New South Wales Department of Education & Training

NEW SOUTH WALES DEPARTMENT OF EDUCATION & TRAINING

Off-Site Construction (Shopfitting) - BCF30100
PRACTICAL ASSESSMENT TASK
DOOR PRACTICAL EXERCISE
Marking scale
Key competency details / Weighting / Out of / Final mark
1 / Insert details relating to identified key competencies
2
3
4
5
Total

Key Competency information can be obtained from CIDO and NTIS
This practical exercise goes in part to satisfy the following national competency standards:

BCG1002A PLAN AND ORGANISE WORK

In particular you must be able to:

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· obtain task instructions or directions from supervisor

· select for directed tasks the necessary logical work sequence, tools/equipment, materials and PPE

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Tasks

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Plan the sequence of work tasks, (a simple job plan listing steps)

Prepare and organise the appropriate tools,

Prepare and organise materials,

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Prepare and use personal protective

equipment (PPE)

BCG1004A CARRY OUT MEASUREMENTS AND CALCULATIONS

In particular you must be able to

· take and record measurements accurately

· perform simple calculations to specifications

· estimate quantities and costs to requirements

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timber frames

concrete

brick/block work

joinery

stairs or steps

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Tasks

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read and interpret drawings

measure and calculate manually

record measurements

operate electronic calculating devices

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BCG1005A USE HAND AND POWER TOOLS

In particular you must be able to

· demonstrate safe and effective operational use of tools and equipment

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drills - pedestal

nail guns

staplers

screwdrivers

sanders

circular saw

jig saws

planes - planers

routers

brooms

chisels

hammers

measuring tapes

chisel mortiser

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BCG1006A USE SMALL PLANT AND EQUIPMENT

In particular you must be able to

· demonstrate safe and effective operational use of tools, plant and equipment

· demonstrate and show understanding of manufacturer’s specifications and recommendations

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air compressor and hoses

industrial wet and dry vacuum cleaner

pallet trolley

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BCG1011A HANDLE CONSTRUCTION MATERIALS AND SAFELY DISPOSE OF WASTE

In particular you must be able to

· carry out correct procedures prior to and during application of materials handling processes and demonstrate safe application in the process of cleaning up

Tools:

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brooms

hoses

shovels

wet and dry industrial vacuum cleaners

wheelbarrows

pallet trolley

materials hoists

forklifts

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materials:

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banding straps

packing pieces

broken or damaged goods

cardboard

plastic

paper

loose material

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BCF2001A USE STATIC MACHINES

In particular you must be able to

· demonstrate correct techniques with safe and effective operational use of machine

· demonstrate correct shut down/switch off procedures with completion of machining operation

Machines

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rip saws

band saws

docking saws

vertical and horizontal drills

dimensional saws

thicknessers

buzzers (jointer/surface planer)

morticers

multi drill machine

table sanders

grinders

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BCF2012A PACKAGE MANUFACTURED PRODUCTS FOR TRANSPORT

In particular you must be able to

· demonstrate safe and effective application of packaging process to product

· adopt and apply effective loose packaging to packaged material for transportation

· identification of typical faults and problems that occur and necessary action taken to rectify

Materials

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stretch wrap

bubble wrap

shrink packaging

pallet wrapping

polystyrene foam moulding

Banding

Cardboard wrapping

Blanket wrapping

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BCF2013A ASSEMBLE COMPONENTS

In particular you must be able to:

· Prepare for the assembly process by using a range of tools and machines to prepare the joints according to information supplied by plans specifications or your trainer.

· Assemble the joints to quality assurance guidelines using correct tools and processes

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roof trusses

wall frames

shopfronts

door and window frames

doors

window sashes

grills

louvres

fitments (including cupboards, counters, shelving, robes)

stairs

relocatable structures

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Assembly applications may include:

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platform or frame jigs

packers/wedges

presses

cramps

clamps

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BCF2016A PREPARE FOR OFF-SITE MANUFACTURING PROCESS

You will demonstrate your ability to

· Prepare component drawings cutting lists, material list, job plans to regulatory requirements during in a range of construction projects.

Manufactured units or products may include but are not limited to:

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stairs

fitments

prefabricated framework

shopfronts

windows

doors

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Materials:

1 / 1500 x 75 x 25mm - stiles

1 / 1200 x 75 x 25mm - rails

1 / 2100 x 150 x 25mm - panel

Tool and machines list: See tools and machines listed above

Machines and tools may be interchanged to suit facilities and job plans.

Specifications:

Door size: 720 x 500 ± 3mm

Frame Joints: see drawings

a. Long and short shoulder through mortise and tenon

b. Stopped long and short shoulder mortise and tenon

c. Dowelled matched joint

d. Dowelled masons mitre joint

Panel Joints:

a. biscuit joint

b. tongue and groove joint

OH&S equipment:

Steel capped work boots and protective clothing as a minimum requirement must be worn in all workshop/ worksite activities.

Hearing protection, eye protection and other mandatory PPE must be worn when using portable power tools or machinery.

Task Details

1. Prepare a full size set out rod for the frame - include joints

2. Prepare a orthographic drawing of the door – Elevation Plan and vertical section scale 1:10

3. Develop the cutting list fully

4. Create a job plan outlining all steps in the job – use this information to complete the safe work method statement.

5. Make and complete the door to specification

Resources

Barrington, Jack, 1992, Practical Australian Carpentry, Vol 1. Sydney:

McGraw-Hill. ISBN 0 0745 2128 4

Basic Building and Construction Skills, 2nd Ed (2000).

Frenches Forest: Pearson Education Australia. ISBN 0 7339 9885 2

Available from TAFE Librarys

TAFE training video - Mortice and Tenon Joints. TAFE NSW (2000) Available from Library

TAFE training video - Portable Power Saws. TAFE NSW (2000)

TAFE training video - Power Planes and Routers. TAFE NSW (2000)

TAFE training video - Dressing timber. TAFE NSW (2000)

TAFE training video - Housing and halving joints. TAFE NSW (2000)

TAFE training video - Plant and equipment. TAFE NSW (2001)

TAFE training video - Grinding and sharpening -plane blades and chisels.

Useful websites

Dowel and biscuit joints

http://en.wikipedia.org/wiki/Dowel_joint#Dowel_Reinforced_Butt_Joint

http://en.wikipedia.org/wiki/Biscuit_joiner

Mortise and Tenon Joints

http://en.wikipedia.org/wiki/Mortise_and_tenon

http://www.australianwoodsmith.com.au/pdf/27haunchedmortise&tenons.pdf

http://www.australianwoodsmith.com.au/index.html

http://au.blogs.yahoo.com/better-homes-gardens/1218/mortise-and-tenon/

Quality assurance:

Tolerances:

All joints to be finished flush and with a maximum gap < 0.5mm. Door to finish square.

Finishes:

Mouldings to be free from defects. NO FILLER TO BE USED IN ANY JOINTS

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SAFE WORK METHOD STATEMENT FORM

Insert name of Collegeè / TAFE – Off Site Construction / REPRESENTATIVE RESPONSIBLE FOR PREPARATION OF THE SAFE
WORK METHOD STATEMENT AND THE DATE SIGNED
Signature______Date ______/______/______
*Eg. Supervisor
Description of the work to be undertakenè / Joinery Shop Work – Door practical exercise / Work Site / Office è
Step by step sequence involved in doing the work ê (attach additional page if more room is needed to list steps) / Risk and rating for each step ê

Safety / Environmental Risk Rating

/ Safety Controls that will be in place to minimise these hazards/risks ê NOTE. Mandatory personal protective equipment including UV protective clothing, boots and helmets are not included in the following Controls but are required on all sites in accordance with DPWS policy.
JOB SPECIFIC REQUIREMENTS
List all Codes of Practice, Legislation, Standards applicable to the work and details of where these are kept è / Material Safety Data Sheets located on site. Code of Practice: Electrical Practices for Construction Work at Properties & Environment Unit. NSW Hazardous Substances Regulations, NSW Manual Handling Regulations, OHS Act 2000 with Manager OHS

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RISK ASSESSMENT

RISK / AFFECT / RISK CLASS RATING /

ACTION REQUIRED

The hazard has the potential to kill or permanently disable you / High Risk / 1 / SWMS must be completed
The hazard has the potential to cause you serious injury or illness that will temporarily disable you / Medium Risk / 2 / SWMS must be completed
The hazard has the potential to cause a minor injury that will not disable you / Low Risk / 3 / A SWMS is not required – however – action must be taken to minimise the risk as far as possible

Please identify the risk involved and place the rating number in the “Rating” Column on page 1. The numbers show you how important it is to do something.

Environmental risks are to be listed on page 1 but a rating is not required for these risks.

Provide a description of what training is given to people involved with the work / Site Induction, Instruction on wearing of Personal Protective Equipment, MSDS controls and recommendations, manual handling training
List the names and qualifications of those responsible for training them / Team leader / Supervisor – Line supervisor training, manual handling training
Identify the plant and equipment that will most likely be used on site eg. ladders, scaffolds, grinders, electrical leads, welding machines, fire extinguishers, manual handling aids ê / List the details of the inspection and maintenance checks that will be or have been carried out on the plant and equipment ê / Signatures of staff who have read and understand the work activities described in the Safe Work Method Statement ê
Electrical plant, leads and ELCBs / Currently tested and tagged. Visual inspection prior to use.
Fire extinguisher / Annual inspection

List the names of person(s) responsible for supervising/inspecting work ê

Person(s) responsible for site supervision of the work, inspecting and approving work areas, compliance with SWMS, protective measures, plant, equipment and power tools
Name:______Position:______Signature:

OBSERVATION CHECKLIST

Candidate’s Name:
Unit / Module:
Date:
Expected
Performance / Critical
Aspects / Actual
Perf / Questions / Appropriate
Response / Actual
Response / Comments
Yes / No / Yes / No
BCF2016A Prepare for off-site manufacturing process
BCG1004A
Carry out measurements and calculations
BCG1002A
Plan and organise work
BCG1005A
Use hand and power tools
BCG1006A
Use small plant and equipment
BCG1011A
Handle Construction materials and safely dispose of waste
BCF2001A
Use static machines
BCF2012A
Package manufactured products for transport
BCF2013A Assemble components / Identify preparation requirements from drawings or instructions
Drawings are to accurate?
Drawings are orthographic representations with details?
Drawings are to an acceptable trade standard?
Carry out material preparation in accordance to job requirements.
Complete cutting list
Identify safety hazards and procedures to adopt, which will minimise risk to self and others.
Job Plan is complete and includes all necessary steps
demonstrate safe and effective operational use of tools and equipment
demonstrate safe and effective operational use of tools, plant and equipment
carry out correct procedures prior to and during application of materials handling processes and demonstrate safe application in the process of cleaning up
demonstrate correct techniques with safe and effective operational use of machine
demonstrate safe and effective application of packaging process to product
Assemble the joints to quality assurance guidelines using correct tools and processes / Why did you prepare a cutting list?
What other type of drawing could have been made
What tool did you use to dress the timber and why that particular tool?
What are the main risks associated with this practical task that you identified when filling out your SWMS and how did you plan to reduce the risk?
What other type of job planning tool could you have used?
How do you know when cutters are blunt on machines
When routing end grain how to you prevent splitting out of solid material
What regular checks should be made of air compressors, lines and hoses
What type of filter is recommended for hand operated industrial vacuum cleaners and why?
How do you dispose of timber based waste products?
How can you prevent Kickback on a table saw
What safety procedures should be adopted when using a pin router
What alternative packing materials are available
Once packaged what should be done to identify the package
What should be done to protect materials during assembly?
When assembly frames what checks should be made? / To verify sizes.
So I didn’t have to keep looking at the drawing.
So that someone else could finish the job if I couldn’t
Isometric
I used a smoothing plane because the timber was not long enough to use a jack plane and the timber was already close to the size.
The main risk is from cuts from chisels and saws. Clamping the material down will minimize the risks as well as using sharp tools.
Gantt Chart
Bar chart
Critical path analysis
Microsoft project
Other
Hard to push material through
Burn marks appear on material
Excess chipping
Use a backing block
Drain moisture
Check oil lubricators
Check hoses for splits
Check regulator pressure
P2 filter
traps fine dust particles
offcuts and chips can be recycled
Fine dust - sealed bag in an commercial skip bin.
Other
Riving knife
Finger board
PPE
Fences stops
Sharp cutters
Staged waste removal
(2 passes)
Bubble wrap
Corrugated paper
Blankets
Other
Contents Labeled or
Addressed
Use clamping blocks
Keep from contacting clamps directly
Square
Twist ( wind)
Size
Joints flush
Excess adhesive removed
Other

Self assessment form: