Start with an agreement signed by both the student and parent(s) where they acknowledge that the shop or stage, both before and after a show, are effectively a construction site, and as such the participants must wear the required Personnel Protective Equipment (PPE). The PPE can vary from day-to-day and may even change as different activities are initiated. Regardless of whether or not OSHA rules legally apply, the approach taken by the class should be that OSHA rules do apply, because your are training them to work in the 'real world'. No PPE? No Work. No work? No Pay (no class credit).
Some PPE can be shared as there is little chance of cross-contamination or transfer of disease, but other items, like safety glasses, ear plugs, and gloves, must be truly 'personal' and snot shared between students.
Shoes, while not generally a disease transfer pathway, are a more specific fit to each individual. ANSIZ41-1999 (or ASTM F-2412-2005 and ASTM F-2413-2005) rated protective shoes should always be worn by students on or off the stage unless they are actually rehearsing or performing in costume (these are sometimes referred to a 'steel toed boots', which is NOT the same as 'steel tipped' boots). There is no rational excuse to not do this. They can be purchased for less than a pair of 'tennis shoes', are available in many different colors a styles (some look like hiking boots, tennis shoes, dress shoes, cowboy boots, etc.), and will protect against items like platforms dropped on their top of the foot as well as sharp objects penetrating through the sole.
Hard hats should be worn whenever operating the fly system, working on the catwalks, working around scenery that is moving, or has low head clearances. Hard Hats should include a chin strap so they don't fall from height when working on the grid or a catwalk.
Bright colored shirts or mesh safety vests should be worn except during dress rehearsals and the run of a show.
Leather gloves for general work to protect hands from bumps, scrapes, cuts, and splinters.
Insulated cotton gloves for handling hot lighting instruments or ultra-cold dry ice.
Latex, Rubber, or Nitril gloves (as appropriate to the type of chemicals or glues being used) when handling chemicals and adhesives.
NO gloves when operating rotary power tools like drills, saws (even if you do own a SawStop!), lathes, routers, planners, etc.
NO radios or Personal Music Players on during shop or stage operations - it is important that verbal warnings and the sounds of stressed or breaking equipment be audible.
Eye protection is not just for the person doing the work - it is for any one in the same room as them, too. Stray nails, tacks, staples can fly a long way with significant power when a hammer misses it's mark or a saw ejects shrapnel. Eye protection should include a lanyard so the glasses don't fall from height when working on the grid or a catwalk.
Dust filters (PPE masks) and dust collection accessories for cutting tools (drills, saws, sanders) should be used wherever practical.
Establish a tool use certification program. This means that NO ONE is allowed to use a tool until they have been trained and demonstrated that they can safely use the tool. Issue a list to each student showing all the tools you have and/or may have in the shop, and then personally go-over the use and abuse (i.e. in appropriate use) for each tool as appropriate for the students and tasks at their grade level. Use a sign-off system that can't be forged (one way to do this is to mark-out all the tools with a red felt marker, then reissue the sheet to the student with the new items unmarked after they have been approved to use it). For each tool for which they have been trained, both the students and their parent(s) have to also sign the list. If they don't have the signed list immediately available when asked, then they shall not be allowed to use the tool (Yes, this is real-world training - a forklift driver without a forklift driver's certification document cannot operate the forklift).
Even a simple thing like a screw driver can be misused, so this should go all the way down to the basics. (Screwdrivers aren't pry bars or punches, don't screw on something that is resting on your hand or leg, they are not throwing knives, use the correct type of screwdriver tip (bit) for the type of screw that is being turned, etc.)
Clean-up after yourself. Tools put away, cords off the floor, paint brushes clean, PPE properly stored (you can have each student purchase or sew-up a small duffle bag for their PPE - a good costume shop project). Floors should be broom clean to keep sawdust and other crud from being tracked into the auditorium, onto the stage, or into other parts to the building. Don't forget to go over the floors of the shop and stage with a magnetic broom, too, to pick-up staples, tacks, screws, and nails. Moping the stage floor is very important after (and during) dance programs due to dancers sweating and creating both biological hazards and slip-n-fall hazards.
Extraneous Personal Effects should be considered. Long hair must be tied-back and secured when operating rotary power tools. Loose jewelry must be removed when operating rotary power tools. Loose fitting 'billowy' shirt sleeves or blouse fronts, or dangling drawstrings on waists, collars, or hoods must be removed when operating rotary power tools.
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Erich Friend
Theatre Consultant
Teqniqal Systems
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