Lesson 1Vehicle and mobile plant hazards: forklifts and overhead cranesThis section breaks down hazards from forklifts, overhead cranes, and other mobile equipment, zeroing in on traffic management, operator skills, signalling, load securing, and shared-space rules to stop 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 proper 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 discusses noise and vibration sources in workshops, their health effects, exposure checks, and control strategies, including engineering fixes, maintenance, admin limits, and right 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, including lifting, pushing, awkward postures, and repetitive tasks, and shows methods for redesign, mechanical aids, and training to prevent muscle and skeleton 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 deals with electrical hazards from fixed machines, portable tools, and temporary wiring, stressing shock, arc, and fire risks, lockout procedures, inspection routines, 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 section tackles thermal and fire hazards from hot work, sparks, and flammable liquids or vapours, detailing ignition sources, fuel controls, hot work permits, fire watch duties, housekeeping, and emergency response planning 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 guarding, barriers, signage, 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 organisation affect risk, covering shift work fatigue, varying experience levels, language barriers, and integrating contractors and temps into site rules, supervision, 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 interact, 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
