Lesson 1Common process hazards: cutting, welding, grinding, painting, assembly - where they occur and exposed groupsConnects common metalworking processes to typical hazards and exposed groups. Reviews cutting, welding, grinding, painting, and assembly, emphasising task-based risk assessment and layered controls across the process flow.
Cutting operations and associated hazardsWelding fire, fume, and electrical risksGrinding sparks, noise, and wheel integrityPainting overspray, VOCs, and ignition sourcesAssembly line pinch points and tool hazardsLesson 2Manual handling and ergonomic hazards: repetitive tasks, heavy lifting, awkward postures in assembly and maintenanceAddresses manual handling and ergonomic risks in lifting, assembly, and maintenance. Includes task analysis, load design, mechanical aids, job rotation, and workstation setup to prevent musculoskeletal disorders and fatigue.
Task and load assessment for manual handlingUse of hoists, conveyors, and lift assistsWorkstation height and reach optimisationRepetitive task redesign and job rotationErgonomic training and early symptom reportingLesson 3Electrical hazards: fixed plant, portable tools, lockout-tagout requirementsCovers electrical risks from fixed plant and portable tools in metal facilities. Addresses inspection, maintenance, lockout-tagout, arc flash, and safe use of extension cords, panels, and temporary power during maintenance or projects.
Fixed plant electrical risk identificationPortable tools, cords, and inspection regimesLockout-tagout steps and documentationArc flash awareness and boundary settingTemporary power and panel access controlsLesson 4Slip, trip, and fall hazards: floor contamination, stairs, elevated platforms, storage practicesIdentifies slip, trip, and fall hazards from floor contamination, stairs, platforms, and storage. Explains inspection routines, housekeeping, drainage, edge protection, and safe access design for production and warehouse areas.
Floor condition, drainage, and contaminationHousekeeping standards and spill responseStair design, handrails, and step visibilityGuardrails and access on elevated platformsStorage layout, stacking, and access aislesLesson 5Mechanical hazards: moving parts, machine guarding, nip points, rotating equipmentDetails mechanical hazards from moving parts, nip points, and rotating equipment. Explains risk assessment, machine guarding types, interlocks, emergency stops, and safe access for cleaning, clearing jams, and maintenance.
Identification of in-running and nip pointsFixed, interlocked, and adjustable guardsEmergency stops and isolation pointsSafe clearing of jams and blockagesMaintenance access and verification of zero energyLesson 6Physical hazards: noise, vibration, heat, cold, lighting and ergonomic risk factorsExamines physical hazards such as noise, vibration, heat, cold, and lighting in metal plants. Describes exposure assessment, health effects, engineering controls, PPE, and ergonomic layout to reduce strain and fatigue in work areas.
Noise mapping, exposure limits, and controlsHand-arm vibration sources and mitigationHeat stress, cold stress, and work-rest cyclesLighting levels, glare, and visual fatigueLayout design to reduce physical strainLesson 7Fire and explosion hazards: flammable liquids, paint booths, combustible dust, hot workExplores fire and explosion risks from flammable liquids, paint booths, combustible dust, and hot work. Covers ignition sources, hazardous area zoning, ventilation, housekeeping, and safe systems of work for routine and non-routine tasks.
Flammable liquid storage and transfer controlsPaint booth design, ventilation, and ignition controlCombustible dust recognition and housekeepingHot work permitting and fire watch dutiesExplosion protection, zoning, and equipment selectionLesson 8Transport and traffic hazards: forklifts, pedestrian routes, loading docks, racking collapseAnalyses transport and traffic hazards from forklifts, trucks, and pedestrians. Discusses route design, speed control, loading docks, racking stability, and segregation measures to prevent collisions and structural failures.
Traffic flow mapping and route segregationForklift selection, inspection, and limitsPedestrian walkways, crossings, and signageLoading dock edge, trailer, and fall risksRacking design, loading, and impact protectionLesson 9Chemical and airborne hazards: paints, solvents, welding fumes, metal dust - sources and exposure pathwaysReviews chemical and airborne hazards from paints, solvents, welding fumes, and metal dust. Covers safety data sheets, exposure pathways, ventilation, respiratory protection, and monitoring strategies in metal operations.
Inventory, labelling, and SDS interpretationWelding fumes and local exhaust ventilationSolvent vapours and confined space concernsMetal dust capture, filtration, and disposalAir monitoring and respiratory PPE selectionLesson 10Contractor and visitor-specific hazards: unfamiliarity, control of work, permit-to-work, induction and supervisionFocuses on hazards affecting contractors and visitors unfamiliar with the site. Explains induction, supervision, permit-to-work, interface with production, and how to control simultaneous operations and non-routine high-risk tasks.
Prequalification and contractor risk profilingSite induction and communication of rulesPermit-to-work for high-risk activitiesSupervision, monitoring, and stop-work authorityManaging simultaneous operations and interfaces
