Lesson 1Mechanical hazards: pinch points, moving parts, lifting, crane and clamp failuresDetail mechanical hazards from movin parts, pinch points, an liftin operations eena fabrication shops. Emphasize guardin, safe use a clamps an fixtures, an plannin crane an hoist moves fi prevent 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 scenariosCheck fall risks when weldin at height pon platforms, scaffolds, an ladders. Focus pon access, edge protection, openings, an dropped objects, plus plannin tie-off points an rescue fi elevated weldin tasks.
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 risksAddress electrical hazards from weldin power sources, damaged cables, poor groundin, an portable tools. Learners assess shock, arc, an fire risks, an apply inspection, bondin, an work practices fi control 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 4Thermal and fire hazards: spatter, hot work ignition sources, combustible materials, cutting torch risksFocus pon thermal an fire hazards from hot work, includin sparks, spatter, slag, an torch flames. Learners identify ignition sources, combustible materials, an controls like permits, fire watches, an hot work zones.
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 oxidesExplore chemical an respiratory hazards from weldin fumes, coatings, solvents, an process gases. Learners link base metals an consumables to specific toxicants an select ventilation an respirators base pon 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 forkliftsReview psychosocial an human factors dat influence weldin safety, includin fatigue, time pressure, distractions, an material traffic. Learners connect dese factors to error likelihood an hazard recognition 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 surfacesCover optical hazards from weldin arcs, includin UV, IR, an visible light exposure, plus reflections from shiny surfaces. Emphasize eye an face protection, curtain use, safe distances, an inspection a lenses an 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 vibrationAnalyze noise an vibration hazards from grindin, cuttin, impact tools, an powered hand tools. Learners estimate exposure, identify hearin an vibration risks, an select controls like dampin an 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 spacesExplore hazards from non-routine weldin an maintenance, includin lockout/tagout failures, tool changes, cleanin inside equipment, an confined space work, emphasizin plannin, permits, an verification steps before entry or re-energizin.
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 partsCover ergonomic hazards from awkward postures, overhead work, repetitive motions, an manual handlin a heavy parts. Emphasize layout, aids, an work methods dat reduce strain an musculoskeletal injury risk.
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
