Lesson 1Thermal hazards: welding burns, hot surfaces, sparksAddresses thermal hazards from welding, cutting, and hot surfaces. Discusses burn mechanisms, radiant heat, sparks, and molten metal, plus PPE, barriers, safe handling of hot workpieces, and emergency response for burn injuries.
Types of burns in metal fabricationHot surfaces, slag, and workpiecesSparks and molten metal projectionsHeat-resistant PPE and clothingScreens, barriers, and safe spacingFirst aid and response for burnsLesson 2Ergonomic and manual handling hazards: lifting, repetitive motions, awkward posturesExplores ergonomic risks from lifting, carrying, and repetitive tasks in fabrication. Covers force, posture, and frequency, plus assessment tools, safe handling methods, workstation design, and use of mechanical aids to reduce strain injuries.
Risk factors in lifting and carrying tasksRepetitive motion and overuse injuriesAwkward postures at benches and weld jigsManual handling of plate, bar, and tubingUse of carts, hoists, and lift assistsJob rotation and ergonomic trainingLesson 3Slip, trip and fall hazards: wet floors, housekeeping, walkwaysCovers slip, trip, and fall hazards in fabrication areas, including wet floors, clutter, cords, and uneven surfaces. Explains risk factors, inspection practices, floor maintenance, guarding of openings, and safe use of ladders and platforms.
Common slip and trip causes in shopsFloor drainage, coatings, and mattingTool, scrap, and hose housekeepingSafe walkways, aisles, and markingsLadder and step platform safe useInspections and corrective actionsLesson 4Noise and vibration hazards: sources, exposure effects, measurement basicsExplores noise and vibration sources such as grinders, presses, and impact tools. Covers exposure limits, hearing damage, measurement basics, vibration-related disorders, and controls including engineering changes and hearing protection.
Major shop noise and vibration sourcesHearing loss mechanisms and symptomsExposure limits and basic measurementsHand-arm and whole-body vibration risksEngineering and administrative controlsHearing protection selection and fitLesson 5Common physical hazards: cuts, machine entanglement, struck-by, pinch pointsReviews common physical hazards including sharp edges, rotating parts, pinch points, and struck-by risks. Explains guarding, lockout, safe tool use, material handling, and inspection practices to prevent cuts, crush injuries, and impacts.
Sharp edges, burrs, and cut preventionRotating parts and entanglement risksPinch points on presses and brakesStruck-by and dropped object hazardsMachine guards and interlock devicesLockout and safe tool handlingLesson 6Fire and explosion hazards: flammable materials, hot work ignition sourcesDetails fire and explosion risks from welding, cutting, and flammable products. Reviews fire triangle, ignition sources, hot work permits, storage of gases and liquids, and controls such as isolation, ventilation, and fire protection equipment.
Fire triangle and explosion basicsHot work ignition sources and controlsFlammable liquids and gas storage rulesHousekeeping to reduce combustible loadHot work permits and area preparationFire detection, alarms, and extinguishersLesson 7Respiratory and eye hazards: dust, aerosols, chemical splashes, UV from weldingFocuses on respiratory and eye hazards from dust, fumes, aerosols, and UV radiation. Covers exposure effects, ventilation, respirator selection and fit, eye and face protection, and safe practices for welding, grinding, and spraying.
Dust, fumes, and aerosol health effectsLocal exhaust and general ventilationRespirator types, fit testing, and careSafety glasses, goggles, and face shieldsUV and IR hazards from welding arcsSafe practices for grinding and sprayingLesson 8Chemical hazards: paint solvents, welding fumes, cleaning agentsExamines chemical hazards from solvents, paints, welding fumes, and cleaners. Addresses exposure routes, acute and chronic effects, SDS use, labeling, ventilation, PPE selection, and safe storage, mixing, and disposal practices in fabrication.
Key chemical types used in fabricationExposure routes and health effectsSafety Data Sheets and labelingVentilation for fumes and vaporsChemical-resistant PPE selectionStorage, mixing, and waste handling
