Lesson 1Vehicle and mobile plant hazards: forklifts and overhead cranesThis section checks out hazards from forklifts, overhead cranes, and other mobile plant, zeroing in on traffic management, operator skills, signalling, load securing, and shared-space rules to avoid collisions, crush injuries, and dropped loads.
Traffic flow planning and exclusion zonesForklift stability, loads, and blind spotsOverhead crane pre-use checks and slingingPedestrian routes, crossings, and spottersParking, battery charging, and refueling areasLesson 2Chemical hazards: solvents, paint fumes, welding gases, metal dustThis section covers chemical hazards from solvents, paints, welding fumes, and metal dust, focusing on exposure paths, health impacts, monitoring, and layered controls like substitution, ventilation, safe storage, and right PPE choice and use.
Solvent and paint components and exposure routesHealth effects of welding fumes and shielding gasesMetal dust generation, inhalation, and ingestion risksEngineering controls and local exhaust ventilationSafe storage, labeling, and PPE for chemicalsLesson 3Noise and vibration sources and effects in workshopsThis section talks about noise and vibration sources in workshops, their health effects, exposure checks, and control plans, including engineering fixes, maintenance, admin limits, and proper choice and use of hearing protection gear.
Main workshop noise and vibration sourcesHearing loss, fatigue, and other health impactsNoise surveys, dosimetry, and exposure limitsEngineering and administrative noise controlsHearing protection selection, fit, and careLesson 4Ergonomic hazards and manual handling during assembly and material storageThis section looks at ergonomic and manual handling risks during assembly and material storage, covering lifting, pushing, awkward postures, and repetitive tasks, and shares ways for redesign, mechanical aids, and training to stop muscle injuries.
Task analysis for lifting and carrying activitiesUse of hoists, jacks, and mechanical handling aidsLayout design to reduce bending and reachingSafe storage heights and rack organizationTraining on body mechanics and team liftingLesson 5Electrical hazards: fixed machines, portable tools, temporary wiringThis section goes over electrical hazards from fixed machines, portable tools, and temporary wiring, stressing shock, arc, and fire risks, lockout steps, inspection routines, earthing, and working with qualified electricians for installs and fixes.
Electrical shock, arc flash, and burn mechanismsInspection of cords, plugs, and portable toolsLockout tagout for maintenance and cleaningSafe use of temporary power and extension leadsGrounding, bonding, and residual current devicesLesson 6Thermal and fire hazards: hot work, sparks, flammable liquids and vaporsThis section deals with thermal and fire hazards from hot work, sparks, and flammable liquids or vapours, covering ignition sources, fuel controls, hot work permits, fire watch duties, housekeeping, and emergency plans for workshop ops.
Ignition sources in cutting, welding, and grindingControl of flammable liquids, gases, and vaporsHot work permits and pre-job area checksFire watch roles, equipment, and responseHousekeeping and segregation to limit fire spreadLesson 7Common physical hazards: sharp edges, moving parts, pinch points, falling objectsThis section reviews common physical hazards like sharp edges, moving parts, pinch points, and falling objects, explaining typical incident scenarios and practical controls including guards, barriers, signs, and safe handling and stacking of materials.
Sharp edges, burrs, and sheet metal handlingMachine guarding and access to moving partsPinch points in presses, rollers, and clampsControls for falling objects and dropped toolsSignage, barriers, and safe walkwaysLesson 8Workforce factors: shift work, mixed experience levels, contractors and temporary staffThis section explores how workforce makeup and setup affect risk, covering shift work tiredness, different experience levels, language issues, and fitting contractors and temp staff into site rules, oversight, and safety culture.
Shift patterns, fatigue, and error likelihoodManaging mixed skill and experience levelsOnboarding and supervision of contractorsTemporary staff induction and task assignmentCommunication, language, and safety cultureLesson 9Overview of metal fabrication processes: cutting, grinding, welding, painting, assemblyThis section outlines main metal fabrication processes and their risk profiles, showing how cutting, grinding, welding, painting, and assembly steps link up, where hazards pop up, and how planning, layout, and standard procedures cut incidents and rework.
Typical workflow from raw stock to finished productCutting and grinding methods and related hazardsWelding and thermal cutting process risk overviewPainting, coating, and curing process safetySafe assembly, fit-up, and in-process inspections
