A student is making a wooden storage box in a school workshop. (a) (i) State three general workshop safety rules that the student must follow. [3] (ii) Expl...

(a)(i) Three general workshop safety rules:

1. Always wear appropriate PPE for the task being performed. [1]
2. Never use a machine without proper training and the teacher's permission. [1]
3. Keep long hair tied back and remove loose clothing, jewellery, and ties before working. [1]

(Other acceptable answers: do not run in the workshop; know the location of emergency stops and fire exits; report any accidents or equipment faults immediately.)

(a)(ii) Keeping the work area tidy reduces the risk of tripping over tools, offcuts, or materials left on the floor. [1] It also ensures that emergency exits, fire extinguishers, and first aid equipment remain accessible at all times, allowing a quick and safe response if an emergency occurs. [1]

(b)(i) Three safety precautions when using a band saw:

1. Ensure the blade guard is adjusted to sit just above the thickness of the workpiece, so the minimum amount of exposed blade is visible. [1]
2. Keep fingers well clear of the blade at all times and use a push stick to feed small pieces past the blade. [1]
3. Stand to the side of the blade, not directly in line with it, in case the blade breaks and is thrown forward. [1]

(Other acceptable answers: do not attempt to cut curves too tight for the blade width; wait for the blade to reach full speed before cutting.)

(b)(ii) A blade guard that encloses the exposed section of the blade above the worktable. [1] It is adjustable in height so that only the minimum length of blade needed for the workpiece thickness is exposed, reducing the risk of the operator contacting the moving blade. [1] (Also acceptable: emergency stop button, blade tension release, wheel guard enclosing the upper and lower wheels.)

(c)(i) Two items of PPE for using a belt sander:

1. Safety goggles (eye protection). [1]
2. Dust mask or respirator. [1]

(Also acceptable: ear defenders if the sander is particularly loud.)

(c)(ii) Sanding MDF produces very fine dust particles that are easily inhaled. [1] MDF dust contains urea-formaldehyde resin, a known health hazard; prolonged inhalation can cause serious respiratory problems, nasal irritation, and allergic reactions. A dust mask filters out these fine particles before they reach the lungs. [1]

(d)(i) COSHH stands for Control of Substances Hazardous to Health. [1] These are UK regulations that require employers (and schools) to assess the risks from hazardous substances used in the workplace (chemicals, dusts, fumes, biological agents) and put appropriate control measures in place to protect workers and students from harm. [1]

(d)(ii) Two precautions when applying wood stain:

1. Wear disposable gloves to avoid direct skin contact with the stain, which may contain solvents and pigments that cause irritation or are absorbed through the skin. [1]
2. Work in a well-ventilated area or near an extraction system to avoid inhaling the solvent fumes. [1]

(Other acceptable answers: keep the container lid on when not in use; read the COSHH data sheet and follow the manufacturer's instructions.)

(d)(iii) Wood stain contains organic solvents that evaporate during application, producing chemical vapour and fumes. [1] Good ventilation ensures these fumes are dispersed and do not build up to harmful concentrations in the breathing zone, preventing dizziness, nausea, headaches, and respiratory irritation. In extreme cases, concentrated solvent vapour can also be flammable. [1]

(e)(i) A foam extinguisher (or CO2 extinguisher) should be used on a fire involving flammable liquids. [1] (Also accept dry powder. Do not accept water, which can spread a liquid fire.)

(e)(ii) Two actions if a fire breaks out:

1. Raise the alarm immediately by activating the nearest fire alarm call point or shouting to alert others in the workshop. [1]
2. Evacuate the workshop through the nearest fire exit and go to the designated assembly point. Do not stop to collect personal belongings. [1]

(Also acceptable: if trained and it is safe to do so, use the correct fire extinguisher on a small fire; call the fire service.)

(f) Correct first aid for a minor cut:

1. Apply firm pressure to the wound using a clean cloth or sterile dressing to stop the bleeding. [1]
2. Once the bleeding has stopped, clean the wound under running water, apply an antiseptic, and cover it with a sterile plaster or bandage. Report the injury to the teacher and record it in the accident book. [1]