Lesson 1Vehicle and mobile plant hazards: forklifts and overhead cranesThis part checks dangers from forklifts, overhead cranes, and other moving machines, looking at traffic control, driver skills, signals, load tying, and rules for shared areas to stop crashes, crushing, and falling 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 part explains chemical dangers from solvents, paints, welding smoke, and metal dust, covering how they enter the body, health problems, checking levels, and safety steps like replacing them, good air flow, safe keeping, 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 part talks about noise and shaking from workshop machines, their health impacts, checking exposure, and ways to control them, like machine fixes, upkeep, work limits, and proper ear protection choice and use.
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 part looks at body strain and lifting risks in assembly and storing materials, like heavy lifts, pushing, bad positions, and repeat work, and shows ways to change setups, use machines, and train to avoid body 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 part covers electric dangers from fixed machines, hand tools, and temp wires, stressing shock, flash, and fire risks, lockout steps, checks, earthing, and working with skilled electricians for setup 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 part deals with heat and fire dangers from hot jobs, sparks, and easy-burn liquids or gases, listing fire starters, fuel checks, hot work papers, fire watches, clean-up, and emergency plans for workshop work.
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 part goes over usual physical dangers like sharp bits, moving parts, trap points, and dropping items, explaining common accidents and simple fixes like guards, blocks, signs, and safe handling and piling 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 part checks how worker groups and setups affect risks, covering night shift tiredness, different skills, language issues, and bringing in contractors and temps into site rules, watching, and safety ways.
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 part outlines key metal work steps and their risks, showing how cutting, grinding, welding, painting, and putting together link, where dangers come from, and how planning, setup, and standard steps cut accidents and redo work.
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
