Lesson 1Mechanical hazards: pinch points, moving parts, lifting, crane and clamp failuresDetails mechanical hazards from moving parts, pinch points, and lifting operations in fabrication shops. Emphasises guarding, safe use of clamps and fixtures, and planning crane and hoist moves to prevent failures.
Pinch points on rollers, presses, and drivesGuarding and interlocks on powered equipmentSafe use of clamps, jigs, and positionersRigging checks for cranes and hoistsHandling plate, beams, and structural shapesLesson 2Falls and work-at-height hazards: platforms, scaffolds, ladders, fall-from-platform scenariosExamines fall risks when welding at height on platforms, scaffolds, and ladders. Focuses on access, edge protection, openings, and dropped objects, plus planning tie-off points and rescue for elevated welding tasks.
Assessing elevated welding and cutting tasksGuardrails, toe boards, and platform openingsSafe ladder selection and positioningPersonal fall arrest and anchor pointsDropped tools and falling object controlsLesson 3Electrical hazards: welding power sources, cable insulation, earth faults, portable tool risksAddresses electrical hazards from welding power sources, damaged cables, poor earthing, and portable tools. Learners assess shock, arc, and fire risks, and apply inspection, bonding, and work practices to control electrical exposure.
Welding power source configurations and risksCable insulation damage and inspection stepsGrounding, bonding, and earth fault hazardsWet locations and increased shock potentialPortable electric tools in fabrication areasLesson 4Thermal and fire hazards: spatter, hot work ignition sources, combustible materials, cutting torch risksFocuses on thermal and fire hazards from hot work, including sparks, spatter, slag, and torch flames. Learners identify ignition sources, combustible materials, and controls such as permits, fire watches, and hot work zones.
Sparks, spatter, and slag travel distancesIgnition of combustibles and hidden spacesCutting torch leaks and flashback risksHot work permits and area preparationFire watch duties and post-work monitoringLesson 5Chemical and respiratory hazards: welding fumes composition, solvent and paint residues, hexavalent chromium, ozone and nitrogen oxidesExplores chemical and respiratory hazards from welding fumes, coatings, solvents, and process gases. Learners link base metals and consumables to specific toxicants and select ventilation and respirators based on exposure.
Welding fume generation and key componentsSolvent, paint, and coating decompositionHexavalent chromium in stainless weldingOzone and nitrogen oxides near the arcVentilation and respirator selection basicsLesson 6Psychosocial and human factors: fatigue, time pressure, distraction from material movement and forkliftsReviews psychosocial and human factors that influence welding safety, including fatigue, time pressure, distractions, and material traffic. Learners connect these factors to error likelihood and hazard recognition quality.
Fatigue effects on attention and coordinationTime pressure and production-driven shortcutsDistraction from forklifts and moving loadsCommunication in noisy, busy shop areasSupervisor role in managing human factorsLesson 7Optical and eye hazards: UV/IR radiation, visible flash, reflected arcs from shiny surfacesCovers optical hazards from welding arcs, including UV, IR, and visible light exposure, plus reflections from shiny surfaces. Emphasises eye and face protection, curtain use, safe distances, and inspection of lenses and shields.
UV and IR radiation from welding arcsVisible flash and arc eye mechanismsReflected arcs from shiny or wet surfacesSelecting welding helmets and filter lensesUsing screens and barriers to protect bystandersLesson 8Noise and vibration hazards: grinding, cutting, impact noise and hand-arm vibrationAnalyses noise and vibration hazards from grinding, cutting, impact tools, and powered hand tools. Learners estimate exposure, identify hearing and vibration risks, and select controls such as damping and PPE.
Typical noise sources in welding shopsHearing damage mechanisms and indicatorsNoise surveys and exposure estimationHand-arm vibration from powered toolsSelecting hearing protection and tool controlsLesson 9Non-routine and maintenance hazards: lockout/tagout, tool change, cleaning inside assemblies, confined spacesExplores hazards from non-routine welding and maintenance, including lockout/tagout failures, tool changes, cleaning inside equipment, and confined space work, emphasising planning, permits, and verification steps before entry or re-energising.
Recognizing non-routine welding and repair tasksLockout/tagout steps for welding equipmentHazards during tool change and adjustmentCleaning inside vessels and large assembliesConfined space permits and attendant rolesLesson 10Ergonomic hazards: awkward postures, repetitive motions, manual handling of heavy partsCovers ergonomic hazards from awkward postures, overhead work, repetitive motions, and manual handling of heavy parts. Emphasises layout, aids, and work methods that reduce strain and musculoskeletal injury risk.
Awkward postures in welding positionsRepetitive grinding and torch movementsManual handling of plates and componentsUse of positioners, jigs, and lift assistsJob rotation and micro-break planning
