#u72

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The risk assessment the whole team worked together on

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Safety!!!

Using tools:

When using tools ensure:

the tool is working correctly

you know how to use it

any safety equipment is used (like goggles, gloves, ear defenders, etc)

you are wearing sensible clothing

your hands are not near the dangerous end

you don’t rush using it

the area around it is safe and clear

the area is well lit

the cord is in tact and plugged in

the tool is in tact and not broken

electrical tools are unplugged after use

Using ladders:

When using ladders, ensure:

you are facing the right way

you have at least three points of contact

the ladder is secure

someone is footing the ladder

away from live wires

if you are using tools up the ladder, the people holding it have hard hats on

the ladder is not damaged

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Building the Set

As a department, we started by looking at the model box and technical drawings. We discussed what needed to be made and what could be bought in. We also got put into three sub groups so that we could all focus on small sections instead of the whole thing. I was put in a group with Chelsea, and we were assigned the forest sections. We looked at the forest and decided what each part of it should be made of. We also discussed what order would be the best to complete the parts. By knowing the scale, which was 1:25, and measuring the items in the section, we could work out how much of each material we needed. 

Staging:

The first thing we started to put together was the staging. For this, we looked at the plan and worked out how many legs we would need. We decided that we wouldn’t have a leg in every single hole, to avoid having two legs in the same place on two different decks. For instance, when we joined two 8” x 4” decks together, we would have one deck with four legs, and the other deck with two legs. As we joined them together, we wouldn’t need twice the number of legs where they are connected. We decided to count the number of legs needed first, before starting to assemble the staging, so that we could prepare all the lengths we needed to speed up the installation of the staging.

After working out the length we needed, we went searching for as many as we could find that were either the same length, or slightly longer, so that we would waste the least amount possible. After searching around we realised that we would have to cut a lot, but that wasn’t a problem. We measured the length with needed with a tape measure and put a pen mark where we needed to cut. We then used the metal grinder to cut the pole to the right size. After doing this to the poles, we used the angle grinder to smooth off any shaper edges so that it was safe to be handled and used. 

When setting up the staging, we would put the legs into the hole they went and tighten up the bolts. This was to ensure that the legs would not fall out when put upright and it made it more rigid. We would then put it upright and if it was against another staging piece, we would put at least two bolts between them, connecting them together. 

Handrails:

The handrails were a tricky and interesting challenge to overcome. We wanted something non-intrusive but also strong enough to stop people from going past them. We decided to use metal wire, as it can be nearly invisible in the right light, but very strong. We could also put it under high tension to make it a lot harder to push past it.

We didn’t have any supports to put the wire between so we designed an upright that could be used and made it. Firstly, we got a 2” (two inches) by 1” (one inch) metal bar as the main upright. We cut it to the right length of 3’ (three foot), which is long enough to stop someone, but not long enough to get in the way of sightlines. We then found a long piece of flat bar that had been folded in half lengthways to create a corner. We used this, after it had been cut down, to create a lip at the bottom of the bar. 

When cutting the bars, I ensured I had goggles on to protect my eyes from the tiny shards of hot metal, and ear defenders to protect my ears from the excess amount of noise. 

We welded this onto the bar so that it would be attached strongly and won’t come off with a bit of pressure. After attaching this piece of metal, we lined it up with a piece of decking and marked where the hole needed to be. After double-checking that the hole is in the middle of the bar, I took it to the pillar drill and slowly drilled a hole through the metal. This hole is so that we can put a bolt in and attach it to the decking. I then put a plastic cap on the top end so that if an actor put their hand on it, it would be safe and not hurt them. After putting the cap in, I then drilled a hole an inch from the top to put the wire through.

Tree Trunks:

After discussing with my team, we decided that the tree trunks would be made out of carpet tubes. These are long cylinders that are made out of cardboard. They are normally used to transport large pieces of canvas or to put carpet around them to be stored. We decided to use these as they were already the right shape for what we needed. After a lot of research, we found a few websites that sell similar to what we wanted, but none that sold them long enough. We then looked at some tubes we already had in the workshop, and found out where they were from. We phoned up the company and ordered some to be delivered.

After they arrived we cut a third of them in half. We did this by measuring the length, dividing by two and then putting marks all the way around at that distance. We then used a handsaw to cut the tubes in half.

We then cut some pieces of wood to small lengths so that we could glue and staple them in the top of the tube. This meant that we could then slide another tube on top and attach them together. We did this so that we could have longer trunks, so that they would reach the top of the theatre.

When we were installing the trunks into the staging we first planned out exactly where we wanted them to go. We placed the white caps on the floor in the right places so we could make sure there was enough space between them. To keep them in place, we screwed the white caps onto the decking, and put the trunks onto them. We then stapled them to the caps. We realised that this would not be enough to keep them staying upright, so we cut a piece of wood roughly the right size and then used the bad saw to make it curved. 

We attached this piece of wood to the end of the tubes. We then drilled a hole in it and used a twisted boom arm to attach it to a lighting bar.

Branches:

We decided to use polystyrene to create the branches for the trees. This was so that they were light enough to be attached to the trunks, whilst also be hung from the lighting bars.

We used the branches from the model box and an overhead projector to project a shape onto a large sheet of polystyrene. This meant that we could use the designs from the model box to create the large-scale versions. We used a chalk on the end of a stick so that we wouldn’t get in the way of the projection.

We then used a hot element to cut out the branches.

Ladders:

For the ladders on the side of the staging, we decided to use some ladders we already had, so that we knew they would be strong enough. I had to check the ladders and make sure that there was nothing that is sharp or sticking out, so the actors couldn’t hurt themselves. I then welded on a plate so we could screw it to the decking. 

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Techniques of a Set Builder

There are many techniques used when building a set. There are different ways of cutting, joining and sculpting materials to the needs of the plans.

Cutting:

There are many different types of saws that can be used for cutting wood.

There is a handsaw that doesn’t require any power, but does take time to cut. 

Another saw that can be used is a table saw. This can be used to cut big sheets of wood, as it is easy to push the sheets on the table while the saw cuts it.

Another saw that is used to cut big pieces of wood is the circular saw. This can be used to cut long thing beams of wood as you bring the blade down to the wood, instead of pushing the wood over the blade.

The last major saw that is used is a jigsaw or bandsaw. These are both very similar machines, which can cut out more intricate lines, instead of just straight lines.

There are also many other methods for cutting, which differ depending on the materials. For instance, to cut polystyrene, you have to use a hot element, like a heated wire, or a serrated knife.

For metal, a grinding wheel must be used as it uses the friction to create heat to melt through the metal. If something sharp were used, it would become blunt straight away.

When using the electrical saws, care must be taken to ensure hands are nowhere near the blade, and glass/goggles must be warn to prevent small splinters of metal or wood, to go into your eyes. Ear defenders must also be worn when the saw creates an excess amount of noise to prevent damage to the ears. 

Joining:

Same as with cutting, there are many different ways of joining materials to each other. The most common way of joining materials is either screws or bolts. These are good because it makes the join temporary so that you can disassemble the set and use pieces of it again.

Another way of joining materials is by using glue. Many different types of glue can be used, depending on the materials. This can often not be as strong as other means, but is a cheap alternative. 

Another method for joining can be welding. This only works for metal but is the best method for attaching two pieces of metal permanently.

When welding, extreme care must be made, wearing a proper visor made to prevent the intense light from damaging your retinas in your eyes. People around must also be warned so they do not accidentally look into it without the visor on. 

Sculpting:

To add detail, you can sculpt away some of the material. This can only be done to a few of the materials. For instance, polystyrene can be sculpted using different shaped pieces of hot metal. This can help you to create curves or cuts, to create the detailing you want. Wood, however, can be sculpted by many different methods. A planer can be used to reduce the widths of wood, or to take off some layers. This can also be done with sandpaper. Depending on the situation, one may be better than the other, for instance, a planer wouldn’t work on a curved surface as well as sandpaper would. A dremel can also be used to carve small sections out of the wood to create very detailed decorations. It is a rotating tiny sandpaper, that can be held like a pencil to remove small bits at a time.

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Materials of a Set

Wood:

Wood is a very easy material to cut. This means that it is quick to use, but can be easily broken. There are a few types of wood: manmade wood, hardwood and softwood. They are both used for different things. The hardwood is more expensive but is a lot stronger. This means it can be used as structural instead of decorative. Whereas the softwood and manmade wood are usually a lot weaker and cheaper; therefore used mostly for decorative.

Manmade wood, like MDF, is made up of the byproduct of wood production compressed. This means it does not have a grain and can be cut easily. This also means that is cannot warp and is very smooth. 

Metal:

Metal is the strongest of materials used, but is also the most expensive. Metal can be bought in sheets, poles or rectangular cylinders. Although sheets are rarely used due to the high cost for little added benefits, the other two are widely used. The poles are always used as legs in steel deck as they need to be strong to hold up the deck. They are harder to cut than wood and need a grinder to cut them, but worth the extra effort to ensure a safe stage. The rectangular cylinders are used as major structural work on pieces of set. They are used because they are very strong and have flat edges to attach wood. They come in many different sizes, so that you can save money if a really wide one is not needed.

Polystyrene:

This is the weakest of all the materials, but still very useful. It can easily be cut or carved using a hot element. The best property of this material is that it is extremely light, weighing barely anything due to the high air contents of it. It is also kind of cheap for the amount you get, which means that you can build large three-dimensional elements with it.