Lesson 1Mechanical hazards: pinch points, moving parts, lifting, crane and clamp failuresCovers mechanical risks from moving parts, pinch points, and lifting in fab shops. Stresses guards, safe clamp use, and planning crane moves to avoid 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 2Falls and work-at-height hazards: platforms, scaffolds, ladders, fall-from-platform scenariosLooks at fall risks welding at height on platforms, scaffolds, ladders. Covers access, edge guards, openings, dropped items, tie-offs, and rescue plans.
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 risks from welders, bad cables, poor earthing, portable tools. Assess shock, arc, fire risks, and use checks, bonding, safe practices.
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 risks from hot work like sparks, spatter, slag, torches. Spot ignition sources, flammables, and use 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 at chemical and lung risks from fumes, coatings, solvents, gases. Link metals and wires to toxins 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. 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 7Optical and eye hazards: UV/IR radiation, visible flash, reflected arcs from shiny surfacesCovers eye risks from arcs: UV, IR, flash, reflections off shiny bits. Stress helmets, lenses, curtains, distances, 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 vibration hazards: grinding, cutting, impact noise and hand-arm vibrationAnalyses noise and shake risks from grinding, cutting, hammers, power tools. Gauge exposure, ear and hand 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 9Non-routine and maintenance hazards: lockout/tagout, tool change, cleaning inside assemblies, confined spacesLooks at unusual welding and upkeep risks like lockout fails, tool swaps, inside cleaning, tight spaces. Stress 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 risks from odd poses, overhead work, repeats, heavy lifts. Stress layout, aids, methods to cut strain and injury.
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
