Name: ___________________ Year Group: ___________________ Picnic Point High School Industrial Arts Department Occupational Health and Safety Metal Strand Training Booklet This booklet covers students for metalwok subjects from yr7 to yr 12 and must be retained at Picnic Point High School. LEVEL ONE COMPETENCY - Introductory Level Typically students who gain accreditation at the Introductory Level will be studying a course of study in: Technology Mandatory Equipment/Machine/Activity Instruct ion Date Testin g Date Student Signature Teacher Certification Signature Workshop Technologies General Workshop Procedures General Machine operation Metal Handtools Battery/Portable Drill operation Wrought Iron Forming Tools Finishing Materials & Solvents Accreditation at LEVEL ONE COMPETENCY achieved. Date: Teacher Signature: LEVEL TWO COMPETENCY - Basic Level Typically students who gain accreditation at the Basic Level will be studying a course of study in: Year 7 Design and Technology Year 8 Design and Technology 1 C.Blanch 2009
The risk of injury when undertaking worshop activities is LOW - Level 1 Risk
CIRCLE “T” FOR “TRUE” OR “F” FOR “FALSE” TO ANSWER THE FOLLOWING:
1. Running is forbidden in the workshop. T/F
2. Scrap materials and offcuts should be left on the floor and/or bench. T/F
3. Sandshoes, thongs or soft footwear may be worn in the workshop. T/F
4. Protective clothing is to be worn during practical classes. T/F
5. Safety zones are necessary around machines and heat treatment areas. T/F
6. Tools, materials or other items must not be left on the edges of benches. T/F
7. Blunt, damaged or badly adjusted tools should be reported to the teacher. T/F
8. You may distract or crowd a pupil at work on a bench or machine. T/F
9. If in doubt about any operation, ask the teacher. T/F
10.Hair nets must be worn when in the workshop area. T/F
11.Only major accidents should be reported to the teacher. T/F
12.All jobs should be cramped to the bench or held in the vice when being worked on T/F
13.The operator is responsible for switching a machine on or off. T/F
14.There is no need for the teacher to give permission to use a machine, power equipment or a gas appliance. T/F
15.Eye protection must be worn when using a machine or power equipment. T/F
16.Discuss some of the risks involved when working in a workshop.________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
The risk of injury when using machines will vary depending on the machine
Place a TICK in the correct BOX for the following statements:
Safe Unsafe
1. Operating a machine without permission and with the teacher absent from the workshop is:
2. Keeping hands clear when machining is:
3. Wearing PPE such as safety spectacles when using a machine is:
4. Checking adjustments before turning a machine on is:
5. Making adjustment while a machine is running is:
6. Removing guards and covers on a machine is:
7. Stopping a machine making unfamiliar noises is:
8. Replacing all tools back into their storage position after use is:
9. Leaving a machine while it is running is:
10.Cleaning a machine with a brush instead of your hand is:
Discuss some of the risks involved when using machines.________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
Technology Safety TutorialMetalworking Hand Tools
The risk of injury when using this machine is LOW - Level 1 Risk
Neatly PRINT the missing words to complete these statements.
1. When tools which are damaged, blunt or badly adjusted are identified, they should be __________ to your teacher immediately.
2. All hand tools must be returned to their proper __________ position after use.
3. Do not attempt to hold work pieces in your _________ when using metal hand tools.
4. Never use a ball pein hammer with a ________ head or a split handle.
5. Striking two hammer ________ together could cause them to shatter.
6. Files should not be used without correctly fitted___________.
7. Always use a banister brush to ____________ metal filings from the work bench and vice.
8. Make sure the teeth of a ___________ blade are facing forward for efficient cutting.
9. Carry sharp edged tools with the _____________ edge pointing to the floor.
10.Do not apply too much force or ____________ when using a hacksaw because this can cause the blade to break.
11.Scribers should not be ___________ around or stuck into work benches.
12.Metal scraps and offcuts should be _________ off benches with banister brushes using dustpans.
Discuss some of the risks involved when using Metal Hand Tools. ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________
The risk of injury when using a Battery Drill is LOW - Level 1 Risk
Neatly PRINT the missing words to complete the following sentences.
1. The operator must seek and gain t___________ approval to use the Battery Drill.
2. The wearing of personal p____________ equipment such as safety spectacles is
necessary when using a Battery Drill.
3. Never hold the work piece in your h_______ when drilling.
4. The work piece should be held firmly in a v_______ or with a c_________.
5. A centre punch is used to make an i_______________ to mark the centre of the hole.
6. Pressing excessively against the work piece will not s________ up the drilling process.
7. As the drill bit breaks through the work piece, the drill should be held f ________ and
care taken to ensure the drill bit does not become s_________.
8. To remove a stuck drill piece, set the r ___________ switch to reverse rotation.
9. Do not touch the drill bit or work piece immediately after drilling, because they could be
extremely h______ and b_______ your fingers.
10.Never operate a battery charger with a d___________ cord or plug.
11.Do not allow the v______ of the battery charger to be clogged or covered.
12. It is most important not to operate the battery charger anywhere near w________.
13.The battery cartridge t____________ should be prevented from being shorted.
Discuss the risks involved when using a Battery Drill. ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________
Technology Occupational Health and Safety InstructionWrought Iron Forming Tools
The risk of injury when using these substances is VERY LOW - Level 1 Risk1. Name 2 hazards associated with using the following metal forming tools
2. Describe the three main reasons for applying a finish to wood products. _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________
3. Why is it necessary to work in well ventilated areas when using volatile materials? _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________
4. Describe the personal protective equipment that should be worn when using toxic finishing materials. _____________________________________________________________________ _____________________________________________________________________
5. List three considerations for the safe storage of combustible finishing materials. a) ___________________________________________________________________ b) ___________________________________________________________________ c) ___________________________________________________________________
6. State two reasons why it is important to use finishing materials in a designated area. a) ___________________________________________________________________ b) ___________________________________________________________________
7. Discuss some of the risks involved when using Finishing products and solvents. _____________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________
The risk of injury when using this machine is MODERATE - Level 2 RiskNeatly PRINT the missing words to complete the following sentences.
1. The Magnabend is a ___________ bending machine capable of bending all types of sheetmetal such as aluminium, copper and steel.
2. The _________________ clamping system allows the work piece to be folded in complex shapes with relative ease.
3. The Magnabend is equipped with a two _____________ interlock to ensure ___________ are not caught under the clamp bar.
4. It is potentially ______________ for one person to inset the work piece and hold the ____________ bars, while another operates the ____________.
5. The operator must have had ______________ and training in the use of the Magnabend and _____________ completed the OHS test.
6. It is dangerous to wear loose ____________ such as long sleeves and ties when operating this machine.
7. Before starting any bending procedure, make sure the ___________ balls on the ends of the clamp bar are resting in the ______________ grooves.
8. The clamp bar needs to be adjusted to the thickness of the work piece, by rotating the _______________ adjustors at either end of the clamp bar.
9. To start the bending procedure, insert the work piece and __________ the bend line, before tilting the bending bar ____________ with one hand and ______________ the green start button with the other hand.
10.After applying this pre-clamping pressure, the operator must use their other __________ to grab the handle and continue to bend _________________.
11.To release the __________________, reverse the bending bar in a _________________ direction for approximately 200mm.
12.The risk of ______________ the bending edge of the clamp bar or _____________ the top surface of the magnet body, is lessened by not placing ____________ objects under the clamp bar.
13.Never attempt to use the clamp bars on their __________ or attempt to hold the clamp bars with your hands while ______________ on the Magnabend.
14.The operator should allow the Magnabend to ________ down for 30 minutes if the ____________ overload switch is tripped.
Speed Spinning Hold RevolvingSpectacles Machine Key HandsCap Safety Switch ChuckOne Zone Stop OperatorTeacher
Technology Safety TutorialLiquefied Petroleum Gas - LPG
The risk of injury when using this machine is MODERATE- Level 2 Risk
Neatly PRINT the missing words to complete the sentences.
1. Keep the f __________ away from other students, gas hoses and the gas cylinders.
2. Keep rags, paper and wood away from the heat t ______________ area.
3. A strong smell of gas, may indicate a l_______ in the hoses.
4. If a leak is suspected, immediately s______ d_______ the main cylinder valve or tap.
5. The safest method for checking gas leaks is by placing s_________ water on the hose
valves.
6. You must assume that all metals in the heat treatment area, are h_____ and capable of
b____________ your hands.
7. After using the L.P.G. e_____________ close down the main c _____________ valve.
8. When the main cylinder valve has been closed, the p__________ in the hoses must be
released.
9. Do not allow the soldering o_______ to fill with gas before lighting it.
10.Fire b__________ should be used in the heat treatment area.
12. Discuss some of the risks involved when using LPG equipment. ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________
Word List
bricks pressure hot shut leak flame down soapy burning treatment equipment oven cylinder
Technology Safety TutorialSpot Welder
The risk of injury when using this machine is SUBSTANTIAL – Level 3 Risk
Answer the following questions by referring to the OHS Instruction Sheet on the Spot Welding Machine.
1. What causes the heating of the metal when spot-welding?
2. Spot welders are commonly used for joining what types of metal? ____________________________________________________________________
3. What needs to be done when spot welding “coated” metals?
4. What is the maximum thickness of sheet metal a portable spot welder can weld?____________________________________________________________________
1. If the clamping pressure is too great, what will result?____________________________________________________________________
2. If the clamping pressure is too little, what will result?____________________________________________________________________
5. In what condition should the pieces of sheet metal be before welding?________________________________________________________________________________________________________________________________________
6. List reasons that can cause a hole to be burnt through the metal:
Technology Safety TutorialSpot Welding Machine
The risk of injury when using this machine is LOW – Level 2 Risk
CIRCLE “T” FOR “TRUE” OR “F” FOR “FALSE” TO ANSWER THE FOLLOWING:
1. The electrical cord and plug should be checked regularly for any faults T/F
2. The spot welding area should be kept clean of paper and other flammable materials. T/F
3. It is not necessary to wear protective eyewear when using the spot welder. T/F
4. It is very dangerous to use the spot welder in an area where water is present.T/F
5. Trailing the electrical cord across benches, machines and passageways is dangerous. T/F
6. Even though dangerous fumes are given off when spot welding, it is not necessary to use this equipment in a well ventilated area. T/F
7. The sparks given off when spot-welding need not be considered as dangerous. T/F
8. The spot welder should only be used with sheet metal and when under direct teacher supervision. T/F
9. It is not necessary to remove the grease and grime from joints to be spot- welded. T/F
10. The spot welder electrode tips need to be kept clean at all times. T/F
11. Discuss some of the risks involved when using the Spot Welder.______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
Technology Safety TutorialMetal Turning Lathe
The risk of injury when using this machine is SUBSTANTIAL – Level 3 Risk
TICK THE CORRECT BOX FOR THE FOLLOWING:
Safe Unsafe
1. Using a metal lathe when not wearing safety spectacles is:
2. Before switching on the metal lathe, checking that the work piece, the cutting tool and the tool holder are secure is:
3. Removing the chuck key and revolving the chuck one revolution by hand before switching on the metal lathe is:
4. Checking that the back gear and belt pulley guards are all in place before switching on the metal lathe is:
5. Making measurements on your work piece while the metal lathe is running is:
6. Stopping the chuck with your hand or the chuck key is:
7. Engaging the back gears or automatic feed while the metal lathe is in motion is:
8. Touching revolving parts and shavings coming off the lathe is:
9. Using the wooden saddle to protect the lathe bed when removing a chuck is:
10.Stopping the machine to make adjustments, oil components and clean parts is:
5. Explain why small or thin pieces of timber should not be sanded on the linisher? _____________________________________________________________________
The risk of injury when using this machine is HIGH - Level 4 Risk
Neatly PRINT the missing words to make the following statements correct.
1. Teacher ______________ must be sought and gained prior to starting any grinding procedure.
2. The disc grinder must be used under direct _______________ of the teacher.
3. Other students are not permitted in the immediate ________ of the grinding procedure.
4. The operator must wear appropriate Personal _______________ Equipment such as eye spectacles.
5. The operator must make sure the electrical lead is free of ___________ and the grinding wheel is free of ___________ and cracks.
6. The Disc Grinder is not safe when used with only one _____________.
7. Never place the Disc Grinder down on the ground or on a work __________ while it is still spinning.
8. It is not safe to use a Disc Grinder if it develops a _____________ or wobble.
9. The flying ____________ are a danger to the operator and anyone standing near the work area.
10.The work piece will be extremely _________ after the grinding procedure.
11.The electrical lead needs to be _____________ away from the cutting area and grinding wheel.
12.The abrasive wheel guard should not be _______________ for any reason.
13.Switch the grinder off at the _____________ when finished with the grinding operation.
14.Never use a Disc Grinder that has a damaged _____________, flange or lock nut.
15.Grinding near _______________ materials is quite an unsafe practice.
16. Discuss some of the risks involved when using the Disc Grinder. ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________
Technology Safety TutorialMetal Turning Lathe
The risk of injury when using this machine is SUBSTANTIAL – Level 3 Risk
TICK THE CORRECT BOX FOR THE FOLLOWING:
Safe Unsafe
11.Using a metal lathe when not wearing safety spectacles is:
12.Before switching on the metal lathe, checking that the work piece, the cutting tool and the tool holder are secure is:
13.Removing the chuck key and revolving the chuck one revolution by hand before switching on the metal lathe is:
14.Checking that the back gear and belt pulley guards are all in place before switching on the metal lathe is:
15.Making measurements on your work piece while the metal lathe is running is:
16.Stopping the chuck with your hand or the chuck key is:
17.Engaging the back gears or automatic feed while the metal lathe is in motion is:
18.Touching revolving parts and shavings coming off the lathe is:
19.Using the wooden saddle to protect the lathe bed when removing a chuck is:
20.Stopping the machine to make adjustments, oil components and clean parts is:
Technology Safety TutorialMetal Cold Saw
The risk of injury when using this machine is SUBSTANTIAL - Level 3 Risk
Answer the following questions by referring to the safety instruction sheet.
1. What operation is the metal cold saw designed to perform?__________________________________________________________________________________________________________________________________________
2. How is the speed of the blade regulated?__________________________________________________________________________________________________________________________________________
3. Why must the metal cold saw be isolated from the electrical power supply when
carrying out maintenance procedures?__________________________________________________________________________________________________________________________________________
4. Why is there a guard placed around the blade assembly?__________________________________________________________________________________________________________________________________________
5. The blade must be checked before every cutting operation. State why this is an
important check.__________________________________________________________________________________________________________________________________________
6. Why should the blade be allowed to cut at its own speed?__________________________________________________________________________________________________________________________________________
7. Keeping the cutting area free of off-cuts is very important. Why?__________________________________________________________________________________________________________________________________________
8. Why wear Personal Protective Equipment when using the metal cod saw?____________________________________________________________________________________________
9. Do not wear loose clothing, especially long sleeves and neck ties. Why?______________________________________________________________________________________________________________________
10.When carrying out a cutting procedure, why should the operator never walk away
and leave the saw unattended?__________________________________________________________________________________________________________________________________________
11.Why do long workpieces have to be supported on both sides of the blade?__________________________________________________________________________________________________________________________________________
12.The operator should never stand or sit directly in front of the revolving blade. Why?__________________________________________________________________________________________________________________________________________
13. In an emergency such as the blade jamming, what action should the operator take?________________________________________________________________________________________________
__________________________________________
Technology Safety TutorialOxy-Acetylene Equipment
The risk of injury when using this equipment is SUBSTANTIAL - Level 3 Risk
Answer the following questions by referring to the OHS Instruction sheets.
1. Why must oxy-acetylene goggles be worn instead of other PPE?________________________________________________________________________________________________________________________________________
2. Why must oxygen and acetylene gas cylinders be handles with care?________________________________________________________________________________________________________________________________________
3. Why is it important to keep the gas cylinder valves clean and free from oil and grease?________________________________________________________________________________________________________________________________________
4. Why are the cylinder valves opened slightly and then closed before attaching the regulators?
5. Why are the cylinder valves closed when the equipment is not in use?________________________________________________________________________________________________________________________________________
6. Why should the gas hoses be kept clear of hot steel?________________________________________________________________________________________________________________________________________
7. In the event of a ‘flashback’ what steps should the operator take?________________________________________________________________________________________________________________________________________
8. What order should the blowpipe valves be shut off during normal use?________________________________________________________________________________________________________________________________________
9. Why is it considered dangerous to weld or cut galvanised iron?________________________________________________________________________________________________________________________________________
10.Why should flammable materials be kept clear of oxy-acetylene cutting? ____________________________________________________________________ ____________________________________________________________________
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