Lesson 1Hot work risks: welding, cutting, brazing — ignition sources and control measuresThis part talks about hot work like welding, cutting, and brazing. It explains where fires can start, how to watch for fires, use permits, oversee contractors, and how those who underwrite insurance check how often hot work happens, who supervises it, and if fire protection is 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, contaminationThis part breaks down what stops business in metal making places, like weak supply chains, machines stopping, power going out, and things getting dirty. It shows how to map what things depend on, how long to recover, and what to think about for business interruption coverage.
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 part checks natural disasters that hit medium-sized towns in America, like floods, strong winds, hail, and earthquakes. It talks about choosing sites, height above water, strong buildings, and how underwriters use danger info and checks to price the 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 part goes over liquids that can catch fire or burn easily in metal factories, like paints, thinners, and fuels. It covers how to store them safely, keep them apart, ventilate areas, protect from fire, and warning signs underwriters look for in handling and stock amounts.
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 part looks at dust and small particles from cutting, grinding, and polishing metal. It explains how explosions start and can chain react, what cleaning is expected, how to design collection systems, and how underwriters check dust controls and possible 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 hazardsThis part describes usual ways metal parts are made, like using CNC machines, forming, welding, and coating. It connects each step to risks of fire, explosion, injury, and machine damage, and shows how the flow of work affects the overall risk picture.
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 part explores stealing, damaging things on purpose, and stock risks in light industry yards and fenced storage areas. It covers valuable materials, security around the edges, lights, cameras, and how underwriters check crime controls and how values pile up.
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 part deals with rules and environment risks in finishing metal and painting. It covers sorting waste, storing it, controlling smoke and gases, permits, handling spills, and how underwriters estimate cleanup costs and what coverage is needed.
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 part checks human elements that affect how often and how bad losses are. It covers cleaning, regular upkeep, training workers, watching them, and controlling contractors, and shows how company culture and rules shape 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 releaseThis part reviews usual causes of losses in metal places, like fires, explosions, machines failing, breakdowns, and releases of bad stuff. It stresses loss records, finding root causes, and how underwriters turn patterns into prices 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
