Topic 7: Potential hazards and risk assessment

Overview

Health and safety is the cornerstone of all practical work in Design and Technology. Topic 7 focuses on understanding the difference between a hazard and a risk, identifying potential sources of harm in the workshop, and applying formal risk assessment processes to implement effective control measures. This knowledge is essential for both the theoretical exam and for demonstrating safe working practices in your NEA (Non-Exam Assessment) portfolio.

Listen to the Topic Podcast

Listen to this 7-minute audio guide covering the core concepts, common exam mistakes, and a quick-fire recall quiz.

Key Knowledge & Theory

Core Concepts: Hazard vs. Risk

A fundamental requirement for this topic is distinguishing between a hazard and a risk. Examiners frequently penalise candidates who use these terms interchangeably.

• Hazard: Anything that has the potential to cause harm (e.g., a sharp chisel, a trailing cable, wood dust).
• Risk: The likelihood that a hazard will cause harm, combined with the severity of that harm.

Risk = Likelihood × Severity

The Six Categories of Workshop Hazards

You must be able to identify and classify hazards into these six main categories:

Technical Vocabulary

• COSHH: Control of Substances Hazardous to Health. UK regulations requiring employers (and schools) to control exposure to hazardous materials.
• Hierarchy of Control: A system used in industry to minimise or eliminate exposure to hazards, ranked from most effective (Elimination) to least effective (PPE).
• PPE: Personal Protective Equipment (e.g., safety goggles, aprons, ear defenders).
• Risk Assessment: A systematic process of evaluating the potential risks that may be involved in a projected activity or undertaking.

Practical Skills

The Risk Assessment Process

You must be able to describe the formal five-step risk assessment process used in industry and in your school workshop:

1. Identify the hazards: Look closely at the tools, materials, and environment.
2. Decide who might be harmed and how: Consider the operator, classmates, teachers, and visitors.
3. Evaluate the risks and decide on precautions: Use a risk matrix to calculate the risk score.
4. Record your findings and implement them: Put control measures into action.
5. Review your assessment and update if necessary: Reassess if a new tool or material is introduced.

Evaluating Risk: The Risk Matrix

To evaluate risk objectively, we use a Risk Matrix. This involves assigning a numerical value (usually 1 to 5) to both the Likelihood of the event occurring and the Severity of the consequence.

For example, using a pillar drill without training:

• Likelihood of injury: 4 (Likely)
• Severity of injury: 4 (Major - e.g., deep cut or entanglement)
• Risk Score: 4 × 4 = 16 (High Risk)

Implementing Control Measures

Control measures must follow the Hierarchy of Control:

1. Elimination: Physically remove the hazard (e.g., do not use the hazardous machine).
2. Substitution: Replace the hazard (e.g., use water-based paint instead of solvent-based).
3. Engineering Controls: Isolate people from the hazard (e.g., machine guards, LEV/dust extraction).
4. Administrative Controls: Change the way people work (e.g., safety training, warning signs, limiting exposure time).
5. PPE: Protect the worker with equipment (e.g., goggles, dust masks). Note: This is the last line of defence.

Portfolio/Coursework Guidance

Assessment Criteria for NEA

In your Non-Exam Assessment (NEA), examiners allocate specific marks for demonstrating safe working practices and applying risk assessment. You are assessed on:

• Your ability to identify specific hazards related to your chosen materials and manufacturing processes.
• The implementation of appropriate control measures in your manufacturing diary.
• Photographic evidence of you working safely (e.g., wearing correct PPE, using machine guards).

Building a Strong Portfolio

To secure top marks in the making section of your portfolio:

• Create a detailed Risk Assessment table before you begin manufacturing. List the process (e.g., "Using the bandsaw"), the hazard, the risk score, and specific control measures.
• Annotate your making diary with safety notes. Instead of just writing "I cut the wood," write "I cut the timber using the tenon saw, ensuring the work was securely clamped in the vice to prevent slipping (Mechanical Hazard control)."
• Show, don't just tell. Include photos of yourself wearing an apron and safety goggles while operating machinery.

Exam Component

Written Exam Knowledge

In the written paper, you will typically encounter questions asking you to:

• Identify hazards in a given workshop scenario or photograph.
• Calculate a risk score given a specific likelihood and severity.
• Suggest appropriate control measures for a specific manufacturing process.
• Explain the difference between a hazard and a risk.

Exam Preparation Strategy

• Practise applying the Hierarchy of Control to different scenarios. If asked for a control measure, try to think of an Engineering or Administrative control before defaulting to PPE.
• Learn the specific COSHH requirements for common D&T materials (e.g., MDF dust, epoxy resin, acrylic cement).