Lesson 1Mechanical dangers: pinch points, moving parts, lifting, crane and clamp failuresTalk about mechanical dangers from moving parts, pinch points, and lifting in fabrication shops. Stress guarding, safe use of clamps and fixtures, and planning crane and hoist moves to stop 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 2Falling and height work dangers: platforms, scaffolds, ladders, falling from platform casesLook at fall risks when welding high on platforms, scaffolds, and ladders. Focus on access, edge guards, openings, and falling objects, plus planning tie-off points and rescue for high welding 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 dangers: welding power sources, cable insulation, earth faults, portable tool risksHandle electrical dangers from welding power, bad cables, poor grounding, and portable tools. Learners check shock, arc, and fire risks, and use inspection, bonding, and work ways to control electrical danger.
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 dangers: spatter, hot work fire starts, burnable materials, cutting torch risksFocus on heat and fire dangers from hot work, like sparks, spatter, slag, and torch flames. Learners find fire starts, burnable 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 breathing dangers: welding fumes makeup, solvent and paint leftovers, hexavalent chromium, ozone and nitrogen oxidesCheck chemical and breathing dangers from welding fumes, coatings, solvents, and process gases. Learners connect base metals and consumables to specific poisons and pick ventilation and masks based on danger.
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, time rush, distraction from material move and forkliftsLook at mind and human factors wey affect welding safety, like tiredness, time rush, distractions, and material traffic. Learners connect dis to error chance and danger 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 light dangers: UV/IR radiation, bright flash, reflected arcs from shiny surfacesCover eye dangers from welding arcs, like UV, IR, and bright light, plus shine from shiny surfaces. Stress eye and face protection, curtains, safe distance, and check of 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 dangers: grinding, cutting, bang noise and hand-arm shakeCheck noise and shake dangers from grinding, cutting, bang tools, and powered hand tools. Learners guess danger level, find hearing 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 9Special and maintenance dangers: lockout/tagout, tool change, cleaning inside assemblies, tight spacesCheck dangers from special welding and maintenance, like lockout/tagout fails, tool changes, cleaning inside gear, and tight space work, stress planning, permits, and check steps before enter 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 dangers: bad postures, repeat moves, hand carry of heavy partsCover body position dangers from bad postures, overhead work, repeat moves, and hand carry heavy parts. Stress layout, aids, and work ways wey cut strain and muscle 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
