Lesson 1Mechanical dangers: pinch points, moving parts, lifting, crane and clamp faultsCovers mechanical risks from moving parts, pinches, and lifts in metal shops. 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 height work risks: platforms, scaffolds, ladders, falling from platformsLooks at fall dangers welding at height on platforms, scaffolds, ladders. Covers access, edge guards, holes, dropped items, tie-offs, and rescue for high-up 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 dangers: welding power units, cable covers, ground faults, portable tool risksHandles electrical risks from welding power, bad cables, poor earths, portable tools. You'll check shock, arc, fire dangers, and use checks, bonds, 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 4Heat and fire dangers: spatter, hot work sparks, burnable materials, cutting torch risksFocuses on heat and fire from hot work like sparks, spatter, slag, torch flames. Spot ignition sources, burnables, 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 breathing dangers: welding smoke makeup, solvent and paint leftovers, hex chrome, ozone and NOXLooks at chemical and lung risks from welding fumes, coatings, solvents, gases. 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 6Mind and human factors: tiredness, rush, distractions from material moves and forkliftsChecks mind and human factors affecting welding safety like tiredness, pressure, distractions, material traffic. Link to error 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 7Eye and light dangers: UV/IR rays, bright flash, reflections from shiny bitsCovers eye risks from welding arcs: UV, IR, bright light, shiny reflections. Stresses eye/face gear, curtains, safe distances, 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, hand-arm vibesChecks noise and vibration from grinding, cutting, impact tools, powered hands. Estimate exposure, spot ear/vibe risks, pick damping, 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 9Extra and upkeep dangers: lockout/tagout, tool swaps, cleaning inside gear, tight spacesLooks at risks from extra welding/upkeep like lockout fails, tool changes, inside cleans, tight spaces. Stress planning, 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 10Body strain dangers: odd poses, repeat moves, hand-lifting heavy bitsCovers body risks from odd poses, overhead, repeats, hand-lifting heavies. Stress layout, aids, methods to cut strain and muscle hurts.
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
