Lesson 1Mechanical hazards: rotating equipment, conveyors, forklifts, pallet storageThis part covers mechanical dangers from rotating machines, conveyors, forklifts, and pallet storage. Learners will find pinch, crush, and struck-by spots, and check guarding, traffic rules, and inspections to avoid serious injuries.
Rotating equipment pinch and entanglement pointsConveyor nip points, guards, and emergency stopsForklift traffic patterns and pedestrian separationPallet stacking, racking stability, and collapse risksPre-use inspections and reporting mechanical defectsLesson 2Environmental and exposure limits: TLVs, PELs, short-term exposureThis part introduces exposure limits like TLVs and PELs for welding fumes, solvents, and dusts. Learners will compare how long exposures last, understand short-term and ceiling limits, and connect monitoring data to ventilation, PPE, and work practices.
Difference between TLVs, PELs, and company limitsShort-term exposure limits and ceiling valuesReading air monitoring and sampling resultsLinking exposure data to ventilation controlsAdjusting tasks and PPE to stay below limitsLesson 3Recognizing early indicators: near-misses, symptoms of exposure, unsafe actsThis part focuses on spotting early signs of hazards, including near-misses, small injuries, exposure symptoms, and unsafe actions. Learners will practice reporting, reviewing trends, and using findings to fix conditions before big incidents happen.
Identifying and documenting near-miss eventsEarly symptoms of chemical or fume exposureObserving unsafe acts and at-risk shortcutsUsing checklists and simple observation toursTurning early indicators into corrective actionsLesson 4Chemical hazards: welding fumes, solvent paints, isocyanates, dustThis part reviews chemical dangers from welding fumes, solvent-based paints, isocyanates, and nuisance or toxic dusts. Learners will link SDS data to exposure routes, symptoms, and controls like ventilation, PPE, and substitution.
Key hazards in welding fumes and metal oxidesSolvent paint vapors and overexposure symptomsIsocyanate sensitization and asthma concernsDust from grinding, blasting, and surface prepUsing SDSs to identify controls and PPE needsLesson 5Fire and explosion risks: flammable liquids, combustible dust, hot workThis part looks at fire and explosion risks from flammable liquids, combustible dust, and hot work. Learners will spot ignition sources, review storage and ventilation rules, and apply hot work permits, housekeeping, and bonding and grounding practices.
Flammable liquid storage, transfer, and labelingCombustible metal and paint dust accumulationHot work permits for welding and cutting tasksIgnition sources from tools, sparks, and smokingVentilation and housekeeping to reduce fuel loadLesson 6Understanding the facility layout: production, paint booth, warehouseThis part teaches how to read the facility layout to find hazards in production, paint booths, and warehouses. Learners will map workflows, traffic routes, and emergency paths to spot congestion, blind spots, and incompatible activities or materials.
Reading plant floor plans and process flow mapsHazards in cutting, forming, and welding zonesPaint booth airflow, mixing rooms, and exitsWarehouse racking, aisles, and staging areasTraffic routes for forklifts, carts, and pedestriansLesson 7Ergonomic hazards: manual material handling, repetitive tasks, awkward posturesThis part deals with ergonomic hazards from lifting steel, handling parts, and repetitive painting or grinding. Learners will spot awkward postures, forceful exertions, and repetition, and look at redesign, mechanical aids, and job rotation to cut strain injuries.
Manual lifting of plate, bar, and finished partsRepetitive grinding, sanding, and tool vibrationAwkward postures at benches, racks, and boothsUse of carts, hoists, and lift tables as aidsJob rotation and microbreaks to reduce fatigueLesson 8Common physical hazards: cuts, slips, falls, struck-by, caught-betweenThis part covers common physical hazards like sharp edges, slips, trips, falls, struck-by, and caught-between events. Learners will check housekeeping, guarding, signage, and safe movement practices to reduce everyday injury risks in the shop.
Sharp edges, burrs, and handling sheet metalFloor conditions, spills, and trip obstaclesWorking at heights, ladders, and platformsStruck-by hazards from moving loads and toolsCaught-between risks at presses and pinch pointsLesson 9Electrical hazards: portable tools, damaged cords, lockout/tagout basicsThis part explains electrical hazards from portable tools, cords, and panels in fabrication and painting. Learners will recognize shock, arc, and fire risks, and review basic lockout/tagout steps, inspection routines, and safe use of extension cords and GFCIs.
Recognizing damaged cords, plugs, and insulationSafe use of portable tools in metal shopsGrounding, GFCIs, and wet location precautionsOverloaded circuits, adapters, and power stripsBasic lockout/tagout steps for maintenance tasks
