Each situation will be different, but there are a few general points to note:
- Make a clear gangway down the centre of the work- shop or around the central benches. The gangways should be kept clear of tools and other materials and can be defined by painted yellow lines on the floor.
- If there is room, align the benches so that the operators are clear of the gangways. One arrangement is to have benches set diagonally as shown in the diagram, so that each operator has his or her own work space. If there is not enough room for this arrangement, at least make sure that gangways are wide enough for people to walk past operators without knocking into them.
- The storage area for broken or mended tools and spares is best sited near the door, to give easy access.
- Natural light gives the best light for working under, so site benches to take advantage of this. A wide bench with room for an operator either side, or two narrow benches back to back, can be sited end on to a window, so that both operators can benefit from natural light.
- A large central bench makes efficient use of space and is a sociable way of running training and work- shop sessions. The TCV London workshop had a central bench 2.5m (8’) by 1.6m (5’) with six vices.
- Position grinders so that grit is thrown towards a blank wall and away from other operators.
- Try to keep the chainsaw bench separate from the general benches so it is less likely to get used for other purposes, and provide sufficient lockable storage space for chainsaw spares and accessories.
General purpose benches
A bench for a single operator need only be 600mm (2’) wide. Benches wider than this tend to accumulate odds and ends along the back which are better stored away. For most of the work described in this manual, a 900mm (3’) wide bench gives adequate space for an operator on either side.
Height will be a matter of personal preference, but 860mm (34”) to 910mm (36”) should suit most people. One or two benches can be made lower, at 810mm (32”) to 860mm (34”), to suit shorter people. To find the correct height for yourself, stand erect with the forearm at right angles to the body, and the wrist limp. The finger tips are at the ideal height.
A bench up to 1.8m (6’) long can have two pairs of legs of 75 x 75mm (3 x 3”), with rails of the same size. A longer bench will need three pairs of legs of 100 x 100mm (4 x 4”) with rails of 100 x 75mm (4 x 3”). The design below shows a bench with tool well, but if not required, a simple flat top can be fitted. If possible the top should be hardwood. Otherwise, use two layers of 18mm (3/4”) blockboard glued and screwed together, covered with a sheet of hardboard which can be replaced when worn. Old solid core flush doors also make useful worktops. For metalworking, 25mm (1”) chipboard topped with galvanised plate can be used.
The apron is important in the construction of the bench as it gives rigidity, especially when lengthwise loads are being applied. The worktop should be fitted from underneath with screws counterbored into the rails, to avoid having metal exposed on the worktop. Cupboards or shelves can be fitted underneath the bench as required.
Dexion can be used to make any size of bench. The square bench shown would be suitable for mounting a grinder. Dexion is available from suppliers of shelving and racking systems.
