Lesson 1Mechanical hazards: pinch points, moving parts, lifting, crane and clamp failuresLooks at mechanical dangers from moving parts, pinch spots, and lifting in fabrication areas. Stresses guards, safe clamp use, and planning crane moves to avoid breakdowns.
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 scenariosChecks fall risks welding up high on platforms, scaffolds, ladders. Focuses on getting up, edge guards, holes, dropped items, plus tie-off spots and rescue for high 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 dangers from welding power, bad cables, poor earthing, portable tools. Learners check shock, arc, fire risks, and use checks, bonding, safe ways to cut 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 risksFocuses on heat and fire dangers from hot work like sparks, spatter, slag, torch flames. Learners spot fire starters, burnable stuff, and controls like permits, fire watches, hot 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 oxidesLooks into chemical and breathing hazards from welding smoke, coatings, solvents, gases. Learners link metals and fillers to poisons and pick ventilation, masks by 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 mind and human factors affecting welding safety like tiredness, rush, distractions, material traffic. Learners link these to mistake chances and hazard spotting.
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 dangers from welding arcs like UV, IR, bright light, reflections off shiny bits. Stresses eye/face gear, curtains, safe distance, lens 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 vibrationChecks noise and shake dangers from grinding, cutting, bang tools, powered hand tools. Learners guess exposure, spot ear and shake risks, pick controls like dampers, 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 unusual welding and upkeep hazards like lockout fails, tool swaps, cleaning inside gear, tight spaces, stressing plans, permits, checks before start 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 10Ergonomic hazards: awkward postures, repetitive motions, manual handling of heavy partsCovers body strain dangers from odd poses, overhead work, repeat moves, handlifting heavy bits. Stresses setup, aids, methods to cut strain and body injuries.
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
