Lesson 1Thermal and fire hazards: welding sparks, hot work, flammable coatings and solventsThis part looks at heat and fire dangers in hot jobs and paint spots. Learners check welding sparks, hot bits, and easy-burn paints, using fixes like permits, fire watches, cleaning up, and keeping fire starters from 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 part deals with body strain and lifting dangers in work spots. Learners look at repeat jobs, heavy or odd loads, work setup, tool shapes, and ways like machines, job swaps, safe lifts to cut 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 part covers body dangers like noise, shakes, bad light, pressed air, rays. Learners tie readings to risk levels, using fixes like build changes, gear, signs, no-go 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 part covers dangers from vehicles and movers in work spots. Learners check forklift and truck moves, load spots, traffic, fixes like signs, watchers, no-go zones to stop crashes.
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 part looks at chemical dangers in making and fix spots. Learners check metal smokes, solvents, isocyanates, cleaners, read safety sheets, tie ways in to fixes like air flow, gear, safe store.
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 part checks mind and setup dangers by work spot. Learners think on shift ways, talk gaps, load, role clear, spot report ways, talk methods, real fixes to cut stress and tiredness.
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 part deals with slip, trip, fall dangers in yards and open spots. Learners check grounds, slopes, weather, load zones, fixes like drains, clean up, grit, set paths for walkers.
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 part checks machine dangers from power tools. Learners spot cuts, shears, catches, pinches on cutters, grinders, movers, check guards, lockouts, checks to stop touch hurts.
Identifying cutting and shearing pointsRotating parts and entanglement risksPinch points on presses and conveyorsFixed and interlocked guard selectionPre-use checks and defect reporting
