Lesson 1Mechanical hazards: pinch points, moving parts, lifting, crane and clamp failuresLooks at mechanical risks from moving bits, pinch spots, and lifting in fab shops. Stresses guards, right use of clamps and setups, and planning crane lifts to avoid breakdowns.
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 scenariosChecks fall dangers when welding up high on platforms, scaffolds, and ladders. Covers access, edge guards, holes, dropped items, plus tie-off spots and rescue for high-up welding.
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 risksDeals with shocks from welders, frayed cables, bad earthing, and portable tools. You'll check shock, arc flash, and fire chances, using inspections, bonding, and safe habits to cut electrical risks.
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 heat and fire risks from hot jobs like sparks, spatter, slag, and torch flames. Spot fire starters, flammable stuff, and controls like permits, fire watches, and hot work areas.
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 oxidesDives into fumes, coatings, solvents, and gases from welding. Link metals and fillers to poisons, pick ventilation and masks based on what's in the air in our shops.
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 mind and body factors affecting welding safety, like tiredness, rush, distractions from moving gear and forklifts. Link them to mistakes and spotting risks properly.
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 eye risks from arcs: UV, IR, bright flashes, and bounces off shiny bits. Stresses eye and face gear, screens, safe distances, and checking 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 vibrationBreaks down noise and shakes from grinding, cutting, banging tools, and hand power tools. Gauge exposure, spot ear and shake risks, pick damping and ear gear.
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 spacesLooks at odd-job and fix-up risks like lockout fails, tool swaps, cleaning insides, and tight spaces. Stress planning, permits, and checks before starting or powering up.
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 partsHandles body strain from odd poses, overhead work, repeats, and lugging heavy bits. Focus on setups, helpers, and ways to cut strain and body injuries.
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
