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

Instructio
n
Date

Testing
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
Equipment/Machine/Activity

Instructio
n
Date

Testing
Date

Student
Signature

Teacher
Certification
Signature

Wood Technologies
Magnabend Folding Machine
Bench/Pedestal Drilling Machine
LPG Heating & Soldering
Spot Welding Machine
Metal Lathe
Linisher
Accreditation at LEVEL TWO COMPETENCY achieved. Date:

Teacher
Signature:

1
C.Blanch 2009

LEVEL THREE COMPETENCY - Intermediate Level

Equipment/Machine/Activity

Instruction
Date

Testing
Date

Student
Signature

Teacher
Certification
Signature

Metal Technologies
Electric / MIG Welding Machine
Disc Grinding Machine100mm
Metal Lathe operation
Metal Cutting Circular Saw
Oxy / Acet Welding & Heating
Accreditation at LEVEL THREE COMPETENCY achieved. Date:

Teacher
Signature:

2
C.Blanch 2009

3
C.Blanch 2009

Technology Safety Tutorial

General Workshop Procedures

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.

________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________

4
C.Blanch 2009

Technology Safety Tutorial

General Machine Procedures

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.

________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________

5
C.Blanch 2009

Technology Safety Tutorial

Metalworking 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.
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
Word List
reported
storage
hands

loose
handles
heads

remove
cutting
hacksaw

pressure
thrown
swept

6
C.Blanch 2009

Technology Safety Tutorial

Battery Drill
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.
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________

7
C.Blanch 2009

8
C.Blanch 2009

Technology Occupational Health and Safety Instruction

Wrought Iron Forming Tools
The risk of injury when using these substances is VERY LOW - Level 1 Risk
1. Name 2 hazards associated with using the following
metal forming tools
1.Twister_______________________________________________________________
______________________________________________________________________
2.Scroll former___________________________________________________________
_______________________________________________________________________
3. Circle former/bender/riveter_______________________________________________
_______________________________________________________________________
4. Small shears __________________________________________________________
_______________________________________________________________________

What is the maximum size of steel used in forming tool and why is it dangerous to try and
use larger steel?
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________

9
C.Blanch 2009

Technology Safety Tutorial

Finishing Materials and Solvents

The risk of injury when using these substances is LOW - Level 1 Risk
1. Define the following finishing terms:
GLOSS: _______________________________________________________________
SATIN: _______________________________________________________________
TOXIC: _______________________________________________________________
COMBUSTIBLE: ________________________________________________________
VOLATILE: ____________________________________________________________
OPAQUE: _____________________________________________________________
TRANSPARENT: ________________________________________________________
SOLVENT: _____________________________________________________________
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.
_____________________________________________________________________
_____________________________________________________________________________________________
_____________________________________________________________________________________________
_____________________________________________________________________________________________
_____________________________________________________________________________________________

10
C.Blanch 2009

11
C.Blanch 2009

12
C.Blanch 2009

Technology Safety Tutorial

Magnabend Folding Machine

The risk of injury when using this machine is MODERATE - Level 2 Risk
Neatly 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.

13
C.Blanch 2009

Technology Safety Tutorial

Bench & Pedestal Drill Drill Press

The risk of injury when using this machine is MODERATE Level 2 Risk

Neatly PRINT the missing words and answer question 15:

1. Always use a machine vice or cramp to ________________ the work.
2. If the Drilling machine is fitted with a Jacobs Chuck, remove the chuck
___________after fitting or removing a drill.
3. If the drill jams, immediately _______________ off the drilling machine and allow it to
fully ___________ before easing off the pressure.
4. Do not reach around or behind a ________________ drill piece.
5. Do not stop the chuck with your _______________.
6. Check that the machine is operating at the correct ________________.
7. Make sure the drill piece is centred and tightly held in the ______________.
8. Do not remove shavings when the drill piece is still ______________.
9. To protect your eyes and hair, wear __________ _______________ and a ______.
10. Only _______ person should use the bench drill at any time.
11. Do not distract or crowd an _______________ at work on the drilling machine.
12. The ____________ is responsible for starting and stopping the drilling machine.
13. The next person to use the bench drill should stand behind the yellow safety
___________.
14. If the drill is not cutting easily, it should be reported to the _______________ and not
be forced.
15. Discuss some of the risks involved when using this machine.
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
___________________________________________________

Word List
Speed
Spectacles
Cap
One
Teacher

Spinning
Machine
Safety
Zone

Hold
Key
Switch
Stop

Revolving
Hands
Chuck
Operator

14
C.Blanch 2009

Technology Safety Tutorial

Liquefied 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
leak
burning
cylinder

pressure
flame
treatment

hot
down
equipment

shut
soapy
oven

15
C.Blanch 2009

Technology Safety Tutorial

Spot 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:

16
C.Blanch 2009

Technology Safety Tutorial

Spot 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
2. The spot welding area should be kept clean of paper and other flammable
materials.
3. It is not necessary to wear protective eyewear when using the spot welder.
4. It is very dangerous to use the spot welder in an area where water is present.
5. Trailing the electrical cord across benches, machines and passageways is
dangerous.
6. Even though dangerous fumes are given off when spot welding, it is not
necessary to use this equipment in a well ventilated area.
7. The sparks given off when spot-welding need not be considered as dangerous.
8. The spot welder should only be used with sheet metal and when under direct
teacher supervision.
9. It is not necessary to remove the grease and grime from joints to be spotwelded.
10. The spot welder electrode tips need to be kept clean at all times.
11. Discuss some of the risks involved when using the Spot Welder.
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
______

17
C.Blanch 2009

Technology Safety Tutorial

Metal 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:

18
C.Blanch 2009

Technology Safety Tutorial

Belt Linishing Machine - Linisher
The risk of injury when using this machine is MODERATE Level 2 Risk
Answer the following questions by referring to the safety instruction sheet on Linishers:
1. Describe THREE sanding operations can be carried out on the Linishing machine.
1.
2.
3.

2. What type of abrasive is used on the sanding belt? ___________________________

3. Describe THREE grades of abrasive and the operation they would be used for:1.
2.
3.
4. Why must a work piece being sanded be held in both hands?
____________________________________________________________________
____________________________________________________________________
5. Explain why small or thin pieces of timber should not be sanded on the linisher?
_____________________________________________________________________

___________________________________________________________

6. What does the yellow line painted on the floor around the Linishing machine mean?

7. State FIVE safety rules that the operator of a Linishing machine should observe
1.
2.
19
C.Blanch 2009
3.
4.
5.

before starting to sand a piece of timber:

20
C.Blanch 2009

21
C.Blanch 2009

Technology Safety Tutorial

MIG Welding Machine
The risk of injury when using the MIG Welder is SUBSTANTIAL - Level 3 Risk
Neatly PRINT the missing words to complete these sentences.
1. The operator must have completed the OHS I_____________ and t______________
2. The OHS t _________ must be satisfactorily completed before using these machines.
3. Teacher a______________ must be sought and gained prior to using these machines.
4. All welding must be carried out in the w___________ b___________ or behind the
protective welding s____________.
5. The correctly tinted f________ welding helmet must be worn when electric welding.
6. When chipping slag after electric arc welding, personal p___________ equipment
(PPE) such as safety s______________ must be worn.
7. Protective l__________ g____________ are to be worn on your hands and leather
spats used to protect your f_________ against hot molten metal.
8. Make sure the job to be welded is properly e___________ .
9. Changing w__________ r_______ with the power switched on and using your bare
hands can be very dangerous.
10. Never use the welding machine where there is w_________ present, especially on the
floor.
11. You should regard all metals in the welding area as being h_____. Handle with caution.
12. In the event of an accidental flash, report to the t___________ immediately. Welding
flash can be very painful and require hospital attention.
13. Persons wearing CONTACT LENSES must not attempt to use this equipment.
14. Discuss some of the risks involved when using the Electric Arc or MIG welding machine.
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________

22
C.Blanch 2009

Technology Safety Tutorial

100mm Disc Grinder

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.
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________

23
C.Blanch 2009

Technology Safety Tutorial

Metal 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:

24
C.Blanch 2009

Technology Safety Tutorial

Metal Cold Saw

The risk of injury when using this machine is SUBSTANTIAL - Level 3 Risk

25
C.Blanch 2009

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 Tutorial

Oxy-Acetylene Equipment
The risk of injury when using this equipment is SUBSTANTIAL - Level 3 Risk
26
C.Blanch 2009

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?
____________________________________________________________________
____________________________________________________________________

27
C.Blanch 2009