Arc Welding and Cutting (OSHA) Course

Lesson 1 • Welding Area Setup and Housekeeping

Defines safe workspace configuration, clearance requirements, and material storage rules. Proper setup directly reduces ignition and injury risk.

Lesson 2 • Regulatory Framework for Welding Safety

Covers the federal and industry safety standards governing arc welding operations. Connects compliance obligations to daily shop-floor decision-making.

Lesson 3 • Emergency Response Procedures

Trains students on immediate actions for fires, electrical incidents, and toxic exposures in welding areas. Prepares workers to respond before emergency services arrive.

Lesson 1 • Body and Skin Protection

Details flame-resistant clothing, leather gloves, and footwear requirements for welders. Proper body protection prevents burns from spatter, slag, and radiant heat.

Lesson 2 • Eye and Face Protection

Explains lens shade selection, helmet types, and filter standards for arc welding. Correct eye protection prevents permanent vision damage from UV and IR radiation.

Lesson 3 • Respiratory Protection Fundamentals

Introduces respirator types, fit-testing requirements, and cartridge selection for welding fumes. Respiratory protection is the last line of defence when ventilation is insufficient.

Lesson 4 • Hearing Protection and Ergonomic Aids

Addresses noise exposure limits, hearing protector ratings, and ergonomic supports for welding postures. Sustained noise and awkward postures cause cumulative occupational injury.

Lesson 1 • Fundamentals of Welding Electrical Systems

Explains AC and DC welding current, open-circuit voltage, and circuit components. Understanding current flow is prerequisite to recognising shock and arc-flash hazards.

Lesson 2 • Grounding and Bonding Requirements

Covers work-lead placement, equipment grounding, and bonding of conductive structures. Improper grounding is a leading cause of electrocution in welding operations.

Lesson 3 • Shock Prevention and Lockout Procedures

Teaches shock-prevention practices and energy-control procedures for welding equipment servicing. Lockout procedures prevent energisation during maintenance and repair tasks.

Lesson 1 • Ventilation Maintenance and Verification

Covers airflow measurement, filter replacement schedules, and system performance testing. Poorly maintained ventilation fails silently, exposing workers to uncontrolled fumes.

Lesson 2 • Shielding Gas Hazards and Safe Handling

Addresses asphyxiation risk from shielding gases, cylinder storage, and regulator safety. Inert shielding gases displace oxygen without warning, creating life-threatening atmospheres.

Lesson 3 • Welding Fume Composition and Health Effects

Identifies metal oxides, flux gases, and coating byproducts released during arc welding. Knowing contaminant identity drives correct exposure limit selection and control choice.

Lesson 4 • Ventilation System Types and Selection

Compares general dilution ventilation, local exhaust ventilation, and backdraft hoods for welding. Ventilation type must match contaminant generation rate and workspace geometry.

Lesson 1 • Combustible Material Control

Covers removal, relocation, and shielding of flammable materials within the welding zone. Eliminating fuel sources is more reliable than relying solely on fire suppression.

Lesson 2 • Fire Suppression Equipment and Fire Watch

Trains students on extinguisher classes, placement requirements, and fire watch duties. An equipped and trained fire watch is the last active defence against welding-ignited fires.

Lesson 3 • Hot Work Permit System

Explains permit issuance, authorisation roles, and closure requirements for welding in non-designated areas. Permits create a documented safety checkpoint before ignition sources are introduced.

Lesson 1 • Safe Transport and Movement of Cylinders

Addresses valve cap use, cylinder cart requirements, and prohibited transport methods. Cylinders dropped or struck can become unguided projectiles if the valve shears.

Lesson 2 • Cylinder Emergency Procedures

Covers response to leaking cylinders, fires involving cylinders, and cylinder overpressure events. Rapid correct response limits escalation from a minor leak to a catastrophic failure.

Lesson 3 • Cylinder Identification and Labeling

Explains colour coding, valve markings, and label requirements for welding gas cylinders. Misidentifying cylinder contents causes incorrect use and potentially fatal incidents.

Lesson 4 • Cylinder Storage Requirements

Covers segregation of fuel and oxidiser cylinders, chaining requirements, and storage area conditions. Improper storage creates catastrophic fire and explosion potential.

Lesson 1 • Equipment Modifications for Confined Spaces

Covers welding machine placement outside the space, cable management, and gas cylinder restrictions. Equipment configuration inside confined spaces amplifies electrical and asphyxiation hazards.

Lesson 2 • Confined Space Classification and Entry Permits

Defines permit-required vs. non-permit confined spaces and the entry authorisation process. Classification determines the level of control required before any worker enters.

Lesson 3 • Atmospheric Testing in Confined Spaces

Covers oxygen, flammable gas, and toxic contaminant testing sequences before and during entry. Atmospheric conditions change during welding, requiring continuous monitoring.

Lesson 4 • Ventilation Strategies for Confined Spaces

Explains forced-air ventilation, exhaust positioning, and prohibited ventilation methods for confined-space welding. Welding fumes accumulate rapidly in enclosed volumes without active ventilation.

Lesson 1 • Plasma Arc Cutting Fundamentals

Explains plasma arc cutting principles, equipment components, and process variables. Understanding the process enables correct setup and hazard anticipation before cutting begins.

Lesson 2 • Air Carbon Arc Gouging Safety

Addresses the unique hazards of air carbon arc gouging, including high noise, heavy fume, and spatter projection. Gouging generates significantly more contaminants than standard arc welding.

Lesson 3 • Safe Work Practices for Cutting Operations

Establishes positioning, workpiece support, and slag management practices for all cutting processes. Proper technique prevents molten metal falls, tip contact burns, and fire ignition.

Lesson 4 • Cutting Fume and Radiation Hazards

Identifies contaminants and radiation types specific to cutting processes and required controls. Cutting coated or painted metals releases highly toxic fumes requiring enhanced controls.