Lesson 1Mechanical hazards: pinch points, moving parts, lifting, crane and clamp failuresCovers mechanical dangers from moving parts, pinch points, and lifting in fabrication areas. Stresses guarding, safe clamp and fixture use, and planning crane and hoist 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 working-at-height hazards: platforms, scaffolds, ladders, fall-from-platform scenariosLooks at fall risks when welding up high on platforms, scaffolds, and ladders. Focuses on access, edge guards, openings, dropped items, plus planning tie-offs 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 electrical dangers from welding power, damaged cables, poor grounding, and portable tools. Learners check shock, arc, and fire risks, and use checks, bonding, and safe practices to cut 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 4Heat and fire hazards: spatter, hot work fire starters, flammable materials, cutting torch risksFocuses on heat and fire dangers from hot work like sparks, spatter, slag, and torch flames. Learners 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 breathing hazards: welding fumes makeup, solvent and paint leftovers, hexavalent chromium, ozone and nitrogen oxidesLooks into chemical and breathing hazards from welding fumes, coatings, solvents, and gases. Learners link base metals and fillers to specific poisons and pick ventilation and masks 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 6Mind and human factors: tiredness, rush, distractions from material shifts and forkliftsReviews mind and human factors affecting welding safety, like tiredness, rush, distractions, and material traffic. Learners link these to mistake chances and hazard spotting 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 7Eye and sight hazards: UV/IR rays, bright flash, reflections from shiny surfacesCovers eye hazards from welding arcs like UV, IR, bright light, and shiny surface reflections. Stresses eye and face gear, curtains, safe distances, and checks on 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 shake hazards: grinding, cutting, bang noise and hand-arm vibrationChecks noise and vibration dangers from grinding, cutting, bang tools, and powered hand tools. Learners guess exposure, spot ear and shake risks, and pick controls like 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 9Unusual and maintenance hazards: lockout/tagout, tool change, cleaning inside assemblies, confined spacesLooks at hazards from unusual welding and maintenance like lockout/tagout fails, tool swaps, cleaning inside gear, and tight spaces, stressing planning, permits, and checks before entry or restart.
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 10Body position hazards: awkward poses, repeat moves, hand-carrying heavy partsCovers body position hazards from awkward poses, overhead work, repeat moves, and hand-carrying heavy parts. Stresses layout, aids, and methods to cut strain and muscle injury risks.
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
