Art 130 Studio Operation Guide
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UH Glass Program Studio Operations Manual Fall 2013 Introduction The Glass Program involves the operation of a very complex physical plant the Glass Studio This studio has a life of its own you are its soul its sweat and its blood In order that we may all produce the highest quality work possible it is absolutely imperative that we each make a consistent concerted effort to assist in the operation of the studio The more experience you bring to the program the more responsibility you bear in its operation and maintenance This is a cooperative effort operation with approximately 40 students using the studio each semester There is a terrific degradation of equipment Every day quotsomethingquot breaks and will stay that way until quotsomeonequot xes it No one gets paid enough to fix these things the reward is gaining the understanding of how to repair them One of the most important things I ve learned while at UH is trouble shooting Troubleshooting a functional object such as a piece of equipment vs a sculpture are not that dissimilar the parameters are different indeed yet gaining experience in the two types of activities will actually enhance one another Gaining creative problem solving skills will make you a highly valued employee Learning to run and operate your own studio is very valuable experience Here at UH you can learn to do this by helping us run and maintain our studio Without further discussion this manual is intended to minimize repairs on the shop and assist in its efficient operation This plan did not simply pop up out of nowhere it has evolved over the last 21 years and will undoubtedly continue to do so You should read this manual thoroughly refer to it often and commit it to memory Then we can get on with the rest of the story your work Thanks to the following individuals for their input and hard work in developing this manual Robert Bento Salome Brant Paul Larned Steve Lee Kun1iNakajima Robert Miller Jacqui Marlin Miko Suzuki and Jeff Woodyard Rick Mills Chair Glass Program University of Hawaii Glass Program Objectives To provide thorough training on the undergraduate and graduate levels in the development of the students technical skills for the manipulation of glass in both the hot and 39cold39 states Hot processes 0 off hand freeform and moldblowing 0 wet sand bonded sand and table casting 0 lost wax fuse casting and hot casting investment molds 0 sheet glass slumping and fusing 0 enameling on 2D and 3D forms 0 mixed mediaprocess and performance Cold processes 0 sheet glass fabrication and joinery 0 sheet glass lamination 0 sandblasting and diamond saw carving 0 2D intaglio cutting 0 2D engraving O lapidary faceting 0 mixed media V To provide a thorough understanding of the physical properties of glass formulation coloration and annealing V To instruct and train the student in the efficient operation of a complex glass studio This includes glass furnace and annealing oven theory design and construction as well as the development of melting and annealing schedules V To support a cooperative environment for leaming where students learn to work together in the operation of quotthe glass studio V To instruct the students in the safe operation of tools equipment and in the use of materials V To provide the historical background of glass working its traditions techniques and its signi cance V To provide the contemporary context for the use of glass as an expressive medium V To challenge and encourage the student to use the unique properties of glass with the intent of individual expression To direct and assist the student in this understanding 2 To help build and train the perceptual and verbal skills of the artist in the critical observation interpretation and evaluation of art work which uses glass as a major component To encourage the speculative mind and to inspire imagination in an environment which is supportive and challenging To recognize the value of hard work and fortitude in the learning process beyond the finished product To allow the student the freedom to experiment explore and to make mistakes in lieu of discovery To provide a logical sequence of courses augmented with workshops and visiting artists which would transfer in scope and quality to other similar institutions To encourage each student as an individual with unique goals aspirations and ideas To help the student articulate his or her visual ideas and realize his or her full potential To prepare the students to leave the glass program with the drive determination and professionalism necessary for irther involvement in the art world Glass Studio Operations 1 Hot Shop Equipment B SLUMPINGI FUSIN G OVENS OVEN POLICY C FURNACES A ANNEALERS Day Ovens Blue 5 amp Red 1 are to be used for regular daytoday annealing LEHRS schedulesl2 hours maximum The Day Oven for any particular day must be shut down sign ipped to quotOFFquot and cycled by 11pm Failure to cycle the oven during your evening closing slot will result in the forfeiture your blowing slot for one week from the day after the infraction A Blue 1 2 3 4 Red 2 3 and 4 are to be scheduled for in advance immediately Saturday clean up at Noon Blue 3 the front loading sandcasting oven should not be red over 1200F due to the mild steel shelving frameWork EACH OVENIS EQUIPPED WITH A HIGH LIMIT CONTROL THAT SHOULD BE ADIUSTED TO 50F OVER YOUR FINAL FIRING OR ANNEALING TEMP THIS IS LOCATED TO THE SIDE OF THE KILN ON THE WALL SHOULD THIS TRIP YOUR OVEN WILL STOP AND CRASH TO RESET DEPRESS THE ROUND BUTTON BEHIND THE PERFORATED STEEL MESH AND ADIU ST THE TEMP TO 50F OVER YOUR FINAL SET POINT TEMP Allocation of oven space will be based on class standing and consistent attendance at Saturday Cleanup If you cannot attend this cleanup time but still require oven space you must make arrangements with the 130 TA Jonathan Swanz one week in advance to be assigned a maintenance or cleaning task Detailed ring schedules names and phone numbers must be recorded in Oven Schedules and Programs Book OVENS MUST BE CLEANED UP AFTER EACH FIRING The left hand furnace quotLuckyquot and the color pot furnace quotPeeweequot will be charged as needed starting prior to Noon by charging crew under the supervision of the quotshop manager Nick Ybl Furnaces should be turned up to ning temperature 2300F and the doors CLOSED 1 hour prior to the first charge A prudent charging schedule which will result in good glass looks like this 5 Lucky PeeWee Ramses 10 AM Furnace turned up 2300F 2quotwc air35quotwc gas 2300 F 1100 1st charge l00 lbs 1st charge 1S lbs lst charge100 lbs 1200 PM 2nd charge100 lbs 2nd charge 20 lbs 2nd charge 100 lbs 100 3rd charge 100 lbs 3rd charge 2O lb s 3rd charge 100 lbs 300 4th charge l50 lbs 4th charge 25 lbs 4th charge 15O lbs D TOOLS E GLORY HOLES Glass should be charged with uxes colorants spread evenly over cullet For Color Furnace and recycled glass mixed in Care should be taken to inspect the charge for foreign debris which the batchers may have missed such as nails bottle caps rings metal scale and color After the last charge the furnace should be left at ning temperature overnight Leave a message on the board for morning blowers as to shop status Record all charges and changes to temperature on the furnace clipboard also Remember the quality of the glass we ALL have to use will be determined by the care taken during the charging cycle The right hand furnace Ramses will be used as the casting furnace on Saturdays from 61 1 45 AM and is to be charged by the Casting Crew immediately thereafter Shop tools wrenches drill bits screw drivers will be available during class time and can be signed out for overnight on the quottool signout listquot on the clipboard in the cold shop Lost or broken tools must be replaced by the student responsib1e After class times all tools will be secured Supplies are secured in the locker up stairs in the cold shop If you need a new belt or diamond bit please ask the studio manager your faculty or TA DO NOT OVER FIRE GLORY HOLES If the color is approaching yellowwhite TURN IT DOWN Over ring the glory holes will result in much earlier breakdown and all blowing will have to stop while the holes are patched Do Not Pop off pipes and punties in the glory holes this is what the pipe warmer is for Chipping pipes in the Glory holes causes them to deteriorate Lighting the glory holes is a 2person job Follow the instructions on the controls and you will have no problems 6 0 Iquot39P quot 8 9 Open doors pull yoke back Check to be sure all switches and valves are off Turn both safety switches on Turn on main gas Light pipe warmer burner with Map Gas Torch and turn on pilot valve After 3060 sec depress and release main red solenoid button If button quotclicksquot continue to step 8 If not repeat step 6 Set air valve so air ow reads quot9quot on gauge Light map gas torch and place in the hole in the back of Burner Call out FIRE IN THE HOLE to make sure no one is in front of the hole and turn main burner control valve until gauge reads quot 12quot and a neutral ame has been established Do not leave glory holes unattended Turn them down for short breaks 15 minutes and OFF for longer breaks The energy expenditure and cost of firing these glory holes is enormous we have to do what we can to keep our energy costs down Gather out excess glass pooling in the bottom of the glory hole at the end of your blowing slot Use a punty and PULL not LEVER the glass out This pooled glass when hot is highly corrosive to the refractory bricks and the longer it is left in there the sooner the glory hole deteriorates and the sooner it will need rebuilding To turn off glory hole 1 Shut burner and main gas valves off then close pilot valve 2 Turn air valve down until gauge reads quot2quot DO NOT TURN AIR OFF 3 Turn safety switches off be sure yoke is pulled back Open doors 1 to prevent glass from sticking Turn the glory hole OFF at the end of your slot if the next person signed up for time is not present other blowers do not need the glory hole ASK Be sure to leave air control slightly on to prevent damage to ribbon burner 7 F MARVERS Wipe off any debris on the marver Nothing is more aggravating than to roll a beautiful clean gather across the marver surface and come up with an unintentional quotManoa Pick upquot No powder or frit is to be place on the 2 large stainless steel marver Use the small steel pick up tables BEN CHES amp FLOOR SPACE G TORCHES Sweep and clean your third of the shop at the end of your blowing slot Sharp glass shards and debris on the oor are DANGEROUS to blowers who are concentrating on their work not where they are walking Tripping with a gather of hot glass is not healthy Sort out good clean recycle glass from your popoff bucket and place in the appropriate recycle can Color scraps are placed on the recycle table out back for secondary sorting 30 of a glass blowers waste comes off the blowpipe largely 39om your moiles At 750 per pound clear recycle is valuable to us Please take the time 5 minutes to do a primary sorting of your scraps Return all tools and equipment You will appreciate this the next time you go looking for a needed tool Report any problems with the Hot Shop to the shop Foreperson or to the G ATA KEEP ALL CYLINDERS AWAY FROM ANY HEAT The cylinders should remain secured to their handtrucks at all times Make certain all cylinder valves and regulators are turned off properly These torches have a trigger valve to apply full power When not actively in use but ready a small ame is all that is needed Help us all save propane Propane is nearly 500 per gallon Keep hoses coiled and all components hoses torches strikers on their appropriate hooks Notify the Hot Shop Foreperson or the GATA if the cylinders are empty or if you experience ANY problems with the torches pA Hot Shop Operations PROCEDURES B CLOSING A OPENING Check on dated chalk board to verify the correct annealer and furnace to use for that day and time Check the status of the Day Oven annealer at the GB5 controller If the annealer to be used is at or below 200F and IDLE then proceed to crack open the doors 2 Allow the pieces to cool until they are easily touchable then carefully unload Thicker pieces should be wrapped in newspaper If the annealer to be used is above 200F DO NOT OPEN DOORS Wait until temperature has dropped Once oven is completely empty restart at the GB5 controller by pressing quotAquot and the unit number you wish to start then quotEquot and the unit number again for example to start RED 1 press quotA1El quot Remember that the BLUE ovens are controlled by the upper BLUE controller and the RED ovens by the bottom RED controller To start Blue 5 press A5 E5 on the blue controller Intermediate and Advanced students who are in scheduled evening blowing slots are responsible for closing the shop PROCEDURES 1 Ovens are OFF by 11 PM and signs are ipped up failure to cycle the day oven will result in the loss of your blowing time If you decide not to blow you are still responsible for making sure the day oven is cycled 2 Furnaces are charged as needed 3 Furnace doors are closed tightly 4 Shop is swept under gloryholes benches marvers and outside courtyard 5 Covers are put back on marvers 6 Garbage cans are emptiedremember to empty non combustible trash in the appropriate dumpsters 7 Tools are returned 8 All doors are secured to glass lab and to courtyard 9 Leave notes on chalkboard concerning shop status a which furnace and annealer to use in the AM b any additional comments concerning shop status c evening slots are responsible for closing the shop 8 C SORTINGI CHARGING CREWS D CASTING CREWS for quothotquot casting with ladles Supervised by quotStudio Managerquot Each crew will be composed of a minimum of 3 students one from each glass course beginning intermediate and advanced and will be responsible for the following duties for one week beginning on Sunday and ending on the following Saturday 1 Sort 100 lbs of clear recycled glass 2 buckets by Tuesday and Thursday morning of each week additional requirements as noted on the chalkboard 2 Recycle is clean clear with your name on it and ready to charge 3 Reinforce sorting and charging procedures to beginning students 4 Enforcing the use of all safety equipment and proper clothing when batching and charging 5 Recording information on batching and charging on chalk board and fumace logs A sixhour block of time on Saturdays from 6 AM12 NOON will be re served for hot casting Each weekly casting crew will be composed of at least 3 but not more than 5 students The crew will be headed by a crew leader responsible for programming the annealing schedule and turning Ramses up to casting temperature The 230 Teaching Assistant during Art 230 semesters will supervise the casting crews in preparation of the studio and during Saturday casting The casting crew is responsible for l Batching and charging Ramses before and after casting 2 Complete shop clean up 3 Recording all pertinent batching and charging information on the chalk board and furnace log 4 Programming and cycling oven after session Maximum 5 people for casting group designated group leader will assign casting order and annealing oven space for participants All weekly casters will be responsible for batching and charging casting furnace The Casting Crew Leader or Studio Manager will be responsible for designating amount needed to charge and will supervise such as well as control firing of furnace and program computer for annealing E SHOP ENVIRONMENT WE NEED CLEAN AIR No quotFraxquot or ber blanket out in the open 9 Keep frits on separate marver this also includes quotManoa Pick upsquot common marvers will not be contaminated with he above or a other substance Use DOWN DRAFT TABLES for Glass powders always use respirators too E HOT SHOP F OREPERSONS Glass majors grads and undergrads have volunteered to kelp manage certain areas of the studio and are responsible for maintaining them They are supervised by faculty and the studio manager Should you have questions problems with a particular area please see the updated list on the cold shop door for the glass major in that area and contact that student and the Studio manage F COLD SHOP TOOL CHECK Tools will be locked up after class time but you may use a tool by signing out for the tools on the signout clipboard in the cold shop Please ask your TA or faculty to check out tools If a tool should break while in your possession bring back the broken parts You will only be charged to replace lost tools or if repair requires parts purchase Likely you won t be charged at all if you fess up to it G SATURDAY SHOP CLEAN UP Every Saturday from 121 PM cleanup duties will be assigned to those present Attendance will be taken and those still present at the end of clean up will have the right to reserve an oven for one cycle the following week If you require an oven but cannot make the Saturday cleanup you may make arrangements with Rick or the GATA to do the work prior cleanup You may elevate your priority rating for special projects by putting in extra shop time H BLOWING TIME ALLOTMENT Assistant required GLASS Graduate students Advanced Undergraduate Glass Majors Advanced non majors Intermediate Undergraduate Glass Majors Classi ed Graduate Non glass Students Unclassi ed Graduates 8 hours plus additional Sunday time 8 hours and 8 hours assisting 4 hours and 4 hours assisting 6 hours and 6 hours assisting 4 hours and 4 hours assisting dependant on proposal amp consultation 9 Undergraduate Nonglass Majors 4 hours Art 130 students 4 hours and 4 hours assisting All students are expected to assist and to have and assistant All students are required to sign in on the weekly blow schedule for there time and any time they vulture 3 Consecutive missed scheduled blowing slots will result in the forfeiture of that slot 3 consecutive vultured slots will result in re assigning that slot to that student Day ovens 12 hour cycle maximum Long cycle reserved space only I maximum length 48 hours Group cast oven maximum time 72 hours Pickup ovens Red 2 and Red 4 must be reserved for use at Saturday clean up SKUTT KILN For color pick up and quick turn around overlay blank pick ups Not to be use for personal annealing SHOP HOURS Remember the hot shop is open from 500AM until 1100PM Monday through Friday with assigned blowing slots You must sign in for your blowing slot on the schedule posted on the door between the hot and cold shops If you are more than 15 minutes late you may lose your slot to someone else who Wants it If you miss your slot two times it may be reassigned to someone who shows a need for more time Spring Semesters Blowing time is may also available on Saturday for those coming to cleanup Sunday the hot shop is closed to all except the instructor and the classi ed graduate students in Glass Blowers will clean up bench area 15 minutes prior to end of shift Watch the clock Other blowers also value their blowing time Blowers on 8ll PM shift are required to turn off day oven Blue 5 or Red 1 at 11 PM Failure to do so will result in loss of blowing time for the following one week The second time will result in a 2week suspension and the third time will result in permanent suspension The hot shop will close by 11 PM every evening Cold Shop Equipment E We have an inventory of tools in each cabinet with a color coded tape on each tool If you take out a tool you are responsible return it to its proper place so the next person can 10 B LAP WHEELS nd it easily Proper use of shop equipment will mean longer tool life less frustration and it will provide safety for the operator Listed below are the various pieces of equipment with a brief run down on their proper operation This information is also available in summary on a card near the equipment A DIAMOND SAW Always wear a face shield and ear protection when using the saw Be sure the water jet is hitting both sides of the saw blade before cutting Set the blade to the proper height for the cut you are making If it is not correct there is a chance of the blade catching in the work and kicking back and of course bending the saw blade These blades are EXPENSIVE Feed work SLOVVLY and carefully A slow feed gives a better cut and prolongs the life of the blade Don39t try to cut through a thick piece in one pass Set the blade height to out through one half of the thickness then tum the piece over and cut through the other half Clean off cutting table when you are nished and toss out scraps of glass Don39t leave them on the tray for someone to get cut on Close all doors when cutting The noise from this saw travels and angers all those in the vicinity Be sure grit size matches the machine you are using Use only coarse 80 grit abrasive sometimes we can only stock 60 grit on the coarse wheel and fine 220 grit abrasive on the ne wheel Rinse your piece and your hands carefully between grits and wipe off your apron If you transfer coarse grit even a few grains to the ne wheel you may ruin hours of careful work by scratching a ne ground surface Set up feed tray so water and grit hits the center edge of the wheel Move your piece back and forth across the full face of the wheel turning it if possible This maintains an even wear on the wheel and you will have nice at bottoms on your work Use recycled grit from the wheel pan while you are working rather than continued portions of new grit This will help us conserve the abrasives which are very expensive and must last the full semester When you are nished turn off the water but allow the wheel to spin until it is dry This is VERY important Someone else can turn off the wheel for you if you are leaving When water is allowed to stand on these wheels they rust and become very uneven C UPRIGHT BELT SANDERS The most important thing to remember in the use of these sanders is to take proper care of the belts Belts should NEVER be left on a sander that is not running The spring loaded tension will stretch the belts and render them useless If you will be leaving your work for a moment it is best to leave the sander running if you will be longer than a minute turn off the sander and remove the belt from the bottom roller which will remove the tension You may leave the belt hanging on the upper roller When you are nished remove the belt completely and replace it on the correct peg Be sure water jet hits the belt during use Only the cork belts should be lightly waxed during polishing to protect against scratching your piece and to prolong the life of the belts It is a good practice to thoroughly wash your pieces between each sanding operation One tiny grain of grit can mean a lot of extra work for you in the next operation D VIBRATIN G LAP ROCIPROLAP Cleanliness is the keyword here Wash thoroughly between grits see above and be sure to weight your piece properly Always check the lap periodically to be sure there is enough water in the tray and that the rubber protectors are properly positioned around your piece When you are replacing the main wheel after washing BE SURE MOTOR PEG IS FIRMLY IN WHEEL HOLE and clean and spray WD 40 all bearings If you turn on the Rociprolap with the wheel improperly positioned you will certainly ruin several thousand dollars worth of equipment E FOREDOM FLEXSHAFT Maintain adequate water lubrication whenever using F STEINART this tool on glass Friction builds up heat quickly and you may break your piece Wear a respirator because the fine dust created if you grind a dry area is not healthy Be sure all bits are replaced when you are done and return everything to its proper place If the handle becomes warm while in use it may be necessary to grease it Check with the Cold Shop F oreperson Glass polishers should never be in the vicinity of a grinding area due to GLASS POLISHER the ease of contamination of either the cork or felt wheels with grinding grit sand or glass chips Unfortunately because of limited space we have no other option but to locate this polisher where you see it in the cold shop Because of this situation it is of the utmost importance that we make certain no foreign debris comes in contact with either of the two wheels To do this follow the instructions below 12 1 Make sure you have received proper training in the use of this piece of machinery 2 Follow all the instructions as posted on this machine 3 Absolutely NO sand castings are to be polished on this machine 4 Make certain that the plexi wheel covers are in place when you nish polishing to prevent any stray abrasives from landing on the wheels 5 0 Make certain that the water supply is turned off and the wheels spun dry when you are nished polishing A soakingwet cork or felt wheel will sag offcenter and be totally ruined Unless you can afford 80000 for a new wheel REMEMBER THIS 6 Do not favor a quotsweet spotquot on the wheel while you are polishing your piece This will wear the wheel unevenly and irregularly Keep your work moving against the entire front surface of either wheel 7 NEVER use any other polishing or abrasive compounds on either wheel other than those that are clearly marked PUMICE or CERIUM If there is any doubt what that mystery cup of pumice like material really is 7 do not use it 8 Make certain that all pumice is rinsed off your work and handsarms before proceeding to the felt wheel for cerium polish Pumice will contaminate the felt wheel and produce an imperfect polish 9 Only glass is to be polished on this machine 10 Make certain that no one is using this machine who is not properly trained This includes you G DENVER ENGRAVER The Denver engraver and the wheels which attach to it are very delicate and painstaking to prepare This machine is off limits to all students unless they have been speci cally trained at a Standardized Lathe Training Session SLTS In order to participate in the SLTS you must purchase a stone wheel which you will prepare mount center and pro le With this wheel you will execute a small engraved piece The preparation of the wheel and the execution of the piece will both count towards your passing of the SLTS If you are interested in using the lathe order your wheels now Dates for the SLTS will be announced General instructions are as follows 1 Follow all instructions as noted for this piece of machinery 2 Do not allow anyone to operate this machinery unless they have been SLTStrained 3 Only glass engraving and cutting is permitted on this machine More detailed descriptions of the types of wheels and pro les available and instructions on the use of the lathe will be given to those who become qualified to use it O Cold Shop Operations B WORK SPACE A SHOP CLEANUP Everyone is responsible for some cleanup work either on Saturday or during the week Cold shop work may be signed up for weekly or as special jobs for those people who are not able to come for general Saturday cleanup See Cold Shop Forepersons or sign up on the posted jobs sheet The cold shop consists of the loft cold shop proper and the outside areasin both front and back of the lab These areas must be cleaned swept de junked and generally policed weekly Every Monday we should look forward to having a clean workplace THERE WILL BE NO STORAGE OF PIECES FOR LONGER THAN TWO WEEKS Items left in the cold shop will be dated weekly and if they remain for longer than two weeks they will be removed Anything that seems of value will be stored in a box and may be reclaimed by performing some cleanup task Broken pieces will be tossed If you are saving something which may appear to be junk please leave a note with it Unclaimed pieces will marked then be tossed If you have a special problem with this please speak to the studio manager and they will try to work something out CLAIM YOUR WORK Starting after rst project review all loft areas must be cleared Taped table space will be reassigned on a first come f1rst served basis only if you have attended Saturday cleanup or have arranged for and done coldshop jobs Blown pieces may not be stored there unless they are a part of your project for review That space will be yours until the second review is completed when the process will begin again The courtyard table should be kept clear or debris tools food etc except during class time or when you are working there Ideally it should be available for cutting large pieces of glass or assembling pieces too large to work on in the loft space Table C PROBLEMS will be cleared on Saturdays so if you forget items on the table over the weekend they will be boxed and you will have to work to retrieve them This might seem difficult hardnosed or OVERLY CONTROLLING But we are only trying to find workable answers to the process of leaming to work together and if you can think of a better way to handle this you will find us amenable to suggestions WE ALL USE THIS STUDIO WE ALL DEPEND ON ITS 100 FUNCTIONALITY If something doesn39t work with this policy then lets discuss changing it and find a way for it to work until then this is the Glass Studio Operations Manual Again If you disagree with our policy come with a constructive idea and we will listen This is YOUR shop and we are trying to do a good job