ANATOMY OF AN EFFICIENT WORKSHOP
ANATOMY OF AN EFFICIENT WORKSHOP
Workshops tend to find
themselves squeezed into
odd corners of barns. But
they deserve a bit of thought,
says Royal Agricultural
College buildings lecturer
Graeme Lockhead
* The workshop
Big or small, all farms have some form of workshop. It may be located in an existing building or be purpose-built. Its size will depend on the acreage and type of farm, the ability of farm staff and the farms distance from local repair premises. Typical work carried out will probably include servicing, repairs, estate maintenance and fabrication of new equipment.
Good workshops are not exclusive to arable farms – livestock units can benefit equally from a facility where fabrication can take place as well as servicing. But it tends to be on arable farms where the need for a well laid-out a designed workshop is greater.
* The site
Ideally, the workshop will be centrally located and close or even linked to the machinery shed to allow machines to be operated on in situ. It should be well away from any livestock and straw/hay storage.
Ideally the site should be at the centre of vehicle activity and should be provided with both fuel storage and a wash-down area. The fuel store should be bunded (capable of holding 110% of the capacity of the tank) and the wash-down area provided with a silt and oil trap before falling to soakaway or dirty water system.
The silt trap may require some design input since the build-up of dirt from machines could be considerable.
* The building
Workshops are often located in converted buildings, so it is not always possible to include the maximum desirable workspace. However, it is essential that the workshop allows for all operations to be carried out with enough space for both machines and staff to move about and with clear, uncluttered workbenches and work areas.
The building should be light and capable of dealing with the biggest machine on the farm. Natural light should be provided via windows in the walls and 20% rooflights. Doors (roller shutter style) should provide good access and be 4.6m (15ft) high and at least 4m (13ft) wide.
Modern workshops need height to allow maximum access, but be wary of overcompensating. Remember that all that extra space will need to be warmed in winter.
The walls, constructed normally in blockwork, should be reinforced if any benches or racks are to be hung. They should be 2m (6ft 6in) high to allow 1m (3ft 3in) of bench and 1m of wall space for tools etc. The floor should be made of concrete, with a brush finish and painted to seal the surface and aid cleaning.
Good ventilation is essential when working on running machinery and either windows should be provided or an extraction system installed.
The internal layout of the building will provide workbenches along one or two walls creating an L-shape, a rack for fabrication parts and a welding bay. The walls of this bay, which should have a dark finish to reduce glare, will need a steel welding bench and a storage cabinet for welding rods. It is advisable to provide fume extraction and screens to protect all who use the workshop.
* The work area
The size of the workshop will depend on individual circumstances, but 15m (50ft) square provides a good starting point for consideration and will provide good all round work space. The size can be calculated by taking the measurements of the largest machine on the farm and adding half that figure again (usually 2-3m) to give enough clear space.
Workbenches should be provided at a height of 1m and depth of 800mm along one wall, and perhaps even two, to provide an L-shape. Tool boards can be provided, fixed to the wall above the bench, as well as wall-mounted trays.
Avoid drawers. A portable tool trolley helps keep tools organised and in a good state of repair and can be moved around the workshop to the point of activity. The vice should be positioned at the mid point of the workbench, or so that good access can be gained from both sides.
One wall should hold the fabrication/steel rack. This should be free-standing and not reliant on the strength of the wall unless designed thus.
Adequate heating is essential, with much of the overhaul and maintenance being carried out during winter months. Portable heaters can provide heat directed at the worker in the main workshop.
Directed heat will need to be provided around the work areas and workbench and this can be achieved by radiant or infra-red heaters, concentrating on a localised area. It is worthwhile spending time working out how much time will be spent in the workshop before considering a more permanent form of heating in order to justify both capital and running costs.
Good lighting is vital and large windows, especially at the workbench, will provide natural light, along with a 20-25% area of rooflighting. Artificial light will need to be provided – as a general guide 10sq m (110sq ft) of floor area needs 60W of filament bulb or 130W of fluorescent tubes. Additional strip lights should be provided over the workbenches.
Inspection lamps should be provided, preferably through a transformer (reducing voltage from 240V to 24V or 12V) as opposed to mains to improve safety. Finally a floodlight should be provided outside the workshop.
The whole electrical system should be connected to a circuit breaker, with clear separation of the lighting, socket and welding/heavy-duty circuits. Try to avoid the use of electrical cables within the workshop. It is an advantage, but by no means essential, to have three-phase supply, especially when using high-capacity drills, grinders and welders. Ensure that all electrical installations are carried out by a qualified electrician.
Compressed air provides a good source of power for tools and is becoming increasingly common in modern workshops. The air compressor, once used only for inflating tyres and paint spraying can be utilised and applied to a variety of power tools.
A ring beam circuit of compressed air sockets should be run around the workshop walls. Compressors and generators should be housed in a separate pump room.
* Store, office and generalstorage
"A place for everything, and everything in its place". An uncluttered, and tidy workshop will get the best out of equipment and staff.
Materials and miscellaneous spares are best stored in racks, with fabrication materials on a free-standing rack capable of carrying the weight of steel. Standard steel lengths come in 7m (23ft) sections and the rack should be able to accommodate this at least.
A storeroom will provide storage for essential spares such as filters and bearing, as well as smaller items such as spray nozzles. Extra security can be provided for electrical and specialist tools by locating them in this part of the workshop.
It is also worth considering locating the farm office near the workshop especially if this is the centre of activity – a move which will also provide extra security. A small table or workbench is often useful in the store to allow work to be done on smaller machines in relative warmth.
* Safety
It is recommended that the farm safety officer be contacted at the planning stage of the new workshop to ensure that the latest regulations are adhered to. Under the Health and Safety at Work Act the employer has the duty of care over his employees and staff. Due care should be taken to reduce the risk of accidents in the workshop, regular checks should be made on all equipment and staff should be trained to an adequate standard.
The main cause of accidents, big and small, is often untidiness which induces frustration and impatience. Keep everything tidy and well-maintained and the workshop will help keep expensive farm machinery in good running order too.
Comply with the HSE regulations by ensuring that a first-aid box is provided and staff are suitably trained. Fire extinguishers must be provided and kept in a prominent place, clear of obstructions.
Also provide fire buckets of water and sand and a fire blanket. Ensure that staff are aware of the procedures for fire and the differences between the extinguishers used.n
"A place for everything and everything in its place." A typical farm workshop often mirrors the individual who spends most time in it.
Right: Purpose built workshop with integral office, generator shed and good access provided by sliding doors. Below: Old stone barns can often be converted but the limiting factor is width. Will only work efficiently if close to machine shed.
WORKSHOPESSENTIALS
• Good access for vehicle and persons (large door 4.6m high. by 4m wide minimum).
• Reinforced concrete floor with painted finish.
• 20 to 25% rooflights.
• Walls 2m high, preferably reinforced.
• Workbench 1m high by 800mm deep.
• Workbench on one or two walls.
• Fabrication rack on one wall, minimum 7m in length.
• Internal lighting in strip lights giving 130W/10sq m.
• External floodlighting.
• Washdown area with sill and oil trap.
• Separate store and office.
• Heating to reflect usage.
• Dedicated welding bay.
• Good tool storage.
Store, office with spare storage above in trays and racks. Stairs and balcony have safety railings provided. See page 19 (top) for exterior view.
Note tool board, vice and lighting making this area a very good place to work.
Welding bay, workbench, good access and heating provided for those cold winter days that will soon be with us.
PREVENTFIRES
• Store fuel/lubricants away from welding equipment.
• Never oil threads on oxy-acetylene welding equipment.
• Restrict smoking to low risk areas.
• Clean up spillages.
• Take care when charging batteries.
Hay barn conversion giving good access to workshop through sliding doors placed centrally. See page 16 for view of interior.
General purpose shed converted to machinery shed and workshop with lean-to added for implement storage. Good all round access both inside and out. See page 18 for views of the interior of the workshop.