Lesson 1Hot work risks: welding, cutting, brazing — ignition sources and control measuresThis section focuses on hot work such as welding, cutting, and brazing. It covers ignition sources, fire watch practices, permits, contractor oversight, and how underwriters assess hot work frequency, supervision, and adequacy of fire protection.
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, contaminationThis section analyzes business interruption drivers for metal manufacturers, including supply chain fragility, equipment downtime, power loss, and contamination. It explains dependency mapping, recovery time, and BI coverage considerations.
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 assessmentThis section evaluates natural catastrophe exposures affecting mid‑sized US cities, including flood, wind, hail, and earthquake. It addresses site selection, elevation, building robustness, and how underwriters use hazard data and inspections 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 practicesThis section reviews flammable and combustible liquids used in metal plants, including paints, thinners, and fuels. It covers storage design, segregation, ventilation, fire protection, and underwriting red flags in handling and inventory 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 potentialThis section analyzes dust and particulate hazards from cutting, grinding, and polishing. It explains primary and secondary explosion mechanisms, housekeeping expectations, collection system design, and how underwriters evaluate dust controls and loss scenarios.
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 hazardsThis section outlines typical metal manufacturing processes such as CNC machining, forming, welding, and coating. It links each process to fire, explosion, injury, and equipment damage hazards, and explains how process flow affects 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 storageThis section explores theft, vandalism, and inventory exposures at light industrial yards and fenced storage. It covers target materials, perimeter security, lighting, surveillance, and how underwriters evaluate crime controls and aggregation of values.
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)This section addresses regulatory and environmental liabilities in metal finishing and painting. It covers waste classification, storage, emissions control, permits, spill response, and how underwriters gauge potential 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 controlsThis section examines human factors that influence loss frequency and severity. It covers housekeeping, preventive maintenance, operator training, supervision, and contractor controls, and shows how culture and discipline affect underwriting decisions.
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 releaseThis section reviews common loss causes in metal facilities, including fires, explosions, equipment failure, and contaminant releases. It emphasizes loss data, root cause analysis, and how underwriters translate patterns into pricing and risk requirements.
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
