Lesson 1Mechanical risks: pinch spots, moving parts, lifting, crane and clamp failuresLooks at mechanical risks from moving parts, pinch points, and lifting in metal shops. 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 2Fall and height risks: platforms, scaffolds, ladders, falling from platformsChecks fall dangers when welding up high on platforms, scaffolds, ladders. Focuses on access, edge guards, holes, dropped items, plus tie-off spots and rescue for high 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 3Electric risks: welding power units, cable covers, ground faults, portable tool dangersCovers electric risks from welding power, bad cables, poor grounding, portable tools. You'll check shock, arc, fire risks, and use checks, bonding, safe ways to cut electric 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 risks: spatter, hot work sparks, burnable stuff, cutting torch dangersFocuses on heat and fire from hot work like sparks, spatter, slag, torch flames. Spot ignition sources, burnables, controls like permits, fire watches, 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 risks: welding smoke makeup, solvent and paint leftovers, hex chrome, ozone and NOXLooks at chemical and lung risks from welding smoke, coatings, solvents, gases. Link metals and fillers to poisons, pick ventilation and masks by 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 moves and forkliftsReviews mind and human bits affecting welding safety like tiredness, pressure, distractions, material traffic. Link these to mistake chances and risk spotting.
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 risks: UV/IR rays, bright flash, bounce-back arcs from shiny bitsCovers eye risks from welding arcs: UV, IR, bright light, shiny reflections. Stresses eye/face gear, curtains, safe distance, lens/shield checks.
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 risks: grinding, cutting, bang noise and hand-arm shakeChecks noise and vibration from grinding, cutting, bang tools, powered hands. Guess exposure, spot ear and shake risks, pick 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 9Special and upkeep risks: lockout/tagout, tool swap, cleaning inside builds, tight spacesLooks at special welding and upkeep risks like lockout fails, tool changes, inside cleaning, tight spaces. Stress planning, permits, checks before entry or power-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 10Body position risks: odd poses, repeat moves, hand-lifting heavy bitsCovers body risks from odd poses, overhead, repeats, hand heavy lifts. Stress layout, aids, methods to cut strain and muscle hurts.
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
