TRADE OF

Industrial Insulation
PHASE 2

Module 1
Sheet Metal and Insulation Fundamentals
UNIT: 1

Introduction to the
Workshop Environment

Produced by

In cooperation with subject matter expert:

Michael Kelly

SOLAS 2014

Module 1 Unit 1.

Introduction to Workshop Environment.

Table of Contents
Introduction .................................................................................................................. 1
Unit Objective .............................................................................................................. 2
1.0
Safety Procedures ........................................................................................... 3
1.1 Attendance and Timekeeping.......................................................................3
1.2 Standards of Behaviour in the Canteen ......................................................3
1.3 Entering Another Workshop Area ..............................................................4
1.4 Emergency Evacuation Procedure ..............................................................4
1.5 Accident Prevention and Reporting ............................................................5
2.0
Hazards ............................................................................................................ 7
2.1 Preventing Workshop Hazards ....................................................................8
3.0
Fire Extinguishers......................................................................................... 11
3.1 Types of Fire Extinguishers .......................................................................11
3.2 Classes of Fires .............................................................................................11
3.3 How to Use a Fire Extinguisher ...............................................................12
4.0
First Aid ......................................................................................................... 14
4.1 Principles of First Aid .................................................................................14
4.2 Calling for Help ...........................................................................................14
5.0
Housekeeping in the Workshop ................................................................. 15
5.1 Safe Disposal of Waste Materials...............................................................15
5.2 Storing Tools and Equipment ....................................................................15
Summary ...................................................................................................................... 17
Suggested Exercises ................................................................................................... 17
Training Resources .................................................................................................... 17

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Introduction
You are about to embark on a learning experience that we hope will be
enjoyable and an influencing time of your life. Your focus should be to develop
the knowledge, skills and competencies that will enable you to enter the labour
market or to bring added value to employers that will facilitate growth and
competitiveness.
Our intention is to provide the best possible environment through attention to
both the physical space in which learning takes place, and to the supporting
environment.
Module 1
Sheet Metal &
Insulation
Fundamentals

Unit 1
Introduction to the
Workshop
Environment

Unit 6
Marking, Cutting,
Punching, Rolling,
Seam Swagingn &
Screwing

Unit 2
Manual
Handling

Unit 7
Swaging (Basic)
Male/Female &
Flange Turning

Unit 3
Measuring,
Marking &
Cutting Out

Unit 8
Pipe Cladding
(Basic) Fabrication
& Application

Industrial Insulation Phase 2

Unit 4
Notching, Folding &
Joining

Unit 9
Metal Cladding
Assembly
Work

Unit 5
General Allowances for
Insulation & Cladding

Unit 10
Pipe Insulation (Hot &
Cold) Material Selection
& Application

Unit 11
Valve &
Flange Box
Fundamentals

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Unit Objective
By the end of this unit each apprentice will be able to:

State the attendance, safety and fire drill procedures.

Identify hazards in the workshop.

Identify different fire extinguisher types and their uses.

State the basic principles of first aid.

Understand the importance of good housekeeping.

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1.0 Safety Procedures

Health and Safety aims to prevent accidents and ill health at the place of work,
and will always play an essential part in our delivery of training. It is necessary
that you play an active role by observing and adhering to safety procedures so
as to ensure we maintain health and safety standards within the training centre.
Key Learning Points
Attendance and time keeping procedures.

Training centre layout, location of evacuation assembly points.

Canteen and training centres operational practice.

Safety procedures applicable to training location.

1.1 Attendance and Timekeeping

The Training Centre is open five days a week Monday to Friday. The start /
finish time for all apprentices in full time training is as follows:

1.
2.
3.
4.
5.

Monday

08.30

15:45

Tuesday

08.30

15:45

Wednesday

08.30

15:45

Thursday

08.30

15:45

Friday

08.30

12:45

Morning Tea Break

10 Minutes

Lunch Break

30 Minutes

Timekeeping is important; you MUST be on time.

Clocking out early is considered a breach of time keeping regulations.
Queue in an orderly manner while clocking IN or OUT.
Do not clock in or out for another apprentice or trainee.
Do not leave the training centre without notifying your instructor and
always clock out and back in on your return.

1.2 Standards of Behaviour in the Canteen

1.
2.
3.
4.
5.
6.

Safety clothing and footwear must not be worn.

Queue in an orderly manner.
Sit at allocated areas only.
Smoking is not allowed.
Adhere to canteen timetables.
Respect and show courtesy to canteen staff and other users.

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7.
8.
9.
10.
11.
12.

Do not remove cutlery or food from the canteen.

Return tray and utensils to the trolley provided.
Purchased food cannot be exchanged.
Shoplifting from the canteen warrants dismissal.
Close circuit television is in operation at all times.
Soft drink cans to be placed in the bins provided.

1.3 Entering Another Workshop Area

From time to time you may need to visit other workshop areas within the
training centre. It is important to note that different hazards may exist in
different areas of the training centre that the apprentice may not be aware off.
When entering another workshop area the following procedures should be
followed:
1.
2.
3.
4.
5.
6.

Notify the instructor on your arrival and state the reason for your visit.
Wear the appropriate personal protective equipment (PPE).
Be aware of hazards which may exist in the workshop area.
Do not operate any tools or machinery without prior permission of the
instructor.
Do not attempt to distract other apprentices.
Failure to comply with the above rules may lead to disciplinary action.

1.4 Emergency Evacuation Procedure

Action by Safety Committee
Co-ordination of the evacuation procedure and subsequent action will be the
responsibility of a number of people such as the Safety Officer, the Safety
Committee Chairman and/ or the Training Centre Manager, who will assemble
at the reception area on the alarm sounding, and he or she will identify what
the threat is.
Responsibility for evacuation of the training Centre / location is allocated to
members of the Safety Committee, each with a distinct area of responsibility.
The individual member will nominate a deputy to carry out the evacuation in
the event of his / her absence from the area.
Action by Instructing Staff
When the fire alarm sounds the following action is to be taken:
Make sure that all trainees / apprentices in the general area leave the building
by their designated exit or nearest safe exit and go to their assembly point.
Instructors will escort their class to the assembly point, do a head count of
their class and report back to the fire warden who is manning the assembly
point.

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Action by Apprentice
When the fire alarm sounds the following action is to be taken:
Leave the Training Centre by your designated exit, or the nearest safe exit and
go to your assembly Point. Do not stop to collect personal belongings (you will
be shown this exit and assembly point during your induction period ).
Remain at the assembly point until the all clear is given
If you are aware that someone is still in the building, please report this to the
responsible person at the assembly point.

Please Note:
When the alarm sounds and you are in an area that is away from your
designated exit, leave by the nearest safe exit and assemble at your
designated assembly point.

1.5 Accident Prevention and Reporting

Injuries are caused by accident. Accidents are unplanned happenings
Unplanned happenings are initiated by unsafe actions
Unsafe actions are often contributed to by a persons attitude
In some cases the cause is mechanical or structural failure.
All persons must be aware of the need for a responsible attitude towards
accident prevention, which will avoid unsafe actions taking place. Skylarking
and horseplay are strictly forbidden and will lead to dismissal.
In order to be aware of specific hazards in any section, you must read the
document on Hazard Identification before you start work. This document is
located in your section.
You must leave a work area in such a way that no one else can get hurt.
Trying to do someone elses job without authority is wrong and dangerous.
There may be risks you cannot foresee.
If someone distracts you, and you get hurt in consequence, you wont be
pleased. Think, before you distract anyone else.
Practical jokes and larking about are often good fun, but not under Training
Centre or work conditions. They are liable to have a tragic ending.
Causes of Accidents
Boredom

Carelessness

Familiarity with the job

Frustration and irritability

Haste

Horseplay

Lack of concentration

Lack of knowledge

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Thoughtlessness
All accidents must be notified to your instructor who will deal with the
situation depending on the extent of the injury involved.

In the event of any accident:

Report the accident to your instructor who will decide the course of action to
be taken.
Category 1

First aid will be administrated on site.

Category 2

First aid will be administrated on site and the patient

will then be transported to the nearest A&E department

Category 3

An ambulance will be called and emergency first aid will

be administrated on site.

You will be asked to give details of the accident and how it occurred, all
of which will be recorded in the accident register.
Depending on the extent of your injuries, your next-of-kin will be
notified.

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2.0 Hazards
Key Learning Points:
Identification of basic workshop equipment and hazards.

Introduction to basic bench fitting tools, e.g. hand tools, marking

out equipment, efficient tool layout.

Individual and group workshop cleaning routines, cleaning roster.

Hazards exist in all workplaces and new hazards can be created in a changing
environment. Hazards can be identified as:

Poor work design.

Human behaviour.

Materials or substances.

Faulty equipment or machinery.

Inappropriate management systems and procedures.

The use of a systematic approach is essential to identify all the possible hazards
through anticipation or analysis.
Employees should be consulted to ensure all hazards and risks are identified
and control measures are appropriate to reduce the associated risk.
It is generally accepted that there are five classes of hazard: Biological

Bacteria, Fungi, Parasites.

Chemical

Acids, Cleaning agents, Dust, fumes.

Environmental

Electromagnetic fields, Dust, Noise, Radiation, Spillages,

Vibration.

Behavioural

Accident, Bullying, Error, Discrimination, Harassment,

Stress.

Physical

Cranes, Electricity, Floors, Hoists, Ladders, Lighting,

Manual Handling, Pressure Vessels, Stairs, Work Platforms.

Hazard identification and risk control documents must be produced for all of
the above hazards.

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2.1 Preventing Workshop Hazards

Tidiness
Tidiness is the foundation of accident prevention. Keep your workplace tidy
and, if you see anything in an obviously unsafe place, remove it or report it.
There are proper places for rubbish and waste. Dumping things any old
where may lead to a fire or an accident. Tidy up as you go along and
remember that the job isnt finished until youve cleared up. A cleaning roster
should be in place to ensure that overall tidiness is maintained.
Handling Materials
Its not what is handled, so much as the way its handled, that leads to so many
accidents. Look out for sharp edges, splinters and nails. Pull out or knock
down projecting nails before you pass material on or throw it out for scrap.
Dont try to carry a load that you cant see over. Containers should be treated
with caution, as many liquids are flammable, corrosive or poisonous. Even if
empty, assume that they are dangerous unless you are sure that the liquid they
contained was harmless. Get help when lifting unduly awkward or heavy
objects. Watch your step as you walk about. Watch for traffic and people
working overhead. Spilt liquids such as oil cause slips and falls. Wipe them up.
Pick up anything that is left lying around. Short cuts are dangerous. Go the safe
way even if it means going the longer way. Use the gangways and walkways
provided. When passing a place where chips or dust fly about, turn your head
away. If possible keep clear of dangerous areas.
Falls
Stack materials so that it is stable and safe. Put tools and other equipment
where they cannot fall or be knocked onto someone below. Dont climb about;
use a suitable ladder. Examine ladders and planks before you use them. Do not
stand under suspended loads.
Machinery
Operate and clean machines according to the instructions. Never take short
cuts. Check that guards are in place before operating a machine. Disconnect
the power supply from the machine before dismantling for cleaning. Handle all
cutting tools with extreme care. Ensure that the floor on which you stand is
free from oil or grease and is dry. All spillages should be cleaned as they occur.
Concentrate on the job and do not be distracted by other activities.
Compressed Air
Compressed air can injure or kill without warning. It can easily damage
sensitive organs such as eyes, ears or internal organs. Death can occur if air is
forced through the skin into the blood stream.

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Electricity
Electricity can injure or kill without warning. Do not mess with it. If using a
portable power tool, for example a drilling machine or an angle grinder, always
check the following:

Is the plug undamaged, clean and dry?

Is it 110 volt (look at the information plate on the tool).

Is the lead sound and undamaged with no cuts or makeshift repairs?

Fires
Fire-fighting equipment is for use in emergencies. Keep it clear of obstructions
so that it can be accessed quickly when required. This also applies to fire doors
and exits. Do not wait until there is a fire to find out where these things are
and how to use them. Find out now.
Clothing
Loose clothing such as ties, open coats, flapping cuffs, bows and scarves are
always dangerous when working near machinery. Smooth shafts, despite their
innocent appearance, are dangerous. Avoid loose clothing because the material
probably wont tear if it catches, but will take you into the machine or around
the shaft. Wear a neat fitting set of overalls.
Understandably, hands are more prone to injury than any other parts of the
body. They are used to handle an endless variety of materials, some quite safe,
others dangerous. Protection for the hands is available in many forms and for
many purposes. What is suitable for handling sheet metal will probably be quite
unsuitable for working with chemicals. So make sure you use the right type of
protection for the job. One important point you should remember is that it is
highly dangerous to wear gloves when working with machinery, particularly
where there is a risk of the gloves being caught up in moving parts. Gloves
should not be used when working with drilling machines or circular saws and
caution should be exercised when using power operated bending rolls.
Wear good safety boots or shoes at work and keep them in good repair. It pays
in the long run because you will get less tired, as well as being less liable to foot
injuries and falls.
Loose hair can easily get caught up in moving machinery apart from the
injury and pain, if the hair roots are damaged your hair will never grow again.
Ensure that your hair is tied up and out of danger.
The head contains the nerve centre, which controls the body. Damage to that
centre can wreck your whole life. That is why it is important to wear a safety
helmet whenever there is a risk of your head being injured. A helmet is
absolutely essential on construction sites and its use in many other industries is
highly desirable.

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Eye Protection
If some foreign body gets into your eye, you should have it attended to
immediately. Your mate may be willing and able to get it out, but your eyes are
too valuable to trust to any unskilled person. You know how uncomfortable
and painful it can be to get a bit of windblown dust in your eye. A bit of metal
or stone, a splash of chemical, sparks from a grinding wheel or slag from a
weld may result in anything from seriously impaired vision to total blindness.
The use of a pair of safety glasses or similar protection will prevent this
happening. Get into the habit of using eye protection always.
Remember you can get a new pair of safety glasses but you are on your
only pair of eyes
Hearing Protection
Loud noise can damage your hearing. When noise levels are high you must
wear ear protectors. If you do not, you will suffer hearing loss and may have to
wear a hearing aid later in life. Machines with high noise levels include
woodworking machinery, heavy metal guillotines, angle grinders and
percussion drills you must wear hearing protection while working with these
machines or while in an area where they are in operation. If in doubt about
noise levels ask your instructor.
Breathing Apparatus
Some processes produce dust or fumes. These may be harmful or may only be
a nuisance. If you work where dust or fumes are produced, dangerous or
otherwise, you must wear suitable masks or breathing apparatus to protect your
lungs. The type of equipment required will depend on the type of dust or
fumes present.
Hand Tools
Keep hand tools in good order. Spanners with splayed jaws, chisels with burred
or mushroomed heads, files, screwdrivers and so on with handles that are
damaged, may lead to injury. Misuse of tools also leads to injury. Carrying tools
in a safe manner will protect yourself and others. Cutting tools should be
carried with edges protected.

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3.0 Fire Extinguishers

Key Learning Points
Identification and selection of fire extinguishers suitable for
carbonaceous, liquid fuel and electrical fires.

Location and recommended use of fire fighting equipment.

There are a number of Fire Stations located around the training centre. They
have already been pointed out to you during the tour of the training centre at
the start of your course. There are also individual fire extinguishers positioned
in all workshops and they will be pointed out to those trainees and apprentices
operating in the areas covered.

3.1 Types of Fire Extinguishers

There are four types of fire extinguisher in common use. Each one
extinguishes specific classes of fire. Newer fire extinguishers use a picture /
labeling system to designate which class of fire they are to be used on. Older
fire extinguishers are labeled with coloured geometrical shapes with letter
designations. The letter designations may be included in the new picture /
labeling system as shown below.
The main types of extinguisher that you will come across are;

Water

( Red )

CO2

( Black )

Dry Powder

( Blue )

Foam
( Cream )
These have been colour coded so that you can identify them quickly. It is very
important that you do not use the wrong extinguisher and put yourself in
danger. The main body colour of the extinguisher is red. The identifying colour
is either in the form of a coloured band or the writing may be in the specific
colour.

3.2 Classes of Fires

There are five classes of fire. Here we will look at the three most common
ones.
Class A

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Fires involving solid materials, mainly of organic origin, which normally burn
under production of embers, e.g. wood, paper, straw, textiles, coal, car tyres.
Use: Water, Foam or Powder.
Class B

Fires caused by combustion of liquids or materials that liquefy, e.g. petrol,

benzene, oils, paints, tar, ether, alcohol, paraffin.
Use: Foam, Powder or CO2
Class C

Fires caused by combustion of gases e.g. methane, propane, hydrogen,

acetylene, natural gas, and city gas
Use: Powder, only if the fire has just started and the gas supply can definitely
be shut off. Otherwise let it burn out. Get out in case of explosion.
Electrical Fires

Fires in electrical equipment are considered to be Class B. Use a Carbon

Dioxide Extinguisher for electrical fires. CO2 is ideal as it is nonconductive
and harmless to electrical equipment. It smothers flames by denying air to the
fire.

3.3

How to Use a Fire Extinguisher

Even though extinguishers come in a number of shapes and sizes, they all
operate in a similar manner.
Here's an easy acronym for fire extinguisher use.
PASS

Pull, Aim, Squeeze, and Sweep

Pull the pin at the top of the extinguisher that keeps the handle from being
accidentally pressed
Aim the nozzle toward the base of the fire.

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Squeeze the handle to discharge the extinguisher, while standing

approximately 8 feet away from the fire. If you release the handle, the
discharge will stop.
Sweep the nozzle back and forth at the base of the fire. After the fire appears
to be out, watch it carefully since it may re-ignite!

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4.0 First Aid

Key Learning Points
First aid principals and accident reporting procedures.

Accident reporting, procedures and records.

If you are not quite up to the mark, your attention is relaxed and thats just
when an accident happens. Your attention is needed at all times in the training
centre or while at work. If you feel unwell, you should report to your
instructor.
The smallest pinprick can lead to blood poisoning. Get first-aid treatment for
all injuries, however slight. Leave any dressing alone after it has been put on.
Tampering with it may infect the wound with germs.
If anyone is badly hurt, send for a member of the First-Aid team before
moving him/her. Moving an injured person without the necessary knowledge
may cause further injury.

4.1 Principles of First Aid

First aid is the initial assistance or care of a suddenly sick or injured person.
First aid is an important part of everyday life, both at home or at work. It is the
care a person applies as soon as possible after an accident or sudden illness.
This prompt care and attention prior to the arrival of an ambulance can
sometimes mean the difference between life and death, or between a full or
partial recovery.
The main aims of first aid are:
(1) Protect the casualty from further harm ensure the scene is safe.
(2) Provide pain relief this could include ice packs or making the patient
more comfortable.
(3) Prevent the injury or illness from getting worse .
(4) Provide reassurance.

4.2

Calling for Help

In Ireland dial 999 for emergency assistance .112 is the GSM international
standard emergency number which can be dialled from digital mobile phones
or fixed landline phones.
There are three things to remember when calling for help:
1.
2.
3.

State which emergency service you want: Ambulance, Fire, Police.

Stay on the line until connected with the emergency service operator
who will need to talk to you before sending assistance.
Give as much information as possible about the location and the nature
of the emergency

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5.0 Housekeeping in the Workshop

Key Learning Points
Professional care of tools and equipment.

Location and identification of special tools, equipment and

consumables.

Identification and marking/engraving toolkit.

Safe disposal of scrap and swarf in an environmentally sound

It is important to keep the work area clean and tidy. All tools and equipment
must be returned to their respective toolbox or storage area when not in use.
When using power tools always wear safety glasses. Do not wear loose
clothing, and always tie back long hair when operating machinery. Ensure that
the floor is kept free of debris, oil and coolant spills. Clean up any spills
immediately.
Guidelines for the Care and Use of Hand Tools
Select the correct size tool for the job.

Do not use worn or damaged tools.

Maintain tools in good condition.

Cutting tools need to be sharp and safe.

Store and carry tools safely.

5.1 Safe Disposal of Waste Materials

All waste materials such as metal cut-offs and scrapped parts should be placed
in special metal scrap bins and sent for recycling.
All other waste material such as oily paper, cloths, filings etc., should be
removed from the workbench or floor using a brush and pan. This waste can
be placed in general disposal bins.

5.2 Storing Tools and Equipment

When a task has been completed all tools and equipment should be returned to
the stores. Some important points to be aware of when storing tools and
equipment are:
1.
2.
3.
4.

ALL power tools should be stored on shelves with their electrical cords
rolled in a neat manner.
Special measuring equipment such as vernier callipers and height gauges
should be placed in their appropriate cases.
Hand tools should be placed in tool boxes and stored neatly.
Extension leads and cords should be rolled up neatly and either hung up
or placed on shelves for safe storage.

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5.

6.

Excess consumables such as welding rods etc, should be returned to the

stores and placed in their relevant compartments for the next apprentice
to use.
Engraving and marking tools should be properly stored in their own
compartment boxes and returned to the stores when not in use.

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Summary
Health and Safety in the work place is everyones responsibility. Developing
your safety sense begins the first day you walk into a training centre or onto a
building site. Read the Safety Code carefully and then re-read it. By following
the safety code throughout your training you will develop your safety sense and
at the same time complete your training without injuries. Developing your
safety sense involves the following:
Attitude of Mind: Each apprentice should be determined not to get hurt or
hurt others.
Alertness:

Always being on the lookout for hazards.

Knowledge:

Recognising by experience, including the experience of

others, what is likely to lead to an accident.

Suggested Exercises
(1) Identify hazards within the workshop.
(2) State the appropriate fire extinguisher for use with the following types
of fire: paper, petrol and electrical fires.
(3) State the attendance and canteen procedures.
(4) State the procedure to be followed when entering another workshop
area.

Training Resources
(1) Induction manual.
(2) Safety videos.
(3) Copy of the training centre safety manual.
(4) Fire equipment.
(5) Course manual.
(6) Apprentice toolkit.
(7) Sample accident report forms.

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Castleforbes House
Castleforbes Road
Dublin 1