Caledonia High School CDT Department

Project Overview

AES was appointed to deliver a complete package of LEV, C‑VAC and specialist extraction systems for the new Caledonia High School CDT Department. The project required a full workshop‑ready installation across wood‑based, metal‑based and multipurpose teaching spaces, ensuring compliance with HSG258, COSHH 2002, and BS4163:2021.

The department includes multiple craft workshops, prep rooms, resource stores, skills spaces and kiln areas, each requiring tailored extraction, machinery installation and safety systems. AES provided design, supply, installation and commissioning of all equipment listed in the project schedule, including the full C‑VAC wood dust extraction system and specialist hot‑works extraction for forge and welding activities.

Client Requirements

The project required a comprehensive extraction and machinery installation package that would:

Deliver LEV capture at source for all woodworking and metalworking machinery
Provide C‑VAC centralised wood dust extraction with automatic control valves
Support forge, welding and hot‑works extraction with a dedicated roof‑mounted discharge system
Integrate extraction across multiple workshops, prep rooms and teaching spaces
Ensure BS4163:2021 compliance for all new educational machinery
Provide operator familiarisation training and full commissioning documentation
Deliver a complete installation package including delivery, offloading, mechanical and electrical works

The equipment schedule confirmed extensive machinery requirements across wood‑based and metal‑based workshops, along with specialist extraction systems and safety signage.

AES Solution

AES designed and delivered a full extraction and machinery installation package tailored to the CDT department layout. Key elements included:

C‑VAC Wood Dust Extraction System

A full CVAC BF30/C200 system was installed, connecting to all woodworking machinery and multiple clean‑up points across workshops and prep rooms. The system included:

Automatic control valves linked to machine operation
Hood airflow indicators at all extraction points
Floor and bench cleaning kits for each workshop
System sizing based on realistic usage diversity across teaching spaces
Full compliance with HSG258 and COSHH 2002

Hot‑Works Extraction System

AES supplied and installed a dedicated forge and welding extraction package, including:

Corridor and riser ducting to a roof‑mounted fan
3m discharge stack and cowl
Fan control wiring and interlocking
All bracketry and ductwork
Capacity for additional stack height if required

Workshop Machinery Installation

Across wood‑based, metal‑based and multipurpose rooms, AES installed:

Full sets of woodworking and metalworking machinery
Galvanised steel ductwork throughout
Compressed air connections
Electrical installation to isolators within 1.5m of each machine
Commissioning in accordance with manufacturer guidance

Installation & Delivery

AES delivered a complete installation package including:

Design services
Delivery and offloading of all machinery
Mechanical and electrical installation
Commissioning of all equipment
Cleaning and re‑commissioning of legacy machinery
Operator familiarisation training at handover

All ductwork was supplied in galvanised steel, and all works were completed in line with BS7671 electrical standards and BS4163:2021 educational workshop requirements.

Outcome

The Caledonia High School CDT Department now benefits from a fully integrated LEV and C‑VAC extraction system designed for safe, modern and compliant workshop teaching. The installation ensures: