Lesson 1House rules and access control: prohibited items in production/warehouse, smoking policies, contractor controlsThis lesson sets out site rules and entry checks for fire safety, covering banned items, no-smoking zones, visitor handling, contractor oversight, ID badges, and penalties for breaking rules everywhere.
List and signage of prohibited ignition sourcesSmoking policies and designated smoking areasAccess control for production and warehouse zonesContractor induction and permit requirementsVisitor escort and briefing on fire rulesDisciplinary steps for repeated violationsLesson 2Safe work procedures for welding and cutting: pre-checks, fire watches, use of welding curtains and heat shieldsThis lesson outlines safe welding and cutting in plastics areas, including pre-checks, site prep, fire watches, screens and shields, and checks after for hidden fires.
Pre-job risk assessment and job planningIsolation and cleaning of the work areaSelection and inspection of welding equipmentUse of welding curtains, screens, and shieldsFire watch duties during and after hot workPost-work checks for smoldering materialsLesson 3Storage and layout controls: aisle widths, separation distances, pallet racking rules, high-risk zone demarcationThis lesson explains safe stacking and layouts to curb fire spread and aid exits, covering walkway widths, gaps between stacks, racking rules, and marking danger zones in plastics ops.
Minimum safe aisle widths and clear egress routesSeparation distances between incompatible materialsPallet racking load limits and stability checksRack protection, flue spaces, and sprinkler clearanceHigh-risk zone demarcation and floor marking rulesStorage height limits near walls and equipmentLesson 4Administrative controls: permits-to-work, hot work permits, confined space entry, permit recordkeeping and responsible signoffsThis lesson details paperwork controls for safe jobs, explaining work permits, hot work and tight space permits, who signs off, records, checks, and linking to incident probes.
Core elements of a permit-to-work systemHot work permit content and validity limitsConfined space entry permits and gas testingPermit issuer, receiver, and supervisor rolesRecordkeeping, retention, and traceabilityAuditing permits and correcting deficienciesLesson 5Flammable liquids management: segregation, quantities, approved containers, secondary containment, shelf limits and ventilation requirementsThis lesson covers handling flammable liquids safely, including separation, amount caps, proper drums, spill trays, air flow, spill plans, and labels for plastics work.
Classification of flammable and combustible liquidsApproved containers and safety cans selectionStorage cabinet use and quantity limitationsSecondary containment and spill control plansVentilation requirements for storage roomsLabeling, signage, and inventory recordsLesson 6Electrical safety program: fixed electrical inspection schedule, portable appliance testing, elimination of temporary wiring and overloaded circuitsThis lesson outlines an electrical safety plan to cut spark risks, with check schedules, plug-in tests, no temp wires, load balancing, and records for rules and insurers.
Fixed installation inspection and test intervalsPortable appliance testing and tagging rulesElimination of temporary and makeshift wiringCircuit loading, panel labeling, and breaker sizingInspection records, defect tracking, and signoffTraining for staff on electrical hazard reportingLesson 7Control of ignition sources: hot work permit system, electrical maintenance schedules, guarding of hot surfaces on molding machinesThis lesson targets spark control in moulding zones, covering hot work permits, power upkeep, hot part guards, static fixes, and shutdown checks before work.
Hot work permit workflow and authorizationScheduled electrical maintenance and testingGuarding and insulation of exposed hot surfacesStatic electricity control and bonding measuresLockout and cool-down before maintenanceVerification of shutdown before cleaning tasksLesson 8Process controls and engineering: local exhaust ventilation for solvents, machine guarding, temperature interlocks, coolant and melt managementThis lesson explains machine fixes to stop fires in plastics lines, like fume extractors, guards, temp cut-offs, and safe handling of coolants, melts, and hot oils.
Local exhaust ventilation for solvent vaporsMachine guarding to prevent friction ignitionTemperature interlocks and overheat shutdownsMonitoring and control of coolant flow and leaksSafe melt handling and purge proceduresPreventive maintenance of process equipmentLesson 9Housekeeping and waste management: procedures for hot plastic scraps, scheduled cleaning, safe waste bins and removal frequencyThis lesson covers cleaning and rubbish handling to limit fires, including hot scrap deals, clean rosters, bin choices, pickup times, and outside storage rules.
Handling and cooling of hot plastic scrapsDaily and weekly cleaning task schedulesApproved waste containers and lid requirementsWaste segregation to reduce fire severityWaste removal frequency and route planningControls for external dumpsters and compactorsLesson 10Fire load reduction strategies specific to plastics and packaging materialsThis lesson tackles cutting fire fuel from plastics and packs, covering material picks, stock limits, separation, pack designs, and reducing burnables in stores and lines.
Limiting maximum combustible stock per areaSegregation of high and low fire load zonesUse of less flammable materials where feasibleOptimized packaging design to reduce fuel loadRotation policies to avoid long-term buildupFire load calculations for planning storage
