Lesson 1Thermal hazards: welding burns, hot surfaces, sparksDeals with heat dangers from welding, cutting, and hot surfaces. Talks about burn causes, heat radiation, sparks, and molten metal, plus protective gear, barriers, safe handling of hot items, and emergency help for burns in local workshops.
Types of burns in metal workHot surfaces, slag, and workpiecesSparks and molten metal projectionsHeat-resistant protective gear and clothingScreens, barriers, and safe spacingFirst aid and response for burnsLesson 2Ergonomic and manual handling hazards: lifting, repetitive motions, awkward posturesLooks into body strain risks from lifting, carrying, and repeated tasks in fabrication. Covers force, posture, and how often, plus checking tools, safe carrying methods, workstation setup, and using machines to cut down strain injuries in Zambian factories.
Risk factors in lifting and carrying tasksRepetitive motion and overuse injuriesAwkward postures at benches and weld jigsManual handling of plate, bar, and tubingUse of carts, hoists, and lift assistsJob rotation and ergonomic trainingLesson 3Slip, trip and fall hazards: wet floors, housekeeping, walkwaysCovers slip, trip, and fall dangers in fabrication areas, including wet floors, mess, wires, and uneven ground. Explains risk causes, checking practices, floor care, guarding holes, and safe use of ladders and platforms in Zambian sites.
Common slip and trip causes in shopsFloor drainage, coatings, and mattingTool, scrap, and hose housekeepingSafe walkways, aisles, and markingsLadder and step platform safe useInspections and corrective actionsLesson 4Noise and vibration hazards: sources, exposure effects, measurement basicsLooks into noise and vibration from tools like grinders, presses, and hammers. Covers safe limits, ear damage, basic measuring, vibration illnesses, and controls like machine changes and ear protection for Zambian workers.
Major shop noise and vibration sourcesHearing loss mechanisms and symptomsExposure limits and basic measurementsHand-arm and whole-body vibration risksEngineering and administrative controlsHearing protection selection and fitLesson 5Common physical hazards: cuts, machine entanglement, struck-by, pinch pointsReviews usual physical dangers like sharp edges, spinning parts, pinch spots, and hit-by risks. Explains guards, lockout, safe tool use, material moving, and checks to stop cuts, crushes, and hits in local fabrication.
Sharp edges, burrs, and cut preventionRotating parts and entanglement risksPinch points on presses and brakesStruck-by and dropped object hazardsMachine guards and interlock devicesLockout and safe tool handlingLesson 6Fire and explosion hazards: flammable materials, hot work ignition sourcesDetails fire and blast risks from welding, cutting, and flammable items. Reviews fire basics, spark sources, hot work permits, gas and liquid storage, and controls like separation, air flow, and fire gear in Zambian workshops.
Fire triangle and explosion basicsHot work ignition sources and controlsFlammable liquids and gas storage rulesHousekeeping to reduce combustible loadHot work permits and area preparationFire detection, alarms, and extinguishersLesson 7Respiratory and eye hazards: dust, aerosols, chemical splashes, UV from weldingFocuses on lung and eye dangers from dust, smoke, sprays, and UV light. Covers effects, air flow, mask choice and fit, eye and face gear, and safe ways for welding, grinding, and spraying in local industries.
Dust, fumes, and aerosol health effectsLocal exhaust and general ventilationRespirator types, fit testing, and careSafety glasses, goggles, and face shieldsUV and IR hazards from welding arcsSafe practices for grinding and sprayingLesson 8Chemical hazards: paint solvents, welding fumes, cleaning agentsExamines chemical dangers from solvents, paints, welding smoke, and cleaners. Addresses entry ways, short and long effects, safety sheets, labels, air flow, gear choice, and safe storage, mixing, and waste in Zambian fabrication.
Key chemical types used in fabricationExposure routes and health effectsSafety Data Sheets and labelingVentilation for fumes and vaporsChemical-resistant PPE selectionStorage, mixing, and waste handling
