Lesson 1Thermal hazards: welding burns, hot surfaces, sparksCovers heat dangers from welding, cutting, and hot surfaces. Discusses how burns happen, heat radiation, flying sparks, and molten metal, plus protective gear, barriers, safe handling of hot items, and quick 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 posturesLooks at body strain risks from lifting, carrying, and repeated tasks in fabrication. Covers force, posture, and repetition, plus checking tools, safe lifting methods, workstation setup, and using machines to cut down 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, walkwaysDeals with slip, trip, and fall risks in fabrication areas, like wet floors, clutter, cables, and rough surfaces. Explains risk causes, checking routines, floor cleaning, guarding holes, 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 basicsLooks at noise and vibration from grinders, presses, and hammering tools. Covers safe exposure levels, hearing loss, basic measuring, vibration illnesses, and fixes like machine changes and ear 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 everyday physical dangers like sharp edges, spinning parts, crush points, and being hit. Explains guards, lockout, safe tool use, material handling, and checks to stop cuts, crushes, and hits.
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 blast risks from welding, cutting, and flammable stuff. Reviews fire causes, spark sources, hot work permits, safe storage of gases and liquids, and controls like separation, airflow, and fire gear.
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 lung and eye dangers from dust, fumes, sprays, and welding light. Covers effects, airflow systems, mask choice and fit, eye/face gear, and safe ways 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 risks from solvents, paints, welding smoke, and cleaners. Covers entry paths, short and long-term effects, safety data sheets, labelling, ventilation, gear choice, and safe storage, mixing, and disposal in workshops.
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
