Lesson 1Mechanical hazards: rotating equipment, conveyors, forklifts, pallet storageThis section looks at mechanical dangers from rotating machines, conveyors, forklifts, and pallet stacks. You'll spot pinch points, crush risks, and struck-by dangers, 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 section covers exposure limits like TLVs and PELs for welding smoke, solvents, and dust. You'll compare exposure times, grasp short-term and ceiling limits, and link monitoring results to ventilation, PPE, and safe work habits.
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 section teaches spotting early hazard signs like near-misses, minor hurts, exposure symptoms, and unsafe actions. You'll practise reporting, checking trends, and fixing issues before big accidents 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 section checks chemical dangers from welding fumes, solvent paints, isocyanates, and harmful dusts. You'll link safety data sheets to exposure paths, symptoms, and controls like ventilation, PPE, and safer alternatives.
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 section examines fire and blast risks from flammable liquids, combustible dust, and hot jobs. You'll identify spark sources, check storage and ventilation rules, and use hot work permits, cleaning, and earthing 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 section teaches reading the workshop layout to find hazards in production areas, paint booths, and stores. You'll map work flows, traffic paths, and escape routes to spot crowds, blind corners, and clashing 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 section tackles body strain hazards from lifting metal, handling parts, and repeated painting or grinding. You'll spot awkward positions, heavy pushes, and repetition, and look at redesign, lifting aids, and job swaps 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 section covers everyday physical dangers like sharp edges, slips, trips, falls, struck-by, and caught-in events. You'll check cleaning, guarding, signs, and safe movement to lower common workshop injury risks.
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 section explains electrical dangers from hand tools, faulty cables, and panels in fabrication and painting. You'll spot shock, flash, and fire risks, and review lockout/tagout steps, checks, and safe use of extension leads and safety plugs.
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
