Fig. 16 shows a garden bench made from timber and mild steel. The garden bench uses both permanent and temporary methods of joining. (a) Name a suitable tem...

This is a multi-part question about a garden bench made from timber and mild steel.

(a) Name a suitable temporary fixing shown at B used to attach the timber slats to the steel frame [1]

Coach bolt / machine screw / hex bolt with nut [1]. These pass through both the timber slat and a hole in the steel frame, and are secured with a nut on the underside. They can be undone with a spanner to remove individual slats.

(b) Suggest a permanent method of joining the steel legs to the seat frame at point A [1]

Welding (MIG welding or arc welding) [1]. This fuses the steel components permanently by melting the parent metal at the joint, creating a strong metallurgical bond that cannot be taken apart without cutting.

(c) Explain why temporary fixings are used for attaching the timber slats rather than permanent ones [2]

Temporary fixings allow individual timber slats to be removed and replaced if they become damaged, split, or weathered over time [1]. This extends the life of the bench as a whole, because only the affected slat needs replacing rather than the entire product [1].

(d) Describe one suitable finish for the steel frame and one for the timber slats [2]

• Steel frame: Galvanising / powder coating / painting with a rust-inhibiting primer and topcoat [1]. These finishes provide a barrier between the steel and moisture, preventing oxidation (rust).
• Timber slats: Exterior wood varnish / teak oil / wood preservative / exterior wood stain [1]. These penetrate or coat the wood to repel water and resist UV degradation, preventing rot and greying.

(e) Name the type of production for 500 benches [1]

Batch production [1]. This involves producing a set quantity (500) of identical products before the equipment is reconfigured. It is more efficient than one-off production but does not justify the high tooling costs of continuous/mass production.

(f) Describe two quality checks on each finished bench [2]

Any two from the following, each worth [1]:

• Check all joints are tight and secure with no movement or looseness.
• Check there are no sharp edges or burrs on the steel frame that could injure the user.
• Check the finish is even and complete with no bare patches where corrosion or weathering could start.
• Check the bench is stable on a flat surface with no rocking.
• Check dimensions match the specification within acceptable tolerances.

(g) Design arm rests for the bench [6]

Award marks across the following criteria:

• Clear sketch showing an arm rest attached to the bench frame, with appropriate proportions and positioning at a comfortable height for a seated user [1-2].
• Appropriate material choice, for example hardwood to match the existing timber slats for visual consistency and weather resistance [1].
• Suitable fixing method, for example bolted to the steel leg upright with a steel bracket, or a welded steel support arm with the timber arm rest bolted on top [1-2].
• Suitable finish identified, for example exterior varnish or teak oil to match the slat treatment [1].

(h) Explain why the bench legs are made from mild steel rather than aluminium [2]

Mild steel is stronger / has greater tensile strength than aluminium for the same cross-section [1], making it better suited to supporting the weight of seated users. Mild steel is also less expensive than aluminium, reducing the manufacturing cost of each bench [1].

(i) State two environmental considerations when choosing materials [2]

Any two from the following, each worth [1]:

• Choose timber from sustainably managed forests / FSC-certified sources to prevent deforestation.
• Choose materials that can be recycled at end of life (both steel and timber are recyclable).
• Minimise waste during manufacture by efficient use of stock material and offcuts.
• Consider the carbon footprint of transporting raw materials and finished products.

(j) Give two reasons why knock-down fittings might be used instead of bolts for flat-pack delivery [2]

Any two from the following, each worth [1]:

• Knock-down fittings do not require tools (or only an Allen key), making home assembly easier for the customer.
• They can be tightened and loosened repeatedly without wear, unlike bolts that can strip threads.
• They allow the product to be packed flat, reducing packaging volume and transport costs.

(k) Name a suitable adhesive for gluing timber slats [1]

Polyurethane adhesive / exterior PVA / epoxy resin / waterproof wood glue [1]. The adhesive must be waterproof to withstand outdoor exposure and bond effectively to timber surfaces.

(l) State one advantage of using stainless steel bolts instead of mild steel bolts for outdoor furniture [1]

Stainless steel does not rust or corrode when exposed to moisture [1], so the bolts will not stain the timber with rust streaks or weaken over time, maintaining both the appearance and structural integrity of the furniture.

(m) Give one reason why the timber slats are spaced apart rather than placed edge to edge [1]

Any one from the following for [1]:

• To allow rainwater to drain through rather than pooling on the seat surface.
• To allow air circulation, which helps the timber dry quickly and prevents rot.
• To allow for expansion and contraction of the timber as its moisture content changes with the weather; without gaps, adjacent slats would buckle or split.