Chapter 3:

Crafting with Care: Workshop, Tool, and Personal Safety

Werq..Werk..Work..Work..Workshop

Creating the physical world is one of the most exciting moments for a designer. This is your chance to take what you have read and truly start to build a world the director and actors can play in; but in order to bring this word alive you must…stay alive and with all your digits. Safety is an integral component to theatre, especially due to the numerous moving parts in a production. Workshop safety is even more important due to the use of power tools which, if used improperly, can cause major injury or death. In the United States, the Occupational Safety and Health Administration (OSHA) governs workplace safety. Established in 1975, the guidance from OSHA has reduced the number of workplace deaths and has provided actionable steps for employers to take to improve workplace conditions for their employees.

Scene Shop Safety

The scene shop is a hub of activity and creativity, but also poses significant risks if safety protocols are not followed. Most scene shops have a safety manual with guidelines to follow while working in the shop. It is imperative to read those guidelines and take them to heart as they are in place to keep you safe and whole. While each shop has its specific needs there are some topics that can be discussed in a broader sense.

Safety Data Sheet

A Safety Data Sheet (SDS) is a detailed document that provides essential information about the properties, hazards, handling, storage, and emergency measures related to chemicals and hazardous substances. It is designed to ensure the safe use of materials in the workplace and protect workers from potential health and safety risks. An SDS is typically organized into 16 sections, which include identification of the substance, hazard identification, composition, first-aid measures, firefighting procedures, accidental release measures, and exposure controls.

(Click here to see the full sample Safety Data Sheet)

Reading a Safety Data Sheet

To safely work with chemicals in a theatre shop or classroom environment, it’s essential to understand how to read a Safety Data Sheet (SDS). Each SDS follows a standardized 16-section format established by the Globally Harmonized System (GHS), and knowing what to look for can prevent accidents and ensure proper handling.

1. Identification Start with Section 1, which provides the product name, manufacturer details, and recommended uses. Confirm that the SDS matches the chemical product you're using, especially if multiple versions exist.

2. Hazard(s) Identification Move to Section 2, where the key hazards are listed. This section includes signal words like Warning or Danger, pictograms (such as flames or skulls), and classification categories. This is your snapshot of how dangerous the material is and what types of risks are involved (e.g., flammability, skin irritation, respiratory effects).

3. Composition/Information on Ingredients In Section 3, you’ll find a list of chemical ingredients, including any substances that may pose additional hazards. This section is especially useful if someone has allergies or sensitivities.

4. First-Aid Measures Section 4 outlines what to do in case of exposure—whether by inhalation, skin contact, eye contact, or ingestion. Read this before you begin working so you know how to respond quickly in an emergency.

5. Fire-Fighting Measures Section 5 includes fire hazards and guidance on how to extinguish fires involving this chemical. Some materials require specific types of extinguishers or may produce toxic fumes when burned.

6. Accidental Release Measures Section 6 describes how to safely clean up spills or leaks, including containment and ventilation procedures. Understanding this helps prevent wider contamination.

7. Handling and Storage Pay close attention to Section 7, which provides best practices for safe handling and how to store the substance to prevent degradation or hazards (e.g., temperature limits, container types).

8. Exposure Controls/Personal Protection Section 8 details the recommended personal protective equipment (PPE), such as gloves, goggles, or respirators, and includes occupational exposure limits. Use this section to prepare your workspace and protect your health.

9–11. Physical, Chemical, and Stability Information Sections 9 through 11 cover physical properties (like color, odor, boiling point), chemical stability, and potential health effects. These sections help predict how the material might behave under different conditions.

12–15. Ecological, Disposal, Transport, and Regulatory Info While not always critical for in-shop use, Sections 12–15 provide details on environmental impact, disposal methods, transportation requirements, and legal regulations.

16. Other Information Finally, Section 16 may include revision dates, reference materials, and additional notes from the manufacturer.

Pro Tip: Always review the SDS before using a new material—even if you’ve used similar ones before. Small changes in formulation can mean big differences in safety requirements. Post the SDS in an accessible location and ensure students or team members know how to interpret them.

Personal Protective Equipment

Personal Protective Equipment (PPE) refers to specialized clothing or equipment worn by individuals to protect themselves from health and safety hazards in the workplace or during specific tasks. Common types of PPE include gloves, safety goggles, helmets, ear protection, masks, and respirators. Each piece of PPE is uniquely designed to protect against different risks such as chemical exposure, impact injuries, or respiratory hazards. One thing that is not often considered by folks is the use of a hair tie as PPE. Long hair should be pulled back especially when working with power tools or moving large objects, essentially anytime the hair might get tangled or caught.

To determine the proper PPE to use, first assess the potential hazards of the environment or task. Consult safety guidelines, workplace policies, and product labels for recommendations. For example, handling hazardous chemicals may require gloves and goggles, while working in a loud environment necessitates ear protection. Choosing the appropriate PPE ensures maximum safety and compliance with relevant regulations.

When choosing PPE, it’s important to ensure that the PPE will do what you expect of it. For instance, ear protection should have a label that tells you how many decibels (dBs) it reduces to ensure you are receiving proper protection. Another consideration is that the material your gloves are made of are meant for different purposes, canvas and rubber gloves provide different types of protection. Choose the appropriate glove for the job at hand.

Fire Safety

Fire safety is an essential part of maintaining a safe environment in any setting, whether at home, in the workplace, or in public spaces. Understanding how fires start and knowing how to respond appropriately can prevent injuries, protect property, and save lives.

The Fire Triangle: Three Elements Needed for Fire

For a fire to ignite and sustain itself, three elements must be present: heat, fuel, and oxygen—a combination known as the "fire triangle." Heat provides the energy necessary to raise materials to their ignition point, with common sources including open flames, electrical sparks, or friction. Fuel refers to any combustible material that can burn, such as wood, paper, fabric, gasoline, or chemicals. Oxygen supports the chemical reaction of combustion, with fire typically requiring an oxygen level of at least 16% to burn, while the air we breathe contains about 21% oxygen. Interrupting or removing any one of these elements will extinguish a fire. For example, smothering flames cuts off the oxygen supply, and cooling the fire with water reduces the heat, both of which can effectively stop the fire from spreading.

Fire extinguishers are crucial tools for controlling small fires before they become unmanageable. However, proper use and understanding of their limitations are vital for safety. Most extinguishers are classified according to the type of fire they are designed to combat:

• Class A for ordinary combustibles (wood, paper, cloth)
• Class B for flammable liquids (gasoline, oil, grease)
• Class C for electrical fires
• Some extinguishers are multi-purpose (A-B-C rated) and can handle several types of fires.

To remember how to use a fire extinguisher effectively, follow the PASS technique:

1. Pull the pin to unlock the extinguisher.
2. Aim the nozzle or hose at the base of the fire, where the fuel source is located.
3. Squeeze the handle or trigger to release the extinguishing agent.
4. Sweep the nozzle from side to side, covering the base of the fire until it is out.

It is important to ensure you have the correct type of extinguisher for the fire and that you maintain a safe exit route in case the fire grows beyond your control. Always alert others and call emergency services before attempting to put out a fire on your own. Regular training and inspections of fire safety equipment help ensure readiness in case of an emergency.

Fire Prevention

Fire prevention in a scene shop is critical due to the presence of flammable materials and equipment that generate heat or sparks. Effective fire prevention begins with maintaining a clean, organized workspace. Sawdust, scrap wood, and paint-soaked rags are all highly combustible and should be disposed of properly in metal containers with tight-fitting lids. Electrical tools and wiring should be inspected regularly to prevent overheating or frayed cords, which can spark fires. Flammable liquids, such as paints, solvents, and adhesives, must be stored in approved, clearly labeled containers away from heat sources, and never left open or unattended. Oftentimes shops will have yellow, clearly labeled, flame cabinets for flammable chemicals to be stored. Additionally, fire extinguishers appropriate for wood, chemical, and electrical fires should be easily accessible, and all workers must be trained in their proper use. Keeping emergency exits clear and knowing evacuation procedures ensures that everyone can respond quickly in the event of a fire. Implementing these precautions helps create a safer, more efficient working environment in the scene shop.

Emergency Procedures

All shops have different procedures, but it is good to have a general understanding of emergency procedures to ensure safety for everyone present. Accidents can happen quickly, making it essential to be prepared and know how to respond effectively. One of the most important steps is identifying and keeping clear all emergency exits. Familiarize yourself with the locations of doors and designated escape routes, and ensure that pathways remain unobstructed by tools, materials, or machinery. Emergency exit signs should be clearly visible, and every worker should know the quickest way to leave the building in case of a fire or other hazard.

In addition to exit awareness, basic first aid knowledge is vital. Common scene shop injuries include cuts, splinters, and burns. For minor cuts or lacerations, immediately clean the wound with water, apply antiseptic, and cover it with a sterile bandage. For deep cuts or heavy bleeding, apply firm pressure with a clean cloth to slow the bleeding and seek medical assistance immediately. In the case of splinters, remove them carefully with sanitized tweezers, clean the area, and apply a bandage if necessary. For burns, cool the affected area with cold water (not ice) for at least 10 minutes before applying a clean, loose dressing. In all cases, a well-stocked first aid kit should be readily accessible, and all workers should know its location. Regular safety drills and training sessions reinforce these emergency procedures, ensuring a swift and coordinated response when every second counts.

Reaching High Spaces

Working at height in a theatrical or production setting requires strict adherence to safety practices when using ladders, lifts, and catwalks, as well as implementing effective fall protection and fall prevention measures. Each tool and space present unique hazards, making careful preparation and awareness critical to prevent accidents and injuries.

When using ladders, always inspect them for damage or instability before use. Choose a ladder of appropriate height for the task to avoid overreaching, and place it on a stable, level surface. Maintain three points of contact—two hands and one foot or two feet and one hand—while climbing or working, and never stand on the top rung. Avoid using makeshift platforms to extend reach and secure the ladder if working near doorways or high-traffic areas.

Lifts, including scissor lifts and boom lifts, provide elevated platforms for work requiring mobility and height. Operators must be properly trained in the equipment’s use, weight limits, and safety features. Before use, inspect the lift for mechanical issues, ensure guardrails are secure, and wear a harness if fall protection is mandated. Operate lifts only on flat, stable surfaces, avoid overreaching, and keep hands and feet inside the guardrails at all times.

Catwalks provide access to lighting rigs and overhead equipment in theaters. When working on catwalks, always use designated walkways and stay within guardrails. Tools should be secured in pouches, on belts, or tied off on a lanyard to prevent falling objects. Wear sturdy, non-slip footwear, and avoid leaning over the railings or extending beyond your balance point. If a fall protection system is available, harnesses must be properly worn and anchored according to manufacturer guidelines.

Fall protection and fall prevention are critical in any elevated work scenario. Fall protection systems, including harnesses, lanyards, and anchors, are designed to arrest falls once they occur. Fall prevention focuses on stopping falls before they happen by using guardrails, toe boards, and personal restraint systems. Workers must be trained on the proper use of equipment and always follow established safety protocols. Regular inspection of safety gear and ensuring proper fit and attachment points significantly reduce fall-related risks. Implementing both proactive prevention and reliable protection creates a comprehensive safety culture that prioritizes worker well-being.

Tool Safety

Tool safety is a fundamental part of working effectively and securely in any shop or construction environment. Understanding how to use tools properly, inspecting them regularly, and wearing appropriate personal protective equipment (PPE) are essential practices that prevent accidents and injuries. Tool safety can be broadly categorized into the safe use of hand tools and power tools.

When working with hand tools, such as hammers, screwdrivers, and chisels, it is important to inspect each tool before use. Look for signs of wear or damage, including cracked handles, loose parts, or dull edges, which can compromise safety. Tools with defects should be repaired or replaced immediately. Additionally, always use the correct tool for the job; for example, using a wrench instead of pliers to tighten a bolt prevents unnecessary force that could lead to slippage and injury. PPE for hand tool use may include gloves for grip and protection from sharp edges, safety goggles to shield eyes from flying debris, and sturdy footwear to protect against dropped tools.

Power tools, such as drills, saws, and sanders, require even more vigilance. Before using any power tool, check the power cord for fraying, ensure that guards and safety mechanisms are in place, and confirm that moving parts are secure and free of obstructions. Inspect blades or bits for sharpness and proper alignment. Never use power tools with damaged cords or missing guards, as these are significant safety hazards. PPE for power tools typically includes safety goggles or a face shield to protect from sparks or dust, hearing protection to reduce noise exposure, and dust masks or respirators when working with materials that generate fine particles.

Selecting the right PPE is crucial for both hand and power tool use. Always read the manufacturer’s instructions and safety labels on tools to understand the specific protective equipment needed. By combining regular inspection of tools with the correct PPE and adherence to proper operating procedures, workers can maintain a safe and productive environment.

Getting to Know the Shop Tools

Scene shops rely on a wide range of tools, each designed for specific tasks in building and assembling stage scenery. Proper knowledge of their use and function is essential for safe, accurate, and efficient work.

A measuring tape is a flexible tool used for measuring distances and dimensions. It features a retractable metal blade marked with standard or metric units. To use it, hook the end over the edge of the material being measured, pull the tape taut, and read the measurement at the point where it aligns with the material’s edge. Precision in measuring is critical to ensure parts fit together correctly.

Reading a measuring tape is a straightforward skill that involves understanding its markings and divisions. Most measuring tapes are marked in inches and centimeters, with inches often subdivided into smaller fractions such as halves (1/2), quarters (1/4), eighths (1/8), and sixteenths (1/16) for precise measurements. To read a measuring tape, first extend the tape to the length you want to measure, making sure it is straight and properly aligned with the object. For measurements in inches, count the whole numbers, then identify the smaller lines between them to determine the fraction of an inch. In metric measurements, the tape is divided into centimeters and millimeters, where each smaller line represents one millimeter. Knowing these increments helps ensure accuracy whether you're working on construction projects, crafts, or other precision tasks. Familiarity with the tape’s markings and consistent practice will make the process easier and more efficient.

Framing squares, combination squares, and speed squares are essential for checking angles and creating straight cuts. A framing square is a large, L-shaped tool primarily used for measuring right angles in framing or larger structures. A combination square has a sliding ruler with a built-in spirit level for checking both 90-degree and 45-degree angles. Speed squares, small and triangular, are ideal for marking straight and angled lines quickly. Each tool is used by placing it flush against the material’s edge to guide cuts or draw accurate lines. 

A compass is a drafting tool used to draw circles or arcs. One leg holds a pointed tip that anchors the tool, while the other holds a pencil. Adjust the distance between the legs to set the circle’s radius, press the point into the material, and rotate the compass to draw a smooth arc.

Wrenches tighten or loosen nuts and bolts. Adjustable wrenches are versatile, with a movable jaw that fits various fastener sizes. To use one, align the wrench snugly on the nut or bolt and turn it in the appropriate direction, applying steady pressure to avoid slipping.

Hand saws cut wood by manual force. Different types, such as crosscut saws or rip saws, are used depending on the grain direction. Hold the saw handle firmly, align the blade with the cut line, and push and pull with steady strokes. Use a hand saw when power tools are unavailable or when working on small, detailed cuts in softwoods.

A utility knife is a sharp cutting tool used for trimming materials like foam, cardboard, or fabric. Extend the blade slightly, apply controlled pressure, and cut along a straightedge for precise lines. Always retract the blade when not in use to prevent injuries.

A circular saw is a power tool used for straight cuts in wood. It has a rotating blade and a baseplate that guides the cut. Adjust the depth and angle as needed, position the blade at the cut mark, and engage the trigger while guiding it steadily along the line. Use a circular saw for quick, portable straight cuts in plywood, dimensional lumber, or framing work.

Miter saws are specialized for precise angled cuts. Set the desired angle on the base, secure the material, and bring the blade down smoothly to complete the cut. Use a miter saw when making repeated angled cuts for trim, framing, or crosscutting boards.

Table saws are stationary tools with a circular blade protruding from a table surface. They are ideal for ripping long pieces of wood. Push the material firmly along the fence, keeping hands clear of the blade. Use a table saw for consistent, accurate rip cuts and when working with large sheet goods.

Band saws have a continuous looped blade and are used for curved cuts. Guide the material slowly into the blade along the cut line while maintaining control. Use a band saw for making intricate curves, cutting irregular shapes, or resawing wood.

Jigsaws are handheld power tools used for intricate curved or straight cuts. Choose the appropriate blade, start the saw, and move it carefully along the line. Use a jigsaw for detailed or interior cuts, such as cutouts in sheet goods or decorative shapes.

A router hollows out material for decorative edges or joints. Select the correct bit, adjust the depth, and guide the router along the material’s edge with even pressure. Use a router for shaping edges, creating grooves, or cutting precise joints like dados and rabbets.

Hand drills and a drill press create holes. A hand drill is portable, while a drill press offers more stability for precise drilling. Secure the bit, position it over the mark, and apply consistent pressure while drilling. 

Hand sanders and power sanders smooth surfaces. A hand sander uses sandpaper on a block, while power sanders use mechanical motion. Apply firm, even pressure to avoid gouging the material.

Grinders and planers shape or level wood. A grinder removes excess material with a rotating abrasive disc, while a planer shaves thin layers to flatten wood. Keep a firm grip and move steadily across the surface. 

Finishing nailers and other pneumatic tools are essential for fastening and assembly in a scene shop, providing speed and precision. A finishing nailer is designed for attaching trim and molding or securing lightweight wood pieces without leaving large holes. It uses compressed air to drive small nails into the material. To use a finishing nailer, ensure it is properly connected to an air compressor, load the nail magazine, and position the tip firmly against the surface before pulling the trigger. Always wear safety goggles and ear protection, as pneumatic tools can be noisy and generate flying debris.

Other pneumatic tools, such as staplers and impact wrenches, rely on air pressure for power. Regular inspection of hoses and fittings is crucial to prevent air leaks or malfunctions. Additionally, never point a pneumatic tool at anyone, and disconnect it from the air supply before performing maintenance or clearing jams. Following manufacturer guidelines and maintaining awareness of your surroundings ensures safe, efficient operation of these powerful tools.

Fasteners like screws, nails, staples, nuts, and bolts join materials. Screws provide strong holds, driven with a screwdriver or drill; nails are hammered into place; staples are used with a staple gun for lightweight materials. Nuts and bolts work together, with bolts acting as threaded fasteners inserted through holes and nuts tightened onto the bolt's thread to secure parts firmly. Selecting the correct fastener ensures durability and stability in the construction process, as each type is designed for specific applications and materials.

Showcase your Learning

Assignment Objective:

Students will demonstrate their knowledge of Scene Shop, Personal, and Tool Safety by creating safety material to be used in the shop.

Assignment Rationale:

As designers and technicians, it's important to understand how to safely build scenery.

Choose your Assignment:

Choose one of the options below to showcase your learning.

1. Create a Poster: Using digital technology or good old poster board create a workshop safety poster that covers at least four (4) safety protocols for the scene shop.
2. Create a Safety Video: Create a safety video that is at least five (5) minutes long that covers at least four (4) safety protocols for the scene shop.
3. Create a Safety Track: Create a safety audio recording that is at least five (5) minutes long and covers at least four (4) safety protocols for the scene shop.
4. Create a Presentation: Create a presentation in which you cover at least four (4) safety protocols for the scene shop.
5. Write an Essay: Write a 1-2 page essay, double-spaced, in which you address the importance of scene shop safety and discuss at least four (4) safety protocols for the scene shop.
6. What Not to Do: Find at least four (4) examples online of what not to do in the scene shop and explain why those actions are unsafe.
7. Roll the Dice! Let the fates decide.

Key Terms

Band Saw – A power saw with a long, continuous blade used to make curved or irregular cuts in wood or other materials.

Catwalk – An elevated platform in a theatre used for accessing lighting and rigging equipment, requiring proper fall protection and caution.

Combination Square – A tool with a ruler and adjustable head used to measure 90- and 45-degree angles and verify straight edges.

Emergency Procedures – Predefined actions and protocols to follow in the event of accidents, injuries, or fires to ensure safety and swift evacuation.

Fall Protection – Systems such as harnesses and lanyards designed to prevent injury in case of a fall when working at height.

Fall Prevention – Measures like guardrails, toe boards, and restraint systems used to stop falls from occurring.

Fasteners – Hardware like screws, nails, staples, nuts, and bolts used to join materials together securely.

Fire Extinguisher – A portable device used to put out small fires. Types include Class A (ordinary combustibles), Class B (flammable liquids), and Class C (electrical).

Fire Prevention – Practices that reduce the risk of fire, including proper storage of flammable materials and maintaining a clean workspace.

Fire Triangle – The three elements needed for a fire to occur: heat, fuel, and oxygen. Removing one element can extinguish the fire.

Framing Square – A large, L-shaped tool used to measure right angles and assist in large-scale layout work.

Jigsaw – A handheld power saw with a narrow blade used for intricate or curved cuts in wood or other materials.

Ladders – Portable climbing tools used to access high areas. Proper setup and use are essential for safety.

Miter Saw – A power tool used for making precise angled cuts, commonly used in framing and trim work.

Occupational Safety and Health Administration (OSHA) – A U.S. federal agency that sets and enforces workplace safety and health regulations.

PASS Technique – Acronym for using a fire extinguisher: Pull the pin, Aim at the base, Squeeze the handle, Sweep side to side.

Personal Protective Equipment (PPE) – Safety gear worn to minimize exposure to hazards (e.g., gloves, goggles, masks, ear protection, helmets).

Planer – A power tool that removes thin layers of wood to level surfaces or achieve a desired thickness.

Power Tools – Electrically operated tools like drills, saws, and sanders that require careful use and appropriate PPE.

Router – A power tool used to hollow out areas of wood or create decorative edges and joints.

Safety Data Sheet (SDS) – A document that provides detailed safety information about a chemical, including handling, storage, hazards, and first aid.

Scene Shop – The area in a theatre where sets and props are built; it contains tools, machinery, and materials used in stagecraft.

Speed Square – A small, triangular measuring tool used for marking straight and angled lines quickly on wood.

Table Saw – A stationary power tool with a circular blade for making straight, long cuts in wood.

Tool Safety – The practice of using tools correctly, inspecting them regularly, and following safety procedures to prevent accidents.

Utility Knife – A handheld knife with a retractable blade used for cutting materials like foam, cardboard, or fabric.

Workshop Safety – Procedures and practices that ensure a safe working environment, especially in areas where power tools and machinery are used.

Wrenches – Tools used to tighten or loosen bolts and nuts. Adjustable wrenches can fit different sizes of fasteners.

Video Resources

• Play it Safe: An Introduction to Safety - Basic introduction to Stage Safety
• Tools & Safety 101 – Introduction to basic tool safety in theatre settings.

References

Gillette, J. M. (2019). Theatrical design and production: An introduction to scene design and construction, lighting, sound, costume, and makeup (8th ed.). McGraw-Hill Education.

Shelley, S. (2013). A practical guide to stage lighting (3rd ed.). Focal Press.

Pilbrow, R. (2008). Stage lighting design: The art, the craft, the life. Nick Hern Books.

Scenic Designers Association. (2020). Guidelines for scenic construction and safety. Scenic Designers Press.