Lesson 1Machine dangers: pinch spots, moving bits, lifting, crane and clamp breaksLooks at machine dangers from moving bits, pinch spots, and lifting in metal shops. Stresses guards, safe clamp use, and planning crane 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 high work dangers: stands, scaffolds, ladders, falls from standsChecks fall risks when welding high on stands, scaffolds, ladders. Focuses on ways in, 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 3Electric dangers: welding power units, cable covers, ground faults, portable tool risksDeals with electric dangers from welding power, bad cables, poor ground, portable tools. You check shock, arc, fire risks, and use checks, links, work ways to control.
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 job fire starts, burnable stuff, torch risksLooks at heat and fire dangers from hot jobs like sparks, spatter, slag, torch fire. You spot fire starts, burnables, 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 breathing dangers: welding smoke mix, solvent and paint bits, hex chrome, ozone and NOXChecks chemical and breathing dangers from welding smoke, coatings, solvents, gases. You link metals and fillers to poisons and pick air flow and 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 6Mind and human factors: tiredness, rush, distractions from moving stuff and forkliftsLooks at mind and human factors affecting welding safety like tiredness, rush, distractions, material moves. You link these to mistake chances and danger 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 7Eye and light dangers: UV/IR rays, bright flash, bounce from shiny spotsCovers eye dangers from welding arcs like UV, IR, bright light, plus shiny bounces. Stresses eye face gear, curtains, safe space, lens shield 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 shake dangers: grinding, cutting, bang noise and hand-arm shakeChecks noise and shake from grinding, cutting, bang tools, powered hands. You guess exposure, spot ear shake risks, pick controls like pads and gear.
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 upkeep dangers: lock/tag, tool swap, cleaning inside gear, tight spacesLooks at special welding upkeep dangers like lock/tag fails, tool swaps, inside cleans, tight spaces, stressing plans, permits, checks before start or power on.
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 fit dangers: bad poses, repeat moves, hand lifting heavy bitsCovers body fit dangers from bad poses, overhead, repeat moves, hand heavy lifts. Stresses setup, aids, ways to cut strain and body 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
