Health, safety and workshop organisation, including dust and chemical hazards
What the exam tests
Risk assessment, control hierarchy, machine and dust safety, chemical safety (COSHH/SDS), electrical safety, housekeeping and emergency arrangements.
Core rules
- Follow the hierarchy of control: eliminate, substitute, engineer controls (guards, LEV), administrative controls, then PPE. PPE is the last line.
- Wood dust is a carcinogen. Hardwood dust has a UK workplace exposure limit of 3 mg/m³ (8-hour TWA); total inhalable dust is 5 mg/m³. Use LEV at the source, keep ducts clear, and never dry-sweep.
- RPE must be face-fit tested and suitable for the hazard; a paper mask is not adequate for fine dust.
- Chemicals: obtain the SDS, assess under COSHH, use in a ventilated area, store in labelled cabinets, and dispose of waste correctly. Solvent vapours are flammable.
- Machines: guards, brakes, isolation and lock-off, emergency stops. Check leads and plugs; use RCD protection.
- Housekeeping: clear walkways, store timber and sheet goods flat and stable, keep flammable waste in metal bins, and maintain fire exits.
Worked example
Risk-assess sanding hardwood on a disc sander: hazard is respirable dust and entanglement. Controls: extraction hood and LEV, guard adjusted to the work, push stick, RPE if residual dust, and a clean-down with a vacuum. Residual risk is low but not zero. The reasoning follows the hierarchy: extraction first, then procedure, then PPE.
Traps
Starting with PPE; dry sweeping dust; ignoring SDS; bypassing a guard; storing solvents near ignition; assuming extraction works without checking airflow; letting dust build on ledges.