A project of Volunteers in Asia Equipment for RBral Workshovs by: John Boyd Published by: Intermediate Technology Publications, Ltd. 9 King Street London WCZE 8HN United Kingdom Paper copies are 2.95 British pounds. Available from: Intermediate Technology Publications, Ltd. 9 King Street London WC2E 8HN United Kingdom Reproduced by permission of Intermediate Technology Publications, Ltd. Reproduction of this microfiche document in any form is subject to the same restrictions as those of the original document. -- _, ,,_ Workshops in the rural areas of developing countries can range from a wattle and daub shack set up under a tree by the roadside, to a much more sophisticated brick building which may even have electricity laid ,on. But whatever the standard of the building use, if the workshop is to be of practicai use, it has to have suitable tools and equipment. This book is a guide to anyone who wishes to equip a workshop, from the basic tools required for a one or two man carpentry work- shop without.power to the more sophisticated ertablishment requiring power equipment for both wood and metal working. Only well- known and reliable equipment is listed here, and the prices given may soon be out of date, but they give an inexperienced person some idea of the budget required for~a particuiar size of workshop. The tools specified are all, illustrated and workshop layouts are suggested. There are also photographs of various sizes of workshop in di,fferent countries, as well as some pictures of farming equipment that has been manufactured at some of the workshops. Suppliers’ addresses are also given in an appendix. This publication will be of immense value to any practical field worker involved in the rural areas of developing countries. John Boyd is an agricultural engineer with wide experience of developing countries. From 1972 to 1976 he was Agricultural Projects Officer of the Intermediate Technology Development Group. During that time he advised on tropical farm mechanisation and small scale engineering projects. His published works include Tools for Agriculture: A Buyer’s Guide to Low Cost Farm Implements: Eight Simple Surveying Levels; and Report on Farm Egwipment Development Project, Dawdawa, Nigeria (Intermediate Technology Publications). Steve Bonnist, John Collett, Tony Mallett and Harold Pearson also contributed to this publication and are members of the Intermediate Technology Development Group. ISBN 0 90303145 0 intermediate Technology Publications Ltd. Printed by The Russell Press Ltd., Gamble St., Nottingham NG7 4ET Telephone Nottingham 74505 by J. E.L. Boyd, Agriculture Unit, Intermediate Technology Development Group with additional material by S.A. Bonnist, J.R. Collett, A. Mallett and H.S. Pearson Intermediate Technology Publications Ltd Intermediate Technology Publications Ltd Exch~sivt ~i~tr~Mt~: Exch~sivt ~i~tr~Mt~: I;:z‘;s, Inc. P. 0. Fhx 555 97116 0 1978, Intermediate Technology Publications Ltd. Published by Intermediate Techno!ogy Publications Ltd. 9 King Street, London WC2E 8HN. U.K. ISBN 0 903031 45 0 The pubiication of this booklet has been made possible by grants from The The pubiication of this booklet has been made possible by grants from The Claremont Trust; The Action for World Developmem Committee of the Episcopal Claremont Trust; The Action for World Developmem Committee of the Episcopal Church of Scotland; and the Ministry of Overseas Development, U.K. The Church of Scotland; and the Ministry of Overseas Development, U.K. The lntermediaie Technology Deve!opmenr Group gratefully acknowledges their lntermediaie Technology Deve!opmenr Group gratefully acknowledges their “, _,_ . ~” 1. I ~t~o~~~t~Qn 2. W~~ks~5~ building for one or two craftsmen asic equipmerrt for a 1-2 man workshop without 3.1 Basic woodworking equipment 3.2 Basic metal working equipment 1 n-3d:*:-nal ~~errful eauipment fo,, a 1-2 man workshop without 4. P4WUI,,“,.... ___._~ , power supply 4.1 Additional useful woodworking equipment 4.2 Additional useful metal working equipment 5. Small power tools for use in a 1-2 man workshop 5.1 Power woodworking equipment 5.2 Power metal working equipment 6. Workshop buildings for 4-6 craftsmen 7. Power equipment for a 4-6 man workshop 7.1 Power woodworking equipment -machine tools 7.2 Power metal working equipment - machine tools 8. Power supply for the workshop 9. Bibliography on small scale workshops Appendix I Suggested list of workshop equipment Appendix I I List of equipment which can be made within the workshop Appendix Ill Notes on metal-working equipment Appendix IV Rural blacksmith entrepreneurs and their capabilities Appendix V Tools and prices Appendix VI Suppliers’ names and addresses 7 9 12 23 34 37 46 49 51 54 67 60 61 62 67 70 72 76 90 Village workshop a? an Ujaama village in Tanzania Watutsi refugees - formerly cattle herders - learning carpentry skills under I LO guidance at the Kayongozi Refugee Centre in Burundi Forge and anvil Trainees at Stereke Boys Centre, Nairobi, learning welding skills Powers hacksaw driven by a hand drill in a rural workshop equipped with electricity Sharpening a drill bit (Mezan Teferi Workshop, Ethiopia) Workshop in Magoye, Zambia &rage Water Development Project workshop, Ethiopia Cutting angle iron in the Gurage workshop Povver drill press stand for metal-working Tie ridger attachments made at the Intermediate Technology workshop Magoye Double ox yoke made in the Magoye workshop Various items made at the Magoye workshop Triangular harrow 9 13 24 45 48 49 51 51 52 59 68 68 69 69 It is hoped that this equipment guide will assist the man in the field who is required ‘to set up a training workshop, a workshop for his own use, or attempting to assist local people in the purchase of equipment. In many cases field staff with very little knowledge of machine shop equipment and costs are landed with the job of equipping a workshop and locating suitable tools. The prices given here will, of course, soon he out of date, but they will give the inexperienced person some idea of the size of budget required for setting up a small machine shop. Only well-known and reliable equipment is listed. Anyone setting up a workshop in a remote part of a developing country should seiect well-known makes of equipment wherever possible. They should not make the mistake of buying cheap equipment, such as ex-public works or old stock, unless the manufacturer is still producing spare parts for the machinery. The same applies to foreign makes which may no longer be imported for one reason or another. This is not so critical as far as hand tools are concerned, providing the quality is good. Hand power tools are used a great deal these days. When buying these tools ask the manufacturer or dealer if there is a heavy duty range available. Heavy duty tools are often much stronger than the handyman range and more suitable for use in a workshop. The tools recommended are those which would be suitable for general purpose wood working and metal working enterprises, which might be called on to make or repair a very wide variety of goods. Specialist workshops would require rather different equipment; for example, a workshop repairing motorised farm machinery would need the equipment listed in Agricultural Machinery Work- shops - Design, Equipment and Management (F.A.O. Agricultural Development Paper No. 66). It is most important to ensure, before the tools are bought, that they can be fully used by the workshop. The hand tools in the lists of basic equipment can be used to do the same work as the much more costly power tools listed in later sections of the book, with the single exception of welding. Power tools only speed up the work, and are not economic unless there is enough work to keep them in use for a substantial part of each day. --.- - An approximate indication of prices in the United Kingdom in mid-1977 has been given. In general, the more complex equipment will be imported into a developing country and will be more expensive than in the United Kingdom. 7 Simple hand tools may well be made wi.ihin the developing country and may be cheaper than in the United Kingdom. Prices of tools are related to their quality and there is sometimes a very v,ide range. For example, in the U.K. a carpenter’s cros= tiu r -“t hand saw couid be priced from f2 (for a cheap saw witabie for occasional use or for an unskilled operator) to f15 (for a top quality saw which will last a lifetime in the hands of a skilled craftsman). This booklet is intended to help people choose appropriate tools and equipment. It is not an instructional textbook on workshop technology. The intermediate Technology Development Group has had experience in helping small craftsmen to s?t up their own ,vvorkshops and operate them successfully as, indeed, have persons and organisations listed in the bibliography in Section 9. This manual contains information arising from the Group’s experience in the field. In case of difficulty in obtaining any items, write to: Intermediate Technology Development Group industrial Services, Myson House, Railway Terrace, Rugby CV21 WT. U.K. Safety and First Aid In case of fire, buckets filled with sand or earth shouid be kept in accessible areas ready for use. Every workshop should have a first aid kit for treating minor cuts and burns. Each worker should know where it is kept, and the kit should be put back in the same place after use. The basic essentials for a first aid kit are: purified water; eye bath; cotton wool; plasters; bandages; scissors; safety pins for fastening dressings; disin- fectant and antiseptic. The first aid box should be regularly insperted and replen- ished as necessary. 8 1 Village workshop at an Ujaama village in Tanzania, built by local men and women, using local skills and materials. It provides an excellent work environment -quiet, cqolanddry. It cost only a few shillings cash and provides a workplace for at least four people. (Photo: G.A. Macphersonl. 9 Workshop tools are expensive, liable to be stolen anti easily ruined if they become rusty, Therefore, the workshop must be waterproof and secure against rheft. To reduce the cost a smal! workshop can be open-sided and the too!s and materia!s kept in a secure store, perhaps a room of the crafsman’s house. HOW- ever, it is better if the complete workshop can be locked. Windows should let in as much light as possible but should not face the afternoon sun. Blacksmithing is best done away from direct sunlight, so that the colour of h-t metal may be seen easily. Blacksmithing and welding may cause a fire if they are done in a wooden building. For the same reason, the woodworking section of a general purpose workshop should be as far as possible from the blacksmithing and welding sections. Blacksmithing and welding produce quan?rties of unpleasant fumes and should therefore be done in a well-ventilated area. Concrete or stone floors are easiest to keep clean, but tools may be easily broten if dropped onto hard floors, Ramnrcd earth is a cheap method of flooring a small workshop. The best way to store tools is on boards with the silhouette of each tool painted SO that missing tools can be idtntified immediately. Materials ara liable to be stolen and should be kept in a secure stu;:. Timber must be kept dry and stored so that it can be easily inspected for termite dar,;?re. Rust on steel is bad for cold metal cutting tools; rust on steel for blacksmithin IS ::TC seriou;. Steel and timber are often supplied in lengths from 3m to Sm. which are best stored horizontally on racks. Shorter lengths can be stored upright. Shelving with compartments is necessary fork storing small items such as different sizes of screws, nails, bolts and nuts. Some important features of the general purpose workshop illustrated opposite are: 1, The doors are 2m wide so that large objects made inside the workshop can be carried out. 2. The horizontal racks for storing long lengths of wood and metal are located so that the materials can be brought in through the door and stacked without being turned. 3. There are vertical storage racks for short lengths of material. 4. Small tools are hung on boards over the workbenches 5. The benches receive light from the windows. 6. The blacksmithing area is near the door (for ventilation), away from direct sunlight and away from the woodwork area. 7. Tools and small parts which might be stolen by customers or onlookers are I stored as far as possible from the door. 8. Equipment used for both wood and metal work (e.g. a post drill) is located between the woodwork and metalwork benches. 10 11