Lesson 1Hot work risks: welding, cutting, brazing — ignition sources and control measuresDis section focus on hot work like welding, cutting, and brazing. It cover fire starters, fire watch practices, permits, contractor watching, and how underwriters check hot work frequency, supervision, and if fire protection good enough.
Common hot work methods in metal shopsIgnition sources and heat transfer pathsHot work permit systems and recordsFire watch duties and monitoring periodsContractor hot work and supervisionUnderwriting questions on hot work controlsLesson 2Business interruption drivers: supply chain, equipment downtime, power loss, contaminationDis section analyze business interruption causes for metal makers, including supply chain weakness, equipment stop, power cut, and contamination. It explain dependency mapping, recovery time, and BI coverage things.
Critical equipment and single‑point failuresSupply chain mapping and key suppliersUtility dependence and power reliabilityContamination, recalls, and rework delaysRecovery time objectives and bottlenecksBI values, limits, and coverage featuresLesson 3Natural catastrophe exposures relevant to mid‑sized US cities (flood, wind, earthquake) and site vulnerability assessmentDis section check natural disaster risks affecting mid-sized US cities, like flood, wind, hail, and earthquake. It talk about site choice, height, building strength, and how underwriters use danger data and checks to rate risk.
Regional CAT perils for metal facilitiesFlood zones, drainage, and elevationWind, hail, and roof system vulnerabilitiesEarthquake exposure and building typeSite access, egress, and emergency planningUse of CAT models and mapping in underwritingLesson 4Flammable and combustible materials used (paints, solvents, fuels) and safe storage practicesDis section review flammable and combustible liquids used in metal plants, like paints, thinners, and fuels. It cover storage design, separation, ventilation, fire protection, and underwriting warning signs in handling and stock levels.
Classes of flammable and combustible liquidsNFPA and OSHA storage and handling criteriaDesign of paint rooms and mixing areasFlammable liquid cabinet and room standardsFuel storage, transfer, and spill controlsUnderwriting red flags in liquid storageLesson 5Dust and particulate risks from metalworking and secondary explosion potentialDis section analyze dust and particle dangers from cutting, grinding, and polishing. It explain primary and secondary explosion ways, cleaning expectations, collection system design, and how underwriters check dust controls and loss situations.
Dust generation in common metal processesCombustible dust properties and testingDust collection and local exhaust designHousekeeping standards and cleaning methodsSecondary explosion scenarios and impactsUnderwriting review of dust controlsLesson 6Typical processes in metal parts manufacturing (CNC machining, welding, painting) and associated hazardsDis section outline common metal making processes like CNC machining, forming, welding, and coating. It link each process to fire, explosion, injury, and equipment damage dangers, and explain how process flow affect overall risk profile.
CNC machining, cutting fluids, and fire riskForming, stamping, and press safety controlsWelding and fabrication line exposuresSurface prep, blasting, and coating hazardsMaterial handling and in‑process storageProcess flow and accumulation of valuesLesson 7Theft, vandalism, and inventory exposure specific to light industrial yards and fenced storageDis section explore theft, vandalism, and inventory risks at light industrial yards and fenced storage. It cover target materials, perimeter security, lighting, surveillance, and how underwriters check crime controls and value grouping.
Attractive metals and high‑value inventory itemsPerimeter fencing, gates, and access controlLighting, cameras, and intrusion alarmsKey control and vehicle security measuresInventory records and valuation practicesCrime loss history and underwriting impactLesson 8Regulatory and environmental liabilities relevant to metal finishing and painting operations (waste, emissions)Dis section address rules and environmental liabilities in metal finishing and painting. It cover waste types, storage, emissions control, permits, spill response, and how underwriters measure possible cleanup costs and coverage needs.
Hazardous waste identification and codingWaste storage, labeling, and accumulation limitsAir emissions, VOCs, and control equipmentWastewater pretreatment and discharge permitsSpill prevention and emergency response plansEnvironmental underwriting information needsLesson 9Human factors: housekeeping, maintenance regimes, operator training, and contractor controlsDis section check human factors dat affect loss frequency and severity. It cover cleaning, preventive maintenance, operator training, supervision, and contractor controls, and show how culture and discipline affect underwriting choices.
Housekeeping standards and inspection routinesPreventive and predictive maintenance plansOperator training, certification, and refreshersLockout/tagout and safe work proceduresContractor selection and on‑site controlsUnderwriter assessment of safety cultureLesson 10Common loss causes: fires, explosions, equipment failure, machinery breakdown, contaminant releaseDis section review common loss causes in metal facilities, like fires, explosions, equipment failure, and contaminant releases. It stress loss data, root cause analysis, and how underwriters turn patterns into pricing and risk needs.
Historical fire and explosion loss patternsMachinery breakdown and fatigue failuresElectrical faults and control panel issuesHydraulic, pneumatic, and coolant leaksContaminant release and cleanup scenariosUsing loss runs in underwriting decisions
