COURSE OVERVIEW:

Welcome to the Manage Serious Safety Threats in Automotive Service Workshops course. This comprehensive course is designed to strengthen your ability to recognise, assess and control the most serious safety risks that arise in automotive repair and service environments, from small independent workshops through to large dealership and fleet operations.

This course begins by outlining the major categories of serious safety threats in automotive service workshops, explaining the legal WHS duties, standards and duty-of-care obligations that apply to owners, managers, supervisors and technicians, clarifying roles and responsibilities for identifying hazards, reporting incidents and implementing controls, and describing how risk assessment, safe work procedures, permits, supervision and consultation processes must be embedded in everyday workshop practice.

Physical layout, housekeeping and surface conditions in workshops play a major role in many preventable injuries, particularly slips, trips and falls. This section examines how wet or oily floors from spills of oil, coolant, fuel, brake fluid and wash water, as well as grease, dirt, loose fasteners and offcuts left on the floor, significantly increase the risk of losing footing in work bays and access areas. It also considers hoses, power leads, air lines and tools stretched across walkways, uneven or damaged floor surfaces with broken tiles, pits and drains, and poor lighting in work bays, under vehicles and around storage racks. The section further explores how cluttered work areas with parts, tyres and tools stored in access paths, and slips and falls from steps, platforms, stairs and inspection pits, combine to create an environment where minor hazards can quickly escalate into serious incidents.

Movement of vehicles in and around the workshop introduces high-consequence risks whenever people and cars share the same space. This section focuses on the potential for workers to be struck or run over by moving vehicles in or near the workshop, crush injuries between vehicles and fixed structures such as benches, hoists and walls, and reversing incidents when moving vehicles in or out of bays or parking areas. It also explores collisions between vehicles, trolleys and pedestrian workers, and uncontrolled vehicle roll when handbrakes are not applied or wheels are not chocked, emphasising the need for disciplined vehicle movement procedures, clear traffic routes and strong communication.

Hoists, jacks and under-vehicle work are central to automotive servicing but, if mismanaged, can result in catastrophic harm. This section examines vehicle falls from hoists due to incorrect lifting points or overload, the collapse of poorly supported vehicles on jacks, stands or ramps, and the risks of being underneath a vehicle when hoist locks fail or are not engaged. It also describes pinch, crush and impact injuries that can occur when raising or lowering hoists, and falls into inspection pits or working at the edge of pits without guarding, highlighting the importance of correct set-up, maintenance, lock-out procedures and exclusion zones whenever vehicles are elevated.

Manual handling and musculoskeletal strain are embedded in almost every task in an automotive workshop and can lead to both acute and chronic injury if not controlled. This section explores lifting and carrying heavy components such as wheels, tyres, batteries, gearboxes and cylinder heads, and handling awkward loads including bumpers, exhausts, bonnets and windscreens that are difficult to grip or balance. It also considers repetitive tasks such as wheel changing, extensive impact wrench work and frequent hand-tool use, as well as awkward postures under dashboards, in footwells, in engine bays or leaning over guards. The section further addresses prolonged stooping, kneeling or working overhead on suspension, exhaust and roof racks, and the physical impacts of pushing and pulling heavy vehicles, toolboxes, jacks and tyre racks around the workshop.

Hand tools, power tools and workshop machinery make modern servicing efficient but also carry significant risk when used without appropriate controls. This section examines cuts, punctures and bruises from hand tools such as screwdrivers, chisels, pliers and knives, and impact and crush injuries from hammers, pullers and presses. It also explores flying particles generated by grinding, cutting, drilling and wire-brushing, the danger of entanglement in rotating parts of drills, grinders, lathes and other machinery, and kickback from power tools such as grinders and impact tools. Noise exposure from rattle guns, compressors, hammering and grinding is also considered, with an emphasis on guarding, equipment maintenance, correct tool selection, PPE and safe operating procedures.

High temperatures, hot components and concentrated heat sources generate ongoing burn and scald risks in workshops. This section looks at burns from hot engines, exhaust systems, turbochargers, radiators and brake components that can retain heat long after a vehicle stops running, and scalds from hot coolant when radiator caps are removed incorrectly. It also addresses contact with hot oil, transmission fluid and other heated fluids, burns from welding, brazing, cutting and soldering operations, and burns from hot tools, heat guns, glue guns and body-repair equipment, reinforcing the importance of cooling times, safe opening procedures, PPE and protective guarding around hot work areas.

Fuels, oils and other workshop fluids are central to automotive work but carry significant fire, explosion, toxicity and environmental risks. This section examines the hazards associated with petrol, diesel and LPG, including fire and explosion risk from vapours and spills and skin and eye irritation or vapour inhalation in poorly ventilated areas. It also explores risks from oils and lubricants, such as prolonged skin contact leading to dermatitis and slippery floor surfaces when spilled, and from brake fluid, power steering and transmission fluids that can cause skin and eye irritation, ingestion hazards and high-pressure injection injuries. Coolants and antifreeze are considered for their toxicity if ingested and the skin and eye irritation that can arise from contact, underscoring the need for safe handling, storage and spill management.

Solvents, paints and chemical products used for cleaning, preparation and refinishing pose both acute and chronic health risks. This section focuses on solvents and degreasers used in parts cleaners, brake cleaner, carby cleaner and panel prep solvents, and the vapour inhalation that can cause dizziness, headache and longer-term health effects. It examines skin defatting and dermatitis from frequent solvent contact, and fire and explosion risks from flammable solvent products. The section also explores exposure to paints, primers, thinners and body repair products in panel and paint areas, and highlights the serious respiratory sensitisation and asthma risks associated with isocyanates present in some two-pack products.

Electrical systems, exhaust gases and refrigerants introduce a mix of chemical, asphyxiation and explosion hazards that must be treated with particular care. This section examines battery acid from lead-acid batteries and the risk of chemical burns to skin and eyes, and explosion risks from hydrogen gas released during battery charging in unventilated areas. It also explores the dangers of exhaust gases, including carbon monoxide and other combustion products accumulating in enclosed workshops, leading to headache, dizziness and asphyxiation if ventilation is poor. Air conditioning refrigerants are considered for frostbite injuries from liquid contact with skin or eyes and asphyxiation risk in confined spaces if large leaks occur, highlighting correct equipment use, leak detection and ventilation controls.

Dusts, fibres and airborne particles generated in repair activities can pose serious respiratory and long-term health risks if not properly controlled. This section addresses brake and clutch dust, including potential asbestos in older vehicles or parts, metal and rust dust from grinding, sanding and cutting components, and filler and paint sanding dust in body shops and repair bays. It emphasises the need for suitable extraction systems, wet methods, respiratory protection and work practices that minimise dust generation and spread.

Fire, ignition sources and explosion events can develop rapidly in workshops where flammable vapours, aerosols and ignition sources coexist. This section explores ignition of fuel vapours, solvent vapours and aerosol propellants by sparks, welding, grinding or smoking, and fires arising from incorrect storage of flammable liquids, oily rags and waste materials. It also examines battery explosions during charging or jump-starting operations, and fires caused by overheated electrical equipment and overloaded power outlets, reinforcing the importance of housekeeping, segregation, ventilation, correct storage and fire-response readiness.

Electrical and high-voltage systems in modern vehicles create new and evolving safety challenges, especially with hybrid and electric vehicles. This section examines electric shock risks from faulty electrical equipment, power tools, chargers and leads, and high-voltage shock or arc flash from traction batteries, orange cables and inverters in hybrid and electric vehicles. It also addresses residual charge in capacitors and power electronics after power down, and short circuits and burns when working on starter motors, alternators or wiring without isolating the battery, highlighting the need for specialised training, lock-out/tag-out procedures and model-specific safety information.

Pressurised systems and stored energy within vehicles can release large forces unexpectedly if not controlled, leading to serious injury. This section explores the release of pressurised fluids from fuel injection, hydraulic and air suspension systems, and high-pressure injection injuries from fuel lines, grease guns and hydraulic systems. It considers sudden movement of springs, torsion bars and suspension components when released, inadvertent airbag and pretensioner deployment during diagnostic or repair work if systems are not rendered safe, and explosion or rupture of tyres during inflation, particularly truck or high-pressure tyres, emphasising safe isolation, restraining fixtures and controlled inflation practices.

Confined and restricted workspaces are common in automotive service and can amplify many other hazards. This section examines work in inspection pits, under dashboards or inside cargo areas where ventilation is limited, and the build-up of exhaust gases, solvent vapours or refrigerant in enclosed spaces. It also considers restricted access that makes emergency escape or rescue difficult, highlighting the need for ventilation, atmospheric awareness, buddy systems and clear rescue plans when working in these environments.

Noise, biological hazards and psychosocial risks combine to influence both immediate safety and long-term health and wellbeing in automotive workshops. This section explores prolonged noise exposure from impact tools, grinding, hammering and engines on test, hand–arm vibration from extended use of impact wrenches, grinders, sanders and other tools, and whole-body vibration during road testing or extended driving of vehicles with defects. It also considers exposure to blood and body fluids on steering wheels, seats and seatbelts after accidents or injuries, used needles and sharps concealed in vehicles, rodent droppings, animal hair and nesting materials in engine bays and cabins, and mould and bacteria in air conditioning systems, damp carpets and boot areas. The section further addresses heat stress in poorly ventilated workshops or outdoor bays, cold and wet conditions in partially open or outdoor work areas, UV exposure for mobile and yard work, time pressure to complete jobs quickly leading to shortcuts or missed safety steps, long hours, overtime and late or weekend work causing fatigue and reduced concentration, and stress arising from customer expectations, comebacks, warranty issues, productivity targets and conflict or aggression from dissatisfied customers or co-workers.

By the end of this course, you will be equipped with comprehensive knowledge, structured risk-assessment methods and practical control strategies to identify, manage and escalate serious safety threats in automotive service workshops, protecting technicians, apprentices, support staff, customers and visitors while supporting safe, efficient and legally compliant workshop operations.

Each section is complemented with examples to illustrate the concepts and techniques discussed.

LEARNING OUTCOMES:

By the end of this course, you will be able to understand the following topics:

1. Introduction to Safety Threats in Automotive Service Workshops

• Major categories of serious safety threats in automotive repair and service environments
• Legal WHS duties, standards and duty-of-care for owners, managers and technicians
• Roles and responsibilities for identifying hazards, reporting incidents and implementing controls
• Risk assessment, safe work procedures, permits, supervision and consultation in workshops

2. Physical Environment, Slips and Trips

• Wet or oily floors from spills (oil, coolant, fuel, brake fluid, wash water)
• Grease, dirt, loose fasteners and offcuts left on the floor
• Hoses, power leads, air lines and tools stretched across walkways
• Uneven or damaged floor surfaces, broken tiles, pits and drains
• Poor lighting in work bays, under vehicles and around storage racks
• Cluttered work areas with parts, tyres and tools stored in access paths
• Slips and falls from steps, platforms, stairs and inspection pits

3. Vehicle Movement and Workshop Traffic

• Being struck or run over by moving vehicles in or near the workshop
• Crush injuries between vehicles and fixed structures (benches, hoists, walls)
• Reversing incidents when moving vehicles in or out of bays or parking areas
• Collisions between vehicles, trolleys and pedestrian workers
• Uncontrolled vehicle roll when handbrakes are not applied or wheels not chocked

4. Hoists, Jacks and Under-Vehicle Work

• Vehicle falling from a hoist due to incorrect lifting points or overload
• Collapse of poorly supported vehicles on jacks, stands or ramps
• Being underneath a vehicle when hoist locks fail or are not engaged
• Pinch, crush and impact injuries when raising or lowering hoists
• Falling into inspection pits or working at the edge of pits without guarding

5. Manual Handling and Musculoskeletal Strain

• Lifting and carrying heavy components (wheels, tyres, batteries, gearboxes, cylinder heads)
• Handling awkward loads (bumpers, exhausts, bonnets, windscreens)
• Repetitive tasks such as wheel changing, impact wrench work and hand-tool use
• Awkward postures under dashboards, in footwells, in engine bays or over guards
• Prolonged stooping, kneeling or working overhead (suspension, exhaust, roof racks)
• Pushing and pulling heavy vehicles, toolboxes, jacks and tyre racks

6. Hand Tools, Power Tools and Workshop Machinery

• Cuts, punctures and bruises from hand tools (screwdrivers, chisels, pliers, knives)
• Impact and crush injuries from hammers, pullers and presses
• Flying particles from grinding, cutting, drilling and wire-brushing
• Entanglement in rotating parts of drills, grinders, lathes and other machinery
• Kickback from power tools (grinders, impact tools)
• Noise exposure from rattle guns, compressors, hammering and grinding

7. Hot Surfaces, Burns and Heat Sources

• Burns from hot engines, exhaust systems, turbochargers, radiators and brake components
• Scalds from hot coolant when radiator caps are removed incorrectly
• Contact with hot oil, transmission fluid and other heated fluids
• Burns from welding, brazing, cutting and soldering operations
• Burns from hot tools, heat guns, glue guns and body-repair equipment

8. Fuels, Oils and Workshop Fluids

• Fuels (petrol, diesel, LPG) – fire and explosion risk from vapours and spills; skin and eye irritation and vapour inhalation in poorly ventilated areas
• Oils and lubricants – prolonged skin contact causing dermatitis; slippery floor surfaces when spilled
• Brake fluid, power steering and transmission fluids – skin and eye irritation, ingestion risk and high-pressure injection injuries
• Coolants and antifreeze – toxic if ingested; skin and eye irritation from contact

9. Solvents, Paints and Chemical Products

• Solvents and degreasers (parts cleaners, brake cleaner, carby cleaner, panel prep solvents) – vapour inhalation causing dizziness, headache and longer-term health effects
• Solvents and degreasers – skin defatting and dermatitis from frequent contact
• Solvents and degreasers – fire and explosion risk from flammable products
• Paints, primers, thinners and body repair products – organic solvent exposure in panel and paint areas
• Paints and two-pack products – isocyanate exposure leading to sensitisation and asthma

10. Batteries, Exhaust Gases and Refrigerants

• Battery acid from lead-acid batteries – chemical burns to skin and eyes from electrolyte
• Battery charging – explosion risk from hydrogen gas in unventilated areas
• Exhaust gases – carbon monoxide and other combustion products in enclosed workshops
• Exhaust gases – headache, dizziness and asphyxiation risk if ventilation is poor
• Air conditioning refrigerants – frostbite injuries from liquid contact with skin or eyes
• Air conditioning refrigerants – asphyxiation risk in confined spaces if large leaks occur

11. Dusts, Fibres and Airborne Particles

• Brake and clutch dust, including potential asbestos in older vehicles or parts
• Metal and rust dust from grinding, sanding and cutting components
• Filler and paint sanding dust in body shops and repair bays

12. Fire, Ignition Sources and Explosion Events

• Ignition of fuel vapours, solvent vapours and aerosols by sparks, welding, grinding or smoking
• Fires from incorrect storage of flammable liquids, oily rags and waste materials
• Battery explosions during charging or jump-starting operations
• Overheated electrical equipment and overloaded power outlets causing fire

13. Electrical and High-Voltage Systems

• Electric shock from faulty electrical equipment, power tools, chargers and leads
• High-voltage shock or arc flash from hybrid and electric vehicles (traction batteries, orange cables, inverters)
• Residual charge in capacitors and power electronics after power down
• Short circuits and burns when working on starter motors, alternators or wiring without isolating the battery

14. Pressurised Systems and Stored Energy in Vehicles

• Release of pressurised fluids from fuel injection, hydraulic and air suspension systems
• High-pressure injection injuries from fuel lines, grease guns and hydraulic systems
• Sudden movement of springs, torsion bars and suspension components when released
• Airbag and pretensioner deployment during diagnostic or repair work if systems are not rendered safe
• Explosion or rupture of tyres during inflation, particularly truck or high-pressure tyres

15. Confined and Restricted Workspaces

• Working in inspection pits, under dashboards or inside cargo areas with limited ventilation
• Build-up of exhaust gases, solvent vapours or refrigerant in enclosed spaces
• Restricted access making emergency escape or rescue difficult

16. Noise, Biological and Psychosocial Hazards

• Prolonged noise exposure from impact tools, grinding, hammering and engines on test
• Hand–arm vibration from extended use of impact wrenches, grinders, sanders and other tools
• Whole-body vibration during road testing or extended driving of vehicles with defects
• Blood and body fluids on steering wheels, seats and seatbelts after accidents or injuries
• Used needles and sharps concealed in vehicles
• Rodent droppings, animal hair and nesting materials in engine bays and cabins
• Mould and bacteria in air conditioning systems, damp carpets and boot areas
• Heat stress in poorly ventilated workshops or outdoor bays in hot weather
• Cold and wet conditions in partially open or outdoor work areas
• UV exposure when working outdoors for extended periods (mobile services, yard work)
• Time pressure to complete jobs quickly leading to shortcuts or missed safety steps
• Long hours, overtime and late or weekend work causing fatigue and reduced concentration
• Stress from customer expectations, comebacks, warranty issues and productivity targets
• Conflict or aggression from dissatisfied customers or co-workers

COURSE DURATION:

The typical duration of this course is approximately 3-4 hours to complete. Your enrolment is Valid for 12 Months. Start anytime and study at your own pace.

COURSE REQUIREMENTS:

You must have access to a computer or any mobile device with Adobe Acrobat Reader (free PDF Viewer) installed, to complete this course.

COURSE DELIVERY:

Purchase and download course content.

ASSESSMENT:

A simple 10-question true or false quiz with Unlimited Submission Attempts.

CERTIFICATION:

Upon course completion, you will receive a customised digital “Certificate of Completion”.