Lesson 1Mechanical hazards: pinch points, moving parts, lifting, crane and clamp failuresLooks at mechanical risks from moving bits, pinch spots, and lifting in fabrication areas. Stresses guards, safe clamp use, and planning crane moves 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 getting up safely, edge guards, holes, dropped items, tie-off spots, and rescue plans.
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 electric risks from welding power units, worn cables, bad grounding, and hand tools. You'll check shock, arc flash, and fire dangers, plus inspections and safe practices.
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 oxidesLooks at chemical and breathing risks from welding smoke, coatings, solvents, and gases. Link metals and fillers to toxins and pick ventilation or masks based on what's in the air.
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 stuff and forklifts. Link these to mistakes and how well you spot risks.
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 welding arcs like 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 vibrationChecks noise and shake risks from grinding, cutting, banging tools, and power hands tools. Guess exposure, spot ear and hand risks, and pick fixes like padding 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 risks from unusual welding and fixes, like lockout fails, tool swaps, cleaning inside gear, 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 partsCovers body strain risks from odd poses, overhead work, repeats, and lifting heavy bits. Stress layout, helpers, and ways to cut strain and muscle 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
