Lesson 1Vehicle and mobile plant hazards: forklifts and overhead cranesThis part checks hazards from forklifts, overhead cranes, and other mobile equipment, stressing traffic control, driver skills, signals, load tying, and shared area rules to stop crashes, crushing injuries, 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 exposure paths, health impacts, checks, and layered controls like swapping, 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 part talks about noise and vibration sources in workshops, their health effects, exposure checks, and control plans, including engineering fixes, upkeep, work limits, and proper choice and use of ear protection.
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 ergonomic and manual handling risks in assembly and material storage, covering lifting, pushing, awkward positions, and repeat tasks, and shows ways for redesign, mechanical help, and training to avoid 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 part covers electrical dangers from fixed machines, portable tools, and temp wiring, stressing shock, arc, and fire risks, lockout steps, checks, earthing, and working with qualified sparkies 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 part deals with heat and fire hazards from hot work, sparks, and flammable liquids or vapours, detailing ignition sources, fuel controls, hot work permits, fire watch roles, 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 part reviews everyday physical hazards like sharp edges, moving parts, pinch points, and falling objects, explaining common incident cases and practical controls including guards, barriers, signs, and safe handling and stacking.
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 explores how workforce mix and setup affect risk, covering shift fatigue, varying experience, language issues, and bringing contractors and temps into site rules, oversight, 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 main metal fabrication processes and their risk profiles, showing how cutting, grinding, welding, painting, and assembly steps link up, where dangers come from, and how planning, layout, and standard steps cut incidents 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
