Professional Documents
Culture Documents
Carpentry and
JoineryOperations
16
1
Introduction
Did you know that hanging a door is one of the most common tasks that carpenters do
in the construction industry? Doors have a variety of functions: they provide security and
privacy, as well as excluding drafts and making buildings weatherproof.
In this unit, you will build on the skills and knowledge you gained in Unit 6: Exploring
Carpentry and Joinery Principles and Techniques. You should have already completed
Unit 6 before starting this unit.
You will learn about health and safety legislation requirements in carpentry and joinery,
which relate to employers and employees in the construction industry.
You will have to produce a setting-out rod for a door. You will also need to use this
setting-out rod to mark out and then make a door. You will then hang this door on a door
frame. Finally, you will have to fit a mortise lock that will allow the door to belocked.
Assessment: This unit will be assessed through a series of practical assignments that will be
set and marked byyour teacher/tutor.
Learning aims
In this unit you will:
A explore health and safety regulations and legislation requirements in performing
carpentry and joinery tasks
B demonstrate practical skills and safe working techniques to carry out joinery tasks
C demonstrate practical skills and safe working techniques to carry out carpentry tasks.
BTEC
Assessment Zone
Assessment criteria
Level 1
Level 2 Pass
Level 2 Merit
Level 2 Distinction
Learning aim A: Explore health and safety regulations and legislation requirements in performing carpentry and joinery tasks
1A.1
1A.1
2A.P1 Maths
English
2A.P1
2A.M1 Maths
English
2A.M1
2A.D1 Maths
English
2A.D1
Learning aim B: Demonstrate practical skills and safe working techniques to carry out joinery tasks
1B.2
1B.2
2B.P2 English
Maths
2B.P2
2B.M2 English
Maths
2B.M2
1B.3
1B.3
Maths
English
2B.P3 English
Maths
2B.P3
2B.M3 English
Maths
2B.M3
2B.D2 English
Maths
2B.D2
1B.4
1B.4
2B.P4 English
Maths
2B.P4
2B.M4 English
Maths
2B.M4
2B.D3 English
Maths
2B.D3
Maths
English
Maths
English
Assessment criteria
Level 2 Pass
Level 1
Level 2 Merit
Level 2 Distinction
Learning aim C: Demonstrate practical skills and safe working techniques to carry out carpentry tasks
1C.5
1C.5
2C.P5 English
Maths
2C.P5
2C.M5 English
Maths
2C.M5
1C.6
1C.6
2C.P6 English
Maths
2C.P6
2C.M6 English
Maths
2C.M6
2C.D4 English
Maths
2C.D4
1C.7
1C.7
2C.P7 English
Maths
2C.P7
2C.M7 English
Maths
2C.M7
2C.D5 English
Maths
2C.D5
Maths
English
Maths
English
Maths
English
English
Maths
make a door
mark out and fit a pair of steel hinges
mark out and fit a mortise deadlock.
Make sure that you meet the assessment deadlines in order to get useful feedback from your
assessor. The unit specification will give you extra guidance about the evidence requirements for
each grading criterion.
Learning aim A
TOPIC
A.1
Remember
These regulations mean that
both employers and employees
have responsibility to make the
workplace safe.
Employers duties
Under HASAWA, employers must fulfil certain duties to ensure the safety and wellbeing
of their employees. Table 16.1 lists these duties and gives compliance examples.
Key terms
Legislation laws passed by
central government.
Compliance following rules or
standards.
Operative a hands-on worker
on a construction site, for
example, a carpenter or tiler.
Duty
Example of compliance
UNIT 16
Employees duties
As an employee, you also have certain responsibilities under this Act. You must make
sure that you work responsibly and behave safely on a construction site. Table 16.2 lists
these duties.
Table 16.2 Employees duties under HASAWA
Duty
Compliance
Activity 16.1
In groups, discuss why it is important that both employers and employees have
responsibilities for health and safety in the workplace.
Employer duties
The WAH Regulations clearly state that working at height should be avoided unless
there is no alternative. No work at height should be undertaken unless it has been
properly planned and the risks assessed. The area where work at height is to take
place must be safe.
Working at height is often affected by weather conditions, and any work should take
account of this. For example, windy weather may make working conditions dangerous,
and work may have to be stopped.
7
TOPIC
A.1
Activity 16.2
You are working in a carpentry company that frequently needs its employees to
work at height. What precautions can you take personally? What control measures
can the carpentry company take?
Employee duties
Employees also have duties under the WAH Regulations. They must report any safety
hazards and stop if they think it is unsafe to work. They must also follow any training
or instructions. They should use any safety equipment according to the training and
instructions they have been given.
Key terms
Toolbox talk a talk given
on a construction site by a
competent person about a
particular aspect of health and
safety.
Method statement a written
document stating how to do a
task in a safe manner.
Contractor duties
Under these Regulations, an employer is called a contractor. This is because it is
contractors that undertake the work on site. Table 16.3 on page 9 lists the duties of
contractors.
Employee duties
Employees must cooperate with their employer so that their employer can comply with
the CDM Regulations. For instance, they should take part in any toolbox talks on the
site, obey site rules and set a good example as a competent carpenter or joiner.
UNIT 16
Duty
Compliance
TOPIC
A.1
Key terms
Inhalation when a substance
enters the body via breathing.
Absorption when a substance
enters the body through the
skin.
Ingestion when a substance
enters the body through the
mouth.
timber preservatives
varnish
wood dust
glues.
Employer duties
Table 16.4 lists the duties of an employer on a construction site and gives an example
of how each duty is met.
Table 16.4 Employer duties under COSHH
10
Duty
Compliance
UNIT 16
Employee duties
The COSHH Regulations also contain duties that an employee must fulfil when
handling substances that may cause harm. Table 16.5 lists these duties, and gives
suggestions about how to comply with them.
Duty
Compliance
Just checking
1 Why do we need health and safety legislation?
2 What is the difference between a hazard and a risk?
11
TOPIC
A.1
Key term
The Provision and Use of Work Equipment Regulations 1998 (PUWER) require that
all work equipment must be inspected, maintained and tested to keep it at a safe
standard, and that it is suitable for its intended purpose. Operatives must be trained
so that they are competent to use the equipment safely.
English
Tip
Do not just list an employers requirements explain why these requirements are needed.
TOPICS
B.1
C.1
Setting-out tools
When producing your door, you will use the same setting-out tools covered in Unit 6
(pages 15051). Now you are going to think about when and how you might use these
in your practical activity.
Key term
Activity 16.3
You are working at a construction site which is a two-hour drive from the carpentry
firm. You will be removing and fitting a new door. Produce a requisition list of all
the tools and materials you will need on the job.
12
UNIT 16
Jack plane
This is used for planing longer lengths of timber, or possibly the edge of a door. It is
different from a smoothing plane, because the base is longer.
Discussion
Think about the different effects
produced by a smoothing plane
and a jack plane when planing
timber.
Cordless drill
Cordless drills are powered by a battery instead of plugging them into the mains.
Cordless drills are used to drill holes as well as to drive in or take out screws.
Most cordless drills are in the range of 10V to 24V. The voltage of a battery is the amount
of power available. Batteries also have amperage measured in ampere hours (Ah). A
higher number of ampere hours means the battery holds more charge and will run for
longer.
Remember
Have a spare charged battery
to hand. This means that if
the battery you are using runs
down, you do not have to wait
for it to charge before you can
continue.
Torque is the amount of turning force the drill will use. You can adjust the torque to suit
the job you are doing. For example, you can set the torque so a woodscrew is driven into
timber at the correct depth. If the torque is set too high, the screwdriver bit could break.
When drilling holes in timber, a small drill bit needs a fast speed to cut the timber.
Alarge drill bit requires a slower speed setting.
You will use twist drills to drill holes to take the woodscrews when you fit a hinge.
Drilling a row of larger holes in a line is also a good way to start when you are cutting
out a mortise for a lock.
There is a huge range of woodscrews available. There are screwdriver bits made to fit
every type of woodscrew. Some common examples are slotted, Phillips and Pozidriv
screwdriver bits.
Materials
Softwoods
Softwoods are usually used in areas that will remain unseen or unfinished. Most
softwoods that are seen have to be painted, varnished or stained. As a general rule,
softwoods are better value and more sustainable than hardwoods.
Link
For more on sustainability,
see Unit 11: Sustainability in
Construction.
13
TOPICS
B.1
C.1
Just checking
1 Can the torque on
a cordless drill be
adjusted?
2 Name a hardwood and
a softwood. Describe
a use for each type of
wood.
Softwoods include:
Pine this is a straw-coloured timber, which is relatively cheap compared with other
timbers.
Cedar this has a reddish-brown wood grain. It has good natural resistance to rot
and insects. For this reason, it is popular for use outdoors.
Hardwoods
Hardwoods look much more appealing than softwoods but can be expensive. They
are also scarcer and less sustainable than softwoods. This is because the trees that
produce hardwoods grow more slowly than trees that produce softwoods, and so it
takes longer to replenish hardwood forests.
Hardwoods include:
Ash this is pale and has many uses, including panelling and ooring. It is often
used for tool handles.
Oak this is long-lasting and very tough, but it is also expensive and can be difficult
to work with. It can split when nailed.
Machined softwood
Key terms
Tongue and groove the
tongue slots into the groove of
another board, forming a joint.
Escutcheon plate this is the
small plate that covers the
keyhole on both sides of the door.
You have already looked at some manufactured boards in Unit 6 (pages 1545).
Machined softwoods are also a useful way of covering large areas. These types of
boards include tongue and groove and vee-jointed board (TGV), which are also called
matchboard. The vee joint makes a visual feature of the joint.
Woodscrews
You may use Pozidriv, Phillips or slotted screws in your practical task, although
slotted screws are not used very often these days.
Pozidriv screws come in varying sizes. The length can vary from 12 mm to 150 mm,
while the gauge (the diameter of the screws shank) can vary from 2 mm to 6.5 mm.
Door furniture
In your practical task, you will use the following door furniture:
A mortise deadlock this is a simple lock that fits into a mortise in a door.
A keyhole escutcheon plate this is the small plate that covers the keyhole on both
sides of the door.
Steel butt hinges these are used to hang the door on the door frame.
Activity 16.4
List all the door furniture on a door in your workshop. Calculate the cost of all
these from a building supplier.
Link
For more about abrasive
papers, see Unit 8: Exploring
Painting and Decorating
Principles and Techniques.
14
Abrasive papers
You are likely to use the same sorts of abrasive papers as you used in Unit 6. Seepage
157 of the student book for information about abrasive papers.
TOPICS
B.2
UNIT 16
C.2
Activity 16.5
When using a cordless drill to fix plywood to a timber-framed wall in a building,
you may be using the drill all day.
1 What are the hazards and risks involved?
2 What can you do to avoid or reduce the risks?
TOPIC
B.3
TOPIC
B.3
The pilot and clearance holes take the main part of the screw. The pilot hole is smaller
than the clearance hole because of the tapered shape of the screw. The pilot hole is
drilled first, then the clearance hole. These holes need to be drilled with the correct
size of twist drill bit.
The countersink takes the head of the screw so that it sits below the surface of the
timber. This can then be filled. The countersink is drilled using a countersink bit.
Setting-out rods
You learned about setting-out rods in Unit 6 (page 163). You now have to measure,
mark out and produce a setting-out rod to make your own door.
Discussion
What is the advantage of using a
setting-out rod?
Remember that your door will only be as accurate as your setting-out rod, so your rod
should be as close as possible to the door specification.
Marking off, also known as taking off, is when you transfer the measurements of the
door onto your timber. It is covered in Unit 6 (page 163).
Maths
Measure, mark out and produce a setting-out rod for a timber door.
Tips
The ner your tolerances, the better your setting-out rod will be. Any inaccuracy in the setting-out rod will affect
the dimensions of your nished door.
Key terms
Tenon this is a projecting
piece of wood made to slot into
a corresponding hole (mortise)
in another piece of wood.
Rail the horizontal parts of the
frame of a door.
Haunch when one side of a
tenon is cut away, the remaining
part of the cut-away side is
called the haunch.
16
UNIT 16
Finishing techniques
Link
You will need to use a smoothing plane to remove any uneven surfaces on the frame.
You will then give the door a final sanding.
Link
Maths
Measure, mark out and produce a timber door with joints to the specification given
to you by your teacher/tutor. The joint gaps should not exceed 3 mm and the
overall dimensions should be within 3 mm.
Tips
Your nished door should have a smooth surface. Practise using different kinds of abrasive papers to see which gives
the best nish.
You must comply with safe working practices, so look back at Unit 6 to refresh your knowledge of safe working
practices before beginning your practical task.
To achieve a Merit, your door must:
TOPIC
C.3
Written information
Location drawing
This is a oor plan of a building that identifies the position of each door and the
direction in which it opens. Each door in the building has a reference number that links
to the door schedule.
Link
For more information about
different kinds of drawings, see
Unit 5: Construction Drawing
Techniques.
17
TOPIC
C.3
Door schedule
The door schedule contains all the information about every door in the building. This
includes the type of door, the hinges and any door furniture or signs.
Maths
You are a junior carpenter working on a new housing development. Your supervisor
has asked you to select the resources that you will need to hang a timber door and
fit a mortise deadlock.
Tip
To push yourself further, you should discuss the resources you need rather than just listing them. Discuss means that
you will select the necessary resources, and then consider the advantages and disadvantages of the tools, equipment
and furniture you have selected.
A typical door is hung on two or three hinges, depending on the weight of the door.
Doors are hung within a door frame, which contains the doorstop or rebate that the
door closes onto.
You need to mark out carefully using a pencil and a tri-square, then cut timber from
the frame and door so that the hinge plates will sit ush with the surface of the timber.
Hinges are commonly made from steel and are secured with eight screws each.
When hanging a standard door with two hinges:
the top hinge should be 150 mm from the top of the door
the bottom hinge should be 225 mm from the bottom of the door.
Maths
As before, you are a junior carpenter working on a new housing development. Your
supervisor has asked you to demonstrate your skills by measuring, marking out and
fitting a pair of steel butt hinges to a timber door and frame.
The hinges must be positioned as specified and must not bind (discussed on page
19). The gaps around the hinge plates should be as small as possible and not
exceed 3 mm.
Tips
A 23 mm gap between the door and frame allows the door to close on the frame, and also gives enough clearance
for coats of paint on the door and door frame.
You must comply with safe working practices, so look back at Unit 6 to refresh your knowledge of safe working
practices before beginning your practical task.
To achieve a Merit, you need to make sure:
18
UNIT 16
Key term
Foreplate the face of the lock
that is visible on the edge of
the door.
Binding
A door is said to be binding when the door does not shut because there is something
wrong on the hinge side of the door. There are different reasons a door may be
binding, as Table 16.6 shows.
Table 16.6 Causes and solutions to doors binding
Reasons
How to rectify
TOPIC
C.3
Torque settings
You can adjust torque settings according to the task you need to do. Small screws
require a lower torque setting than larger screws. It is important to choose the correct
torque setting, as this will help the drill last longer. It also reduces the risk of slipping,
or the screw or screwdriver bit breaking.
For more about torque, see page 13.
Key term
Keep a metal plate with
an attached metal box that
receives the mortise lock bolt,
and locks the door.
Maths
Measure, mark out and fit a mortise deadlock to your timber door and its frame, and
make sure it works. Around the foreplate and keep, the gaps should be as small as
possible and not exceed 3 mm, and the lock keep should be correctly positioned.
Tips
Make sure that you work safely at all times by following the safe practices covered in Unit 6.
Practise your chiselling technique to make sure that you can produce a neat mortise before starting your practical
task. It is good idea to practise cutting in the keep on a scrap piece of timber rst.
To achieve a Merit, you need to:
20
UNIT 16
WorkSpace
Will Jackson
Apprentice carpenter
Im working as an apprentice carpenter for a
local carpentry firm. The work is very varied
and we fit doors, windows, fences and gates.
Recently, we even built a greenhouse.
My day starts with loading the van in the
morning with tools and materials. We then go
to the house that requires the work. The first
thing I do when I get to the house is lay out
the dust sheet in the work area. Next I check
all the doors to be replaced and the new
doors to be fitted to see that they are all the
correct sizes. I take off all the old doors that
will be replaced and put them outside the house.
At the moment, Im assisting a more experienced
carpenter who is fitting new interior doors. I help cut
out for the hinges on the doors and door frames.
My future plans are to complete my
apprenticeship, and my employer says Ill
get a pay rise when I do that. I hope
to have my own company one day,
when Im older and have got
enough experience.
Think about it
1 Why is punctuality important in Wills
working day?
2 What have you learned in this unit that
would help you to do Wills job?
3 When accepting a delivery of doors
from a door manufacturing company,
Will notices that one of the doors is
damaged. What should he do?
21
Glossary
A
E
Escutcheon plate this is the small plate that covers the
keyhole on both sides of the door.
O
Operative a hands-on worker on a construction site, for
example, a carpenter or tiler.
F
Flush at the same level. For example, the hinge plate will
be recessed to sit level with the surface of the timber.
Foreplate the face of the lock that is visible on the edge
of the door.
H
Haunch when one side of a tenon is cut away, the
remaining part of the cut-away side is called the haunch.
I
Ingestion when a substance enters the body through the
mouth.
Inhalation when a substance enters the body via
breathing.
22
R
Rail the horizontal parts of the frame of a door.
Requisition list a list of everything needed to complete a
task, including all tools, materials and equipment.
T
Tenon this is a projecting piece of wood made to slot
into a corresponding hole (mortise) in another piece of
wood.
Tongue and groove the tongue slots into the groove of
another board, forming a joint.
Toolbox talk a talk given on a construction site by a
competent person about a particular aspect of health
and safety.
Index
A
abrasive papers 14
access equipment 6, 7, 8
apprentice case study 21
ash 14
assessment
activities 12, 16, 17, 18, 20
criteria 34
methods 2, 5
B
bare-faced tenon 16
binding, rectifying door 19
brace, positioning 17
C
carpentry
apprentice case study 21
techniques 1721
written information 1718
cedar 14
chemical hazards 10
chisel work 19
clearance hole 15, 16
Construction (Design and Management) Regulations
(2007) 89
compliance examples 9
contractor duties 8, 9
employee duties 8
control measures
COSHH 10, 11
work at height 8
Control of Noise at Work Regulations (2005) 11
cordless drill 13, 15
bits 13
safety 15, 20
speed of 20
torque settings 20
COSHH (Control of Substances Hazardous to Health)
Regulations (2002) 1011
employee duties 11
employer duties 10
countersinking 15, 16
D
door
causes of binding 19
hanging 2, 18
hinges 18
setting-out rods 2, 16
trap/block 13
door frame
assembling 16
finishing 17
door furniture 14
door schedule 17, 18
drill see cordless drill
drill bits 13
E
ear defenders 11
equipment
health and safety 6, 7, 8
PUWER 12
escutcheon plate 14
F
foreplate 19, 20
H
hand tools 13
handling heavy loads 9
haunch 16
health and safety 612
legislation 612
policy 6
risk assessments 6, 7, 9, 10, 11, 15
Health and Safety at Work etc. Act (1974) 67
compliance examples 6, 7
employee duties 7
employer duties 6
method statements 6, 8, 9
health surveillance 10, 11
hearing protection 11
hinges, steel butt 14
fitting 18
J
jack plane 13
joinery techniques 1517
23
Index
K
keep 20
L
legislation, health and safety 612
lifting heavy loads 9
location drawing 17
M
machined softwood 14
Manual Handling Operations Regulations (1992) 9
marking off 16
matchboard 14
materials 1314
hardwoods 14
softwoods 1314
method statements 6, 8, 9
mobile elevated platforms 8
mortise deadlock 14
fitting 17, 19
mortise and tenon 16
N
netting, safety 8
O
oak 14
P
Phillips screws 13, 14
pilot hole 15, 16
pine 14
Pozidriv screws 13, 14
PPE (Personal Protective Equipment) 6, 7, 10
noise protection 11
using drills 15
preparing wood for screws 1516
Provision and Use of Work Equipment Regulations
(1998) 12
R
rail 16
rebate 16, 18
regulations, safety 612
reporting hazards 7, 8, 11
requisition list 12
resources 1215
risk assessments 6, 15
COSHH 10
24
manual handling 9
noise 11
working at height 7
S
scaffolding safety 6, 8
screwdriver bits 13
setting-out rods 2, 12, 16
slotted screws 13, 14
removing stuck 14
smoothing plane 17
softwoods 1314
machined 14
steel butt hinges 14
fitting 18
stepped mortise and tenon 16
sustainability of timber 2, 13
T
taking off 16
techniques
carpentry 1721
joinery 1517
timber 2, 1314
tongue and groove board 14
toolbox talks 8
tools and equipment 1215, 20
torque 13, 15, 20
toxic substances 1011
training
COSHH 10, 11
safety 7, 8, 9
V
vee-jointed board 14
W
weather conditions and work at height 7
welfare facilities 6, 9
wood glues 16
COSHH requirements 10
wood, types of 1314
woodscrews 13
correct bit 20
preparing wood for 1516
types 14
Work at Height Regulations (2005) 78
employee duties 8
employer duties 78
Acknowledgements
The publisher would like to thank the following for their kind permission to reproduce their
photographs:
(Key: b-bottom; c-centre; l-left; r-right; t-top)
Pearson Education Ltd: Jules Selmes (19); Gareth Boden (18); David Sanderson (9, 11).
Photos.com: Mark Bowden (4); Jacek Chabraszewski (2); dzmitri mikhaitsow (21).
Shutterstock.com: Ecelop (10). Veer/Corbis: naumoid (5); Irina Tischenko (3); 350jb (Banner).
All other images Pearson Education
Picture Research by: Caitlin Swain
Every effort has been made to trace the copyright holders and we apologise in advance for any
unintentional omissions. We would be pleased to insert the appropriate acknowledgement in any
subsequent edition of this publication.
25
Published by Pearson Education Limited, Edinburgh Gate, Harlow, Essex, CM20 2JE.
www.pearsonschoolsandfecolleges.co.uk
Text Pearson Education Limited 2013.
Typeset by Phoenix Photosetting, Chatham, Kent, UK
Original illustrations Pearson Education Limited 2013
Illustrated by Phoenix Photosetting
Picture research by Caitlin Swain
Indexing by Torquil Harkness
The right of John Murray-Smith to be identified as author of this work has been asserted by him in
accordance with the Copyright, Designs and Patents Act 1988.
Unit 16 first published 2013.
17 16 15 14 13
10 9 8 7 6 5 4 3 2 1
British Library Cataloguing in Publication Data
A catalogue record for this book is available from the British Library
ISBN 978 1 446906 46 0
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26