Lesson 1Mechanical hazards: pinch points, moving parts, lifting, crane and clamp failuresCovers mechanical hazards from moving parts, pinch points, and lifting in fabrication shops. Stresses guarding, safe clamp and fixture use, and planning crane and hoist operations to avoid 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 scenariosLooks at fall risks during welding at height on platforms, scaffolds, and ladders. Covers access, edge guards, openings, dropped objects, plus tie-off points and rescue for high-level 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 hazards from welding power supplies, damaged cables, poor earthing, and portable tools. Learners check shock, arc, and fire risks, using inspections, bonding, 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 hazards from hot work like sparks, spatter, slag, and torch flames. Learners spot ignition sources, flammable materials, 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 oxidesCovers chemical and breathing hazards from welding fumes, coatings, solvents, and gases. Learners match base metals and consumables to toxins and pick ventilation and respirators for 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 mental and human factors affecting welding safety, like tiredness, rush, distractions, and material traffic. Learners link these to error 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 7Optical and eye hazards: UV/IR radiation, visible flash, reflected arcs from shiny surfacesCovers eye hazards from welding arcs like UV, IR, visible light, and reflections off shiny surfaces. Stresses eye and face protection, screens, safe distances, and 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 vibration hazards: grinding, cutting, impact noise and hand-arm vibrationAnalyses noise and vibration from grinding, cutting, impact tools, and powered hand tools. Learners gauge exposure, spot hearing and vibration risks, and choose 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 9Non-routine and maintenance hazards: lockout/tagout, tool change, cleaning inside assemblies, confined spacesLooks at hazards from non-routine welding and maintenance like lockout/tagout issues, tool swaps, internal cleaning, and confined 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 10Ergonomic hazards: awkward postures, repetitive motions, manual handling of heavy partsCovers body strain hazards from odd postures, overhead work, repeats, and heavy lifting. 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
