hand exposure	Correct tong size and jaw form for the stock, pre-use condition check, planned route and supervised technique
Anvil	Hot work, sharp edges, noise, trip hazards around the stand	Stable installation, clear floor, controlled tool placement, defined cooling area and hearing controls where assessed
Gas or solid-fuel forge	Heat, fire, combustion products, fuel hazards	Authorised operation, ventilation, DSEAR and fire controls where relevant, equipment maintenance, clear hot zone and supervised shutdown
Power hammer or press	Crushing, trapping, ejection, noise and unexpected movement	PUWER guarding and controls, restricted access, authorised users, safe isolation for maintenance and direct supervision appropriate to competence
Bench or angle grinder	Wheel failure, ejection, sparks, dust, noise and entanglement	Correct wheel and guard, inspection and maintenance, HSG17-based training, secure work, extraction where required, task-specific PPE and authorised use
Drill press or other rotating machine	Entanglement, ejection and contact with rotating parts	Guards, secure workholding, controlled hair and clothing, no unsuitable gloves near rotating parts, training and isolation for adjustment or maintenance
Welding and thermal cutting equipment	Fume, optical radiation, burns, spatter, fire and gas hazards	COSHH assessment, LEV, RPE where required, screens, fire controls, equipment checks and authorised supervised use
Mild steel stock	Sharp edges, hot surfaces, manual handling	Identified grade, safe storage, suitable handling aids and designated hot or cooling locations
Galvanised, painted, plated or unknown stock	Hazardous fume or dust when heated or abraded	Do not process until coating and material are identified and an approved COSHH control method is in place
Solvents, coatings and patination chemicals	Vapour, skin or eye exposure, fire and environmental harm	Substitution where possible, labelled storage, safety data, COSHH controls, ventilation and task-specific PPE
Scale, swarf and offcuts	Cuts, slips, punctures, hot fragments and poor housekeeping	Suitable bins, segregation, no hand-sweeping of sharp waste, controlled clean-up method and clear floors

Step-by-Step Demonstration: Supervised Pre-Use Workstation Safety Check

This demonstration is intentionally a non-production safety routine. Do it with the forge cold and powered equipment not in use unless your supervisor explicitly directs otherwise. It does not authorise you to energise, test-run, adjust or repair equipment.

Receive the task briefing. Confirm the job, drawing or work instruction, risk assessment, safe system of work and the limits of your authorisation with the supervisor.
Check the area. Verify that access routes, floor, lighting, barriers, emergency routes and the working envelope are clear enough for the planned task.
Identify the material. Confirm the stock grade or identity and coating status from approved information; quarantine unknown, painted, plated or contaminated material.
Check hand tools without using them. Inspect the hammer, tongs and other hand tools for obvious defects under the workshop checklist; remove suspect tools from use and report them.
Check powered-equipment status visually. Confirm required guards, warning signs and isolation or out-of-service labels are present; do not open guards, defeat devices or energise equipment to investigate.
Check extraction status. Where LEV is required, check the normal user indicator or approved simple check specified by the workplace; report an abnormal indication rather than adjusting the system yourself.
Select required PPE. Use the task-specific assessment and supervisor instruction; check fit, compatibility and condition, and control loose hair, clothing and jewellery.
Plan movement and hot-item control. Point out the route for stock, the authorised hot-work zone, the cooling or quarantine location and how others will be kept clear.
Obtain supervisor sign-off. Explain any defect, uncertainty or change. Do not start the hazardous operation until the supervisor confirms that the workstation and controls are ready.
Maintain and hand over. During authorised work, keep controls in use and stop if conditions change. At the end, follow the site's shutdown and isolation procedure, allow materials to cool in the defined location, return tools and stock, segregate waste and report defects, incidents or near misses.

Quality criteria for the demonstration

A high-quality safety check is complete, observable and reproducible. Another trained person should be able to see that the work area is clear; materials are identified; tools are serviceable; guards and safety devices are present; LEV status is normal where required; PPE matches the assessment; stock movement and cooling locations are defined; restricted operations remain restricted; defects are reported; and supervisor authorisation has been obtained.

Speed is not a quality criterion. Skipping a check because a task is familiar is a loss of control, not efficiency.

Stop-Work Triggers and Common Errors

Stop and report when

Stop the task and follow the site's reporting or emergency procedure if you encounter a missing or damaged guard; an unexpected machine movement or unusual vibration; a failed or abnormal LEV indicator; an unidentified metal or coating; a fuel smell, suspected leak or abnormal flame behaviour; a blocked escape route; uncontrolled hot metal in a shared route; damaged electrical equipment; unsuitable or missing task-required PPE; unexpected smoke or fume; a lifting situation outside the plan; or any instruction you do not understand.

Do not attempt a repair, gas intervention, electrical fault-finding or machinery isolation beyond your training and authorisation. In an emergency, raise the alarm and follow the workplace emergency plan. Firefighting, first aid and rescue actions should be undertaken only within your training and the site's arrangements.

Common errors and why they matter

Common error	Why it is unsafe or poor practice	Better response
Assuming dark metal is cool	Steel may remain hot enough to burn after visible colour has faded	Use the designated hot-item system and cooling location; do not rely on appearance
Taking a quick grinding cut with a damaged or missing guard	Short duration does not remove the ejection or wheel-failure hazard	Stop, isolate or label out according to procedure, and report the defect
Heating reclaimed metal before identifying its coating	Coatings and contamination may create hazardous fumes	Quarantine, identify and obtain COSHH approval first
Relying on gloves as the main control	Gloves do not remove heat, entanglement, impact or fume hazards	Apply the hierarchy of controls and use only task-specified gloves
Wearing gloves near rotating machinery without task approval	A glove can increase entanglement risk	Follow the machine-specific safe system and supervisor instruction
Blowing grinding dust around the workshop with compressed air	Dust can become airborne and expose others	Use the approved dust-control and clean-up method
Leaving hot offcuts in ordinary scrap	Another person may handle them as cold material	Use the designated hot or cooling area before approved disposal
Carrying long stock through a busy route without warning	The stock can strike people or enter another work zone	Plan the route, clear the area and use agreed communication
Continuing with weak extraction because the job is nearly finished	Exposure continues while the control is ineffective	Stop and report; do not resume until the required control is restored
Bypassing an interlock to save setup time	It defeats an engineered safeguard and can expose people to dangerous motion	Keep safeguards functional and use only authorised setup procedures

Maintenance, Defects and Isolation

Maintenance can create hazards that are not present during normal operation, especially unexpected start-up or release of stored energy. HSE requires work equipment to be maintained in a safe condition and maintenance to be planned and carried out safely.

A learner's normal role is to carry out only the routine checks and minor care specifically included in their training. Isolation and lock-off are not casual learner tasks. The workplace must define who is competent and authorised to isolate electrical, pneumatic, hydraulic, mechanical, gravitational or fuel energy and how that isolation is verified. A defect tag or out-of-service label communicates status; it does not replace a proper isolation where one is required.

Official source: HSE — Maintenance of work equipment.

Incidents, Near Misses and Learning Culture

Report injuries, near misses, damage, control failures and unsafe conditions promptly through the workplace system. A near miss is valuable information because it can reveal a failed control before someone is injured.

RIDDOR is a legal reporting system for specified work-related injuries, diseases and dangerous occurrences. Learners should not assume that every event is personally reportable to HSE. The responsible person decides and submits any RIDDOR report where the law requires it. Your role is to make sure the employer or training provider receives accurate internal information quickly.

Official source: HSE — Reportable incidents.

Sustainability and Safe Craft Practice

Sustainable blacksmithing is not achieved by weakening safety controls. A well-run training forge can reduce waste and energy use while preserving control measures.

Use accurate cutting lists and stock planning to reduce scrap. Reuse clean offcuts only when their material identity remains known and they are suitable for the job. Segregate ferrous and non-ferrous scrap to improve recycling. Keep tools and equipment maintained so they work efficiently and last longer. Select lower-hazard coatings, cleaners or joining processes where technically suitable and approved. Manage contaminated rags, chemical residues and process waste under the site's environmental and COSHH arrangements; do not pour unknown quench residues or chemicals into drains.

Energy efficiency can include sensible production planning, avoiding unnecessary reheating and maintaining forge equipment in good condition by competent people. Never turn off required LEV, guards, interlocks or other safety systems merely to save energy. Safety-critical ventilation and controls take priority while the hazardous process is operating.

Inclusive and Accessible Safe Practice

Safe practice should work for the person, not force every learner into one body size or communication style. PPE must fit the wearer and remain compatible with other PPE. Workstations, handling methods and supervision should account for individual capability without stereotyping. Clear demonstrations, written checklists, visual zone markings and plain-language briefings support learners with different communication and learning needs.

If you need an adjustment, raise it with the training provider before the task. An adjustment must maintain an equivalent level of risk control; it should not be achieved by removing a guard, reducing supervision or using unsuitable PPE. British Sign Language or other communication support may be part of an inclusive learning arrangement, but emergency signals and machine communication still need to be understood by everyone in the work area.

Media and Demonstration Videos

United Kingdom: HSE risk assessment video

This HSE video supports the England legal and risk-management context used in this course. Watch it to identify the difference between finding hazards and deciding on controls. It does not replace the forge-specific risk assessment.

India: manufacturer abrasive-wheel safety video

The following video is from CUMI, an India-based abrasive manufacturer. It is included as a manufacturer perspective on abrasive-wheel hazards and product handling. It is not English legal guidance and does not create cross-country equivalence. For work in England, HSE HSG17, PUWER, the instructions for your actual machine and wheel, and your workplace training take precedence. Do not copy mounting or operating procedures from a video unless your employer has trained and authorised you for that exact task.

Current Authority and Standards Check

This module was prepared for expert review using sources current on 1 September 2026.

Area	Competent or authoritative source for England	Current point used in this module
General risk management	Health and Safety Executive	Management of Health and Safety at Work Regulations 1999: identify hazards, assess risk, eliminate or control
Work equipment	Health and Safety Executive	PUWER 1998: suitable, maintained equipment; adequate information, instruction and training; guarding and isolation where required
Hazardous substances	Health and Safety Executive	COSHH: assess and control exposure to hazardous substances including dusts and fumes
Welding fume	Health and Safety Executive	All welding fume can cause lung cancer; suitable controls are required
Fire and explosion	Health and Safety Executive	DSEAR 2002 controls dangerous-substance fire and explosion risks
Noise	Health and Safety Executive	Control of Noise at Work Regulations 2005 action and limit values
Vibration	Health and Safety Executive	Control of Vibration at Work Regulations 2005 action and limit values
Vocational standard	Skills England	Blacksmith ST0378 v1.1, Level 3, approved for delivery in England
Eye and face protection standard	British Standards Institution	BS EN ISO 16321-1:2022+A1:2025 is current
Safety footwear standard	British Standards Institution	BS EN ISO 20345:2022+A1:2024 is current

Expert-review note: Before local delivery, a competent reviewer should check this module against the training provider's current risk assessments, fire-risk arrangements, machinery manuals, LEV commissioning and examination records, PPE performance requirements, safeguarding and supervision arrangements, and any site-specific procedures. Official rules and workplace instructions always take precedence.

Glossary

Term	Practitioner meaning in this module
Anvil	A heavy metal support used for forging and other metalwork; its working area must be organised as part of a safe station.
Face	The flat working surface of an anvil.
Horn	The projecting rounded or shaped end of an anvil used in forming work.
Hardy hole	A square hole in many anvils for suitable bottom tools; use is task-specific and supervised.
Pritchel hole	A smaller round hole in many anvils, traditionally associated with punching or clearance.
Tongs	Hand tools shaped to hold and control workpieces; the jaws should suit the stock and task.
Stock	Raw or partly processed material, such as bar, plate or section, from which work is made.
Scale	Oxide that forms on hot steel surfaces and can detach as hot particles.
Swarf	Chips, filings or fine waste produced by machining, drilling or grinding.
Forge	The hearth or furnace used to heat metal for forging; in training it is an authorised hot-work area.
Quench	Controlled cooling in a specified medium; quench operations have thermal, splash and material risks and require instruction.
LEV	Local exhaust ventilation: engineering control designed to capture airborne contamination close to where it is produced.
RPE	Respiratory protective equipment selected for a specific inhalation hazard and wearer; it is not a substitute for effective source control where that is practicable.
PPE	Personal protective equipment used against residual risk after stronger controls have been considered.
COSHH	Control of Substances Hazardous to Health Regulations.
PUWER	Provision and Use of Work Equipment Regulations.
DSEAR	Dangerous Substances and Explosive Atmospheres Regulations.
WEL	Workplace exposure limit, as listed where applicable in HSE publication EH40.
Risk assessment	A structured assessment of hazards, who may be harmed, the level of risk and the controls needed.
Safe system of work	A defined method of organising a task so hazards are controlled.
Competent person	A person with the appropriate skills, knowledge, training and experience for the safety-critical role concerned.
Authorisation	Formal workplace permission to perform a task or use equipment within defined limits.
Isolation	Making equipment safe from relevant energy sources by an approved method before specified work; only trained and authorised people should carry it out.
Guard	A physical protective measure intended to prevent access to dangerous parts or contain hazards.
Near miss	An unplanned event that did not cause injury or damage but had the potential to do so.
Hot-work zone	An area controlled for work that produces heat, flame, sparks or hot material, according to the site's arrangements.

Reflection

In your learning journal, describe one feature of workshop organisation that protects other people as well as the operator; identify one control that acts at the source rather than relying on PPE; and name one condition that should make you stop, report and wait for competent guidance. Then compare your notes with the actual rules in your training workplace.

Interactive Tasks

Quiz: Test Your Knowledge

Which control is highest in the HSE hierarchy of controls? (Elimination) (!PPE) (!Signage) (!Hearing protection)

What should you do before processing metal with an unknown coating? (Stop and identify the material and coating) (!Heat it briefly to see what happens) (!Grind the coating away without assessment) (!Assume old paint is harmless)

What is the main purpose of local exhaust ventilation? (Capture airborne contamination close to its source) (!Make the workshop look cleaner) (!Replace all respiratory protection automatically) (!Increase forge temperature)

Under PUWER who should use work equipment that carries specific risk? (People with the required training and authorisation) (!Any learner who has watched a video) (!Any visitor wearing safety glasses) (!Only the person nearest the machine)

What is the safest response to a damaged grinder guard? (Stop use and report the defect) (!Remove the guard completely) (!Finish one quick cut first) (!Hold the work farther away)

Which statement about manual handling is correct in England? (The law does not set one universal safe lifting weight) (!Every adult may safely lift twenty kilograms) (!Team lifting removes all risk) (!Training removes the need for assessment)

Why must hot offcuts have a controlled cooling location? (Other people may mistake them for cold metal) (!They always cool faster on the floor) (!They cannot be recycled after cooling) (!They make hand tools magnetic)

What should a learner do if an LEV indicator shows abnormal performance? (Stop the affected task and report it) (!Continue because extraction is optional) (!Open the duct and repair it) (!Wear ordinary clothing as a substitute)

What is PPE in the hierarchy of controls? (The last line of defence against residual risk) (!A replacement for machine guarding) (!A substitute for supervision) (!The first control to choose)

Which authority publishes the Blacksmith apprenticeship occupational standard used in this England module? (Skills England) (!OSHA) (!Safe Work Australia) (!WorkSafe New Zealand)

Memory Game

PUWER	Work equipment safety duties
COSHH	Hazardous substance exposure controls
LEV	Source capture of airborne contamination
DSEAR	Fire and explosion risk controls
Isolation	Approved separation from hazardous energy
Guard	Barrier against dangerous machine parts
Near miss	Event with harm potential but no injury
Authorisation	Workplace permission within defined limits

Drag and Drop

Match the correct terms.	Topic
Remove the hazard	Elimination
Replace with a safer option	Substitution
Isolate people from the hazard	Engineering controls
Change the way work is organised	Administrative controls
Protect the individual from residual risk	Personal protective equipment

Match each description to the control level before checking your answers.

Crossword Puzzle

Ventilation	What general term describes moving or extracting air to control airborne contaminants?
Isolation	What approved safety action separates equipment from hazardous energy before specified work?
Guarding	What machine-safety approach prevents access to dangerous moving parts?
Housekeeping	What practice keeps floors routes tools and waste under control?
Supervision	What organised oversight supports learners who are not yet fully competent?
Extraction	What process removes fume or dust close to where it is generated?

LearningApps

Cloze Text

A workplace hazard is something with the potential to cause

. Risk assessment should lead to action that eliminates hazards where possible or

the remaining risk. Under the hierarchy of controls, PPE is the

line of defence. Before heating or grinding reclaimed metal, you must confirm the material and

. Local exhaust ventilation should capture airborne contamination close to its

. A damaged machine guard is a reason to stop and

. Hazardous equipment should only be used within your training, supervision and

. Official workplace instructions always take

over this learning resource.

Open-Ended Tasks

Easy

Hazard spotting walk: With a tutor, walk through the cold workshop while no hazardous operation is underway and create a labelled sketch showing routes, restricted zones, stock storage, cooling areas and emergency access points.
Tool condition poster: Produce a one-page visual poster showing the non-operational condition checks your training provider expects for hammers and tongs, and have a supervisor verify every item before display.
Safety vocabulary cards: Create illustrated cards for PUWER, COSHH, LEV, DSEAR, PPE and near miss using plain English and one blacksmithing example for each term.
Hot metal communication: Design a clear sign or communication cue for the workshop's approved hot-item system, then compare it with the actual site procedure and revise your design.

Standard

Workstation handover video: In a cold and non-operating training area, record a short supervised video demonstrating the pre-use safety check and handover without energising machinery or heating metal.
Risk control redesign: Choose one approved training task and redraw the layout so pedestrian routes, hot-metal movement and spark or fume zones cross as little as possible, then justify the changes using the hierarchy of controls.
COSHH information audit: With your tutor, select one substance already approved for workshop use and trace its label, safety data, COSHH assessment, storage rule and disposal route without opening or using the substance.
Near miss interview: Interview a tutor or experienced practitioner about an anonymised near miss and produce a cause-and-control map that focuses on system improvements rather than blame.

Advanced

Forge safety review: Working with a competent supervisor, compare one local forge risk assessment with current HSE guidance and produce an expert-review note identifying evidence that controls are implemented and maintained.
LEV verification project: Without adjusting or opening the system, document the learner-visible LEV indicators, user checks, defect-reporting route and examination-record process, then explain which actions require a competent specialist.
Sustainable workflow study: Map material, energy and waste flows for a small artistic-metalwork project and propose reductions in scrap, handling and reheating that do not weaken any safety control.
Training workplace briefing: Create and deliver a ten-minute induction briefing for a hypothetical new learner covering authorisation, supervision, stop-work triggers, hot-metal control, machine restrictions, reporting and inclusive communication, then obtain tutor feedback.

Learning Assessment

Safe workplace analysis: Analyse a workshop layout supplied by your tutor and explain how you would separate people, hot-metal movement, machine danger zones and fume-producing work using controls stronger than PPE where practicable.
Control selection case study: For an approved artistic-metalwork task, justify a layered control strategy using elimination, substitution, engineering controls, administrative controls and PPE, explaining why each selected measure is proportionate.
Defect response scenario: Explain the decisions you would make if a grinder guard were damaged, LEV performance were abnormal and the production deadline were approaching, including what you would stop, report and leave to authorised personnel.
Unknown material scenario: Evaluate a heritage repair job involving unidentified paint and propose a safe information-gathering and approval process before any heat, grinding or welding takes place.
Supervision plan: Design a competence-based supervision plan for a new learner moving from observation to supervised participation, showing how authorisation boundaries and evidence of competence would be communicated.
Safety and sustainability transfer: Apply the module to a different metalwork project and explain how stock planning, maintenance, waste segregation and energy efficiency can improve sustainability without compromising extraction, guarding, supervision or other safety controls.

Evidence of Learning

Strong evidence of learning includes accurate knowledge of the England legal and vocational context; correct use of practitioner terms; recognition of hot-work, machine, fume, noise, vibration, manual-handling, fire and housekeeping hazards; and an ability to distinguish hazards, risks and controls.

Practical evidence includes a supervised, complete pre-use workstation check; correct recognition of authorisation boundaries; safe reporting of defects and near misses; correct identification of stop-work triggers; and reliable use of the workplace's hot-item and material-control systems.

Product evidence may include an annotated workshop layout, a verified hand-tool checklist, a risk-control redesign, a COSHH information audit, a safety briefing or a sustainability workflow map. Transfer evidence is shown when you can apply the same reasoning to a new commission, heritage repair or fabrication task without assuming that a control from one process automatically fits another.

OERs on the Topic

The following freely accessible official resources are suitable for review in England. HSE web content is available under the Open Government Licence v3.0 except where otherwise stated.

Open Licence and Media Attribution

Unless otherwise stated, the original instructional text and task design of this aiMOOC are offered under the Creative Commons Attribution-ShareAlike 4.0 International licence. Wikimedia Commons files retain the individual licences shown on their file pages. HSE and Skills England material linked here is Crown copyright and reusable under the Open Government Licence where the source states this. British Standards are copyrighted standards and are linked for identification and current-status checking; their text is not reproduced here. YouTube videos remain under the rights and terms specified by their publishers and platform; embedding them does not relicense them.

Media used in this module: