Lesson 1Vehicle and mobile plant hazards: forklifts and overhead cranesThis section analyses hazards from forklifts, overhead cranes, and other mobile plant, focusing on traffic management, operator competence, signalling, load security, and shared-space rules to prevent collisions, crush injuries, and dropped loads.
Traffic flow planning and exclusion zonesForklift stability, loads, and blind spotsOverhead crane pre-use checks and slingingPedestrian routes, crossings, and spottersParking, battery charging, and refueling areasLesson 2Chemical hazards: solvents, paint fumes, welding gases, metal dustThis section explains chemical hazards from solvents, paints, welding fumes, and metal dust, focusing on exposure routes, health effects, monitoring, and layered controls such as substitution, ventilation, safe storage, and appropriate PPE selection and use.
Solvent and paint components and exposure routesHealth effects of welding fumes and shielding gasesMetal dust generation, inhalation, and ingestion risksEngineering controls and local exhaust ventilationSafe storage, labeling, and PPE for chemicalsLesson 3Noise and vibration sources and effects in workshopsThis section discusses noise and vibration sources in workshops, their health effects, exposure assessment, and control strategies, including engineering solutions, maintenance, administrative limits, and correct selection and use of hearing protection devices.
Main workshop noise and vibration sourcesHearing loss, fatigue, and other health impactsNoise surveys, dosimetry, and exposure limitsEngineering and administrative noise controlsHearing protection selection, fit, and careLesson 4Ergonomic hazards and manual handling during assembly and material storageThis section examines ergonomic and manual handling risks during assembly and material storage, including lifting, pushing, awkward postures, and repetitive tasks, and presents methods for redesign, mechanical aids, and training to prevent musculoskeletal injuries.
Task analysis for lifting and carrying activitiesUse of hoists, jacks, and mechanical handling aidsLayout design to reduce bending and reachingSafe storage heights and rack organizationTraining on body mechanics and team liftingLesson 5Electrical hazards: fixed machines, portable tools, temporary wiringThis section covers electrical hazards from fixed machines, portable tools, and temporary wiring, emphasising shock, arc, and fire risks, lockout procedures, inspection routines, earthing, and coordination with qualified electricians for installation and repairs.
Electrical shock, arc flash, and burn mechanismsInspection of cords, plugs, and portable toolsLockout tagout for maintenance and cleaningSafe use of temporary power and extension leadsGrounding, bonding, and residual current devicesLesson 6Thermal and fire hazards: hot work, sparks, flammable liquids and vapoursThis section addresses thermal and fire hazards from hot work, sparks, and flammable liquids or vapours, detailing ignition sources, fuel controls, hot work permits, fire watch duties, housekeeping, and emergency response planning for workshop operations.
Ignition sources in cutting, welding, and grindingControl of flammable liquids, gases, and vaporsHot work permits and pre-job area checksFire watch roles, equipment, and responseHousekeeping and segregation to limit fire spreadLesson 7Common physical hazards: sharp edges, moving parts, pinch points, falling objectsThis section reviews common physical hazards such as sharp edges, moving parts, pinch points, and falling objects, explaining typical incident scenarios and practical controls including guarding, barriers, signage, and safe handling and stacking of materials.
Sharp edges, burrs, and sheet metal handlingMachine guarding and access to moving partsPinch points in presses, rollers, and clampsControls for falling objects and dropped toolsSignage, barriers, and safe walkwaysLesson 8Workforce factors: shift work, mixed experience levels, contractors and temporary staffThis section explores how workforce composition and organisation influence risk, covering shift work fatigue, differing experience levels, language barriers, and the integration of contractors and temporary staff into site rules, supervision, and safety culture.
Shift patterns, fatigue, and error likelihoodManaging mixed skill and experience levelsOnboarding and supervision of contractorsTemporary staff induction and task assignmentCommunication, language, and safety cultureLesson 9Overview of metal fabrication processes: cutting, grinding, welding, painting, assemblyThis section outlines main metal fabrication processes and their risk profiles, showing how cutting, grinding, welding, painting, and assembly steps interact, where hazards arise, and how planning, layout, and standardised procedures reduce incidents and rework.
Typical workflow from raw stock to finished productCutting and grinding methods and related hazardsWelding and thermal cutting process risk overviewPainting, coating, and curing process safetySafe assembly, fit-up, and in-process inspections
