Lesson 1Thermal and fire hazards: welding sparks, hot work, flammable coatings and solventsThis section explores thermal and fire hazards in hot work and coating areas. Learners will assess welding sparks, hot surfaces, and flammable coatings, and apply controls including permits, fire watches, housekeeping, and segregation of ignition sources and fuels.
Hot work task and area assessmentControl of sparks and hot slag travelFlammable liquids and coating storageHot work permits and fire watch rolesExtinguishers, alarms, and escape pathsLesson 2Ergonomic and manual handling hazards: repetitive tasks, heavy lifting, awkward postures, tool designThis section addresses ergonomic and manual handling hazards in work areas. Learners will analyze repetitive tasks, heavy or awkward loads, workstation layout, tool design, and methods such as mechanical aids, job rotation, and safe lifting techniques to reduce strain.
Task analysis for repetitive motionsAssessing load weight, size, and gripSafe lifting and team handling methodsWorkstation layout and reach zonesTool handle design and vibration controlLesson 3Physical hazards: noise, vibration, poor lighting, compressed air, ionizing/non-ionizing radiation considerationsThis section covers physical hazards such as noise, vibration, lighting, compressed air, and radiation. Learners will link measurement results to risk levels and apply controls including engineering changes, PPE, signage, and restricted access zones.
Noise mapping and hearing risk areasHand–arm and whole-body vibrationLighting levels and glare assessmentSafe use of compressed air toolsIonizing and non-ionizing radiation zonesLesson 4Vehicle and mobile equipment hazards: forklift interactions, loading/unloading procedures, traffic managementThis section covers hazards from vehicles and mobile equipment in work areas. Learners will examine forklift and truck movements, loading and unloading zones, traffic flow, and controls such as signage, spotters, and exclusion zones to prevent collisions.
Forklift routes and pedestrian walkwaysLoading dock and bay interface risksSpotter use and communication signalsTraffic signage, mirrors, and speed limitsParking, staging, and blind corner controlsLesson 5Chemical hazards: metal fumes, paint solvents, isocyanates, cleaning agents and SDS interpretationThis section focuses on chemical hazards in production and maintenance areas. Learners will review metal fumes, solvents, isocyanates, and cleaners, interpret Safety Data Sheets, and link exposure routes to controls such as ventilation, PPE, and safe storage.
Identifying hazardous chemicals on siteExposure routes and health effectsReading key SDS sections for tasksVentilation, LEV, and enclosure useLabeling, storage, and segregationLesson 6Psychosocial and organizational hazards: fatigue from shift work, communication gaps between shifts, workload pressureThis section examines psychosocial and organizational hazards by work area. Learners will consider shift patterns, communication gaps, workload, and role clarity, and identify reporting channels, consultation methods, and practical improvements to reduce stress and fatigue.
Shift patterns and fatigue indicatorsWorkload, pace, and staffing levelsCommunication between shifts and teamsRole clarity, supervision, and supportReporting stress and seeking assistanceLesson 7Slip, trip and fall hazards and yard-specific risks: uneven surfaces, loading/unloading, weather effectsThis section addresses slip, trip, and fall hazards in yards and outdoor areas. Learners will assess surfaces, gradients, weather effects, and loading zones, and apply controls such as drainage, housekeeping, gritting, and designated pedestrian routes.
Surface condition and gradient checksHousekeeping in loading and laydown areasWeather, ice, and drainage controlsPedestrian routes and crossing pointsInspection routines and defect loggingLesson 8Mechanical hazards: cutting, shearing, entanglement, pinch-points for guillotines and grindersThis section examines mechanical hazards from powered machinery and tools. Learners will identify cutting, shearing, entanglement, and pinch points on guillotines, grinders, and conveyors, and review guarding, lockout, and inspection practices to prevent contact injuries.
Identifying cutting and shearing pointsRotating parts and entanglement risksPinch points on presses and conveyorsFixed and interlocked guard selectionPre-use checks and defect reporting
