Workshop safety, health and environment
This domain tests your ability to identify hazards in a metalwork workshop and to select controls in a defensible order. Expect questions on PPE, machine guards, gas cylinders, fire extinguishers, electrical safety, fume and noise, and housekeeping. A strong answer names the hazard, the likely harm and a practical control.
Core rules
- Apply the hierarchy of control: eliminate the task, substitute a safer method, use engineering controls such as guards or extraction, then administrative controls, with PPE as the last line.
- Wear goggles or a face shield for grinding and chipping, a filtered welding helmet for arc welding, leather apron and gauntlets for hot work, safety boots, and hearing protection near noisy machines. Do not wear gloves at a drill press or lathe.
- Keep guards in place. On a bench grinder, set the tool rest about 3 mm from the wheel and the tongue guard about 6 mm from the wheel face; check the wheel for cracks before starting.
- Store gas cylinders upright and secured. Keep oxygen and acetylene apart, fit flashback arrestors, and never allow oil or grease on oxygen fittings.
- Match extinguishers to fire class: water for class A solids only; foam or dry powder for flammable liquids; CO2 for electrical equipment; dry powder for gases; special powder for metal fires. Isolate electricity before using water.
- Use RCD protection, inspect leads, extract welding fume, keep walkways clear, and put oily rags and swarf in metal bins.
Worked example
A student is about to grind a cold chisel. The guard is loose and the tool rest is 8 mm from the wheel. Reason: stop the machine and report the guard; adjust the rest to about 3 mm; check the wheel; wear goggles and a face shield; stand to one side when starting; support the chisel and use light pressure. The loose guard is an engineering-control failure, so extra PPE alone is not an acceptable fix.
Traps that cost marks
- Saying only 'wear PPE' when the question asks for a guard, extraction or procedure.
- Suggesting water on an electrical or oil fire.
- Wearing gloves near rotating machinery.
- Returning hot workpieces to the bench without a quench or marked cooling area.