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Manufacturing & Marine · course plan

⚠ Pending professional review

This course plan, its lessons and its assessments has not yet been verified by a licensed engineer or certified journey-level tradesperson or by a certification or approval body. It is a study draft and may contain errors. Do not use it as instructions for work on a job site or on live equipment. Always follow your instructor, your supervising professional, and current official references and regulations.

VoTechWorks program approval and accreditation are still in progress. Credentials are issued only by the certifying bodies named in each program, after their own exams.

Shipbuilding / Marine Fabrication

9 courses · 1,800 clock hours · 12 mo full-time. Grading is competency-based: each course requires the written exam, a competent skills demonstration with zero safety faults, a signed log, and a passed safety audit; percentage weights only rank performance above the competency floor.

~~$25,480~~ COMPLIMENTARYprogram tuition

9courses

79lessons

1,800hours

31assessments

Development progressPlanCourses, lessons and assessments written for this tradeLessons79 of 79 lesson pages writtenPractice632 practice questionsResources117 reference entries (study list)Review76 lesson pages reviewed by a licensed professional

Study now: 79 lesson pages are open (lesson titles below are links).

MFG-SHIP13-01 Universal core

Universal Core: Safety, Math, Communication & Career for Shipbuilding and Marine Fabrication

148 hr · ~~$1,185~~ COMPLIMENTARY

This foundational course equips learners with the safety knowledge, trade mathematics, technical literacy, and professional skills required to work safely and effectively in a shipyard or marine fabrication facility. Content is anchored in OSHA 10-hour construction standards, first aid and CPR, and the measurement and drawing-reading tasks that appear daily in hull construction, welding, and fitting work. Successful completion prepares learners for every subsequent course in the program and satisfies the safety and core-competency prerequisites for NCCER Shipfitting and NCCER Maritime Welding credentialing.

Outcomes

Demonstrate OSHA 10-hour construction safety knowledge and apply lockout/tagout, confined-space entry, and fall-protection procedures correctly in a shipyard context.
Perform trade math calculations—including fraction and decimal conversion, area, volume, and angle measurement—to the accuracy required for marine fabrication layout and material takeoff.
Read and interpret shipbuilding drawings, weld symbols per AWS A2.4, and written work orders well enough to extract dimensions and specifications without assistance.
Use basic digital tools—including a job-related calculator application, a digital angle finder, and a shipyard safety management system interface—to record and communicate work information.
Administer hands-only CPR and use an AED, and provide basic first-aid response appropriate to common shipyard injuries.
Demonstrate career-readiness behaviors including punctuality, professional communication with supervisors and co-workers, and accurate completion of timesheets and incident-report forms.

Course text

How the course runs. 7 blocks: Shipyard Hazard Recognition and OSHA 10 Construction Safety; Confined-Space Entry, Fall Protection, and Fire Watch; First Aid, CPR, and AED for Shipyard Workers; Trade Math for Marine Fabrication; Reading Shipbuilding Drawings, Weld Symbols, and Work Orders; Digital Tools, Documentation, and Communication in the Shipyard; Career Readiness, Workplace Professionalism, and Program Introduction.

What competent looks like. Demonstrate OSHA 10-hour construction safety knowledge and apply lockout/tagout, confined-space entry, and fall-protection procedures correctly in a shipyard context. Perform trade math calculations—including fraction and decimal conversion, area, volume, and angle measurement—to the accuracy required for marine fabrication layout and material takeoff. Read and interpret shipbuilding drawings, weld symbols per AWS A2.4, and written work orders well enough to extract dimensions and specifications without assistance. Use basic digital tools—including a job-related calculator application, a digital angle finder, and a shipyard safety management system interface—to record and communicate work information. Administer hands-only CPR and use an AED, and provide basic first-aid response appropriate to common shipyard injuries. Demonstrate career-readiness behaviors including punctuality, professional communication with supervisors and co-workers, and accurate completion of timesheets and incident-report forms.

Lessons · 7 blocks

#	Lesson	Hr	Type	Objective	Activities	Materials	Check
1	Shipyard Hazard Recognition and OSHA 10 Construction Safety	28	theory	Students correctly identify and categorize the OSHA Focus Four hazards—falls, struck-by, caught-in/between, and electrocution—as they appear in shipyard and marine fabrication environments, and explain the regulatory framework governing each.	Instructor-led walkthrough of a set of shipyard photographs: students label each visible hazard by OSHA category on a worksheet, then compare answers in small groups and discuss discrepancies. Case-study analysis of three documented marine industry near-miss reports: students identify which OSHA standard applies, what PPE was required, and what corrective action was taken or should have been taken. Role-play a lockout/tagout procedure on a training board with a simulated welding machine and a grinding circuit: one student acts as authorized employee, one as affected employee, while classmates evaluate each step against a printed LOTO checklist.	OSHA 10-hour Construction Industry outreach course materials; OSHA 29 CFR 1926 Subpart M (fall protection) and Subpart S (underground construction, caissons—used for confined-space analogy); NCCER Core Curriculum Module on Safety; shipyard hazard photo set; LOTO training board and hasp-and-lock kit; laminated OSHA Focus Four quick-reference cards.	Scored worksheet: students must correctly classify at least 16 of 20 hazard photographs by OSHA category (80%). LOTO role-play evaluated by instructor against a 10-step checklist; all safety-critical steps must be performed correctly (100% on critical steps).
2	Confined-Space Entry, Fall Protection, and Fire Watch	14	demo	Students demonstrate the permit-required confined-space entry sequence, correct use of a self-retracting lifeline and harness, and fire-watch duties during simulated hot work, meeting the procedural requirements referenced in OSHA standards for the shipbuilding industry.	Instructor demonstrates four-gas atmospheric testing (oxygen, LEL, CO, H2S) with a calibrated multi-gas monitor inside a training tank mock-up; students then each take a reading, record it on a permit form, and decide accept or abort entry. Harness fitting station: each student dons a full-body harness, has the fit checked by the instructor using a six-point inspection protocol, then connects to a horizontal lifeline and walks a simulated elevated deck edge. Fire-watch drill: student acts as fire watch while instructor performs a brief simulated grinding operation; student must position correctly, maintain a charged extinguisher ready, identify when sparks leave the hot-work perimeter, and call a simulated stop-work.	Calibrated four-gas multi-gas monitor (training unit); confined-space entry permit forms (blank); full-body harnesses (one per student) and self-retracting lifeline; 10-lb ABC dry-chemical fire extinguisher (training unit); hot-work permit forms; OSHA 29 CFR 1915 Subpart B (confined spaces in shipyards) reference handout.	Competency checklist evaluated by instructor: confined-space atmospheric test recorded correctly and decision justified (pass/fail); harness donned with zero critical errors on six-point inspection (100% on critical points); fire-watch positioning and response to simulated spark migration correct (pass/fail). All three stations must pass to earn credit for the lesson.
3	First Aid, CPR, and AED for Shipyard Workers	14	lab	Students perform hands-only CPR at the correct rate and depth on a manikin, operate a training AED through one complete cycle, and apply first aid to the four most common shipyard injuries—laceration, eye contamination, burn, and crush/musculoskeletal—following current American Red Cross or American Heart Association guidelines.	CPR skills station: each student performs two minutes of continuous chest compressions on an instrumented manikin that provides real-time feedback on rate and depth; instructor reviews printout and coaches corrections. AED simulation: student responds to a manikin in cardiac arrest, retrieves a training AED, follows audio prompts through pad placement, shock delivery, and resumption of CPR—timed from collapse to first shock. Wound-care rotation: four stations (laceration with pressure bandage, eye wash at an eyewash station, thermal-burn cooling and covering, and improvised splinting for a forearm); students rotate and are assessed by a peer using a provided checklist.	CPR manikins with feedback capability (one per two students); training AED units; eyewash station; sterile gauze, bandage rolls, triangular bandages; burn gel and non-stick dressings; rigid splints; American Red Cross or American Heart Association First Aid/CPR/AED student manual.	CPR manikin feedback must show compression rate 100–120/min and depth at least 2 inches for at least 70% of compressions during the two-minute test. AED cycle must reach simulated shock delivery without skipping a prompt. All four first-aid stations scored pass/fail by peer checklist; instructor verifies any marginal results. Students who fail any station receive immediate remediation and one retest.
4	Trade Math for Marine Fabrication	30	theory	Students solve trade math problems—fraction and decimal conversion, ratio and proportion, area and volume of geometric shapes common to hull sections, angle calculation, and unit conversion between imperial and metric—with at least 80% accuracy on timed problems representative of NCCER Shipfitting and Maritime Welding assessments.	Guided problem sets in which students calculate the area of a trapezoidal web frame, the volume of a rectangular bilge tank, and the number of linear feet of weld seam on a cylindrical pipe given diameter and schedule—using only a basic scientific calculator, mirroring credentialing exam conditions. Measurement relay: pairs of students measure actual steel plate samples and a section of pipe with a steel tape, combination square, and digital protractor; they record dimensions in both inches-and-fractions and decimal equivalents, then calculate plate weight using a steel weight reference chart. Error-finding exercise: instructor provides five completed material-takeoff forms that each contain one deliberate arithmetic or unit-conversion error; students locate and correct each error and explain in writing what went wrong.	Scientific calculators (non-graphing, the type permitted in NCCER testing); steel tape measures; combination squares; digital protractor/angle finder; steel plate samples and pipe coupons; steel weight reference chart (pounds per square foot by thickness); NCCER Core Curriculum math modules; instructor-prepared problem sets.	Timed 25-question trade math quiz at end of lesson: students must score at least 20/25 (80%). Problems cover all topic areas taught. Students scoring below 80% complete a targeted review and a parallel-form retest before proceeding.
5	Reading Shipbuilding Drawings, Weld Symbols, and Work Orders	24	theory	Students extract dimensions, weld type, groove geometry, and material specification from a set of multi-view orthographic shipbuilding drawings and annotate a blank reference line with the correct AWS A2.4 weld symbol for a specified joint, achieving at least 80% on a drawing-reading exercise.	Drawing interpretation session: each student receives a reduced-size structural drawing of a ship's transverse web frame; working individually, students list all part numbers, bill-of-materials items, and critical dimensions on a structured answer sheet, then compare against an answer key in a class debrief. Weld symbol decode-and-build: instructor presents 15 weld symbols drawn to AWS A2.4 conventions; students write out in plain language what each symbol requires (process, position, size, finish, backing), then sketch the corresponding joint cross-section. Work-order reading exercise: students receive a realistic typed work order for fitting and welding a bilge-keel bracket, including a revision cloud on the drawing; they must identify which dimension changed, what material was substituted, and what inspection hold point applies before welding.	Set of shipbuilding structural drawings (industry-sourced or instructor-prepared to realistic standards); AWS A2.4 Standard Symbols for Welding, Brazing, and Nondestructive Examination (current edition, reference copy); AWS A3.0 welding terminology reference; sample work orders and revision-cloud drawing; drafting templates.	Drawing-reading exercise graded against answer key: 80% correct on dimensions and specifications extracted. Weld symbol decode scored: 12 of 15 correct (80%). Work-order exercise: student must correctly identify the revision, material change, and hold point—all three required for pass.
6	Digital Tools, Documentation, and Communication in the Shipyard	18	practice	Students use a digital angle finder, a tablet-based safety observation app, and a standard word-processing tool to complete a written near-miss report and a digital material-request form that meet the accuracy and format standards used in commercial shipyards.	Digital measurement station: students use a digital angle finder to measure the bevel on five pre-cut test plates; they record readings in a spreadsheet template, calculate mean and range, and flag any reading outside a given tolerance—simulating quality-control data entry. Near-miss report writing: using a realistic scenario card describing a slipping hazard near a staging area, each student drafts a complete near-miss report in a provided form template, including a corrective-action recommendation; instructor evaluates for completeness, accuracy, and professional language. Toolbox-talk delivery: each student prepares and delivers a two-minute verbal safety topic to three classmates, using one visual aid (printed or digital); classmates score the delivery on a provided rubric covering clarity, accuracy, and engagement.	Digital angle finders (one per two students); tablets or laptops with spreadsheet software and a word processor; sample safety observation app interface (instructor-demonstrated); near-miss report form template; toolbox-talk visual-aid examples; professional communication rubric.	Digital measurement log: all five angle readings recorded in correct format; mean and range calculated correctly; tolerance decision correct for all five. Near-miss report scored on a 10-item checklist: 8 of 10 items complete and accurate (80%). Toolbox-talk rubric: average peer score of 70% or higher, with instructor override for factual errors.
7	Career Readiness, Workplace Professionalism, and Program Introduction	20	field	Students articulate the career pathway from entry-level shipfitter or welder to journeyman and beyond, complete a program credential plan mapping each course to target credentials, and demonstrate professional workplace behaviors by punctual arrival, correct PPE donning, and accurate timesheet completion across the final week of the course.	Industry panel: two or three working journeymen shipfitters or marine welders (in person or video) describe their career paths, apprenticeship experience, and advice for new entrants; students prepare three questions in advance and submit a written reflection summarizing at least two actionable lessons. Credential mapping exercise: using the program credential chart provided by the instructor, each student fills in a personal plan showing which NCCER, AWS, and ABS/USCG credentials they are targeting, the exam areas for each, and which program courses address those areas. Simulated first-week-of-work routine: for five consecutive class sessions students punch in on a time clock (or sign a timesheet), don full PPE to instructor standard before entering the lab area, and complete a daily pre-task safety checklist; instructor scores compliance each day using a behavioral checklist.	Program credential chart (instructor-prepared); NCCER Registry overview handout; AWS Certified Welder program overview; ABS/USCG welder qualification overview; timesheet forms; PPE kit (hard hat, safety glasses, hearing protection, steel-toed boots, gloves); daily pre-task safety checklist.	Written reflection on industry panel: minimum one page, must reference at least two specific pieces of advice—graded pass/fail by instructor. Credential plan: complete with no blank fields and logical course-to-credential mapping—pass/fail. Five-day PPE and timesheet compliance: 90% compliance rate (no more than one missed item across all five days) required to pass.

Assessments

Assessment	Type	Weight	Pass standard	Method & rubric
OSHA and Shipyard Safety Knowledge Exam	Written exam	25%	70% correct (28 of 40 questions); all questions on lockout/tagout critical steps and confined-space entry decision-making must be answered correctly regardless of overall score.	A 40-question multiple-choice and true/false written exam covering OSHA Focus Four hazards, lockout/tagout procedure, permit-required confined-space entry, fire-watch duties, fall protection, and first aid/CPR protocols as applied to a shipyard environment. Questions are written at the level and style of the NCCER Core Curriculum module assessments so students gain familiarity with that format while demonstrating genuine safety knowledge. Accuracy · Safety · Communication · Professionalism
Trade Math and Drawing-Reading Knowledge Exam	Written exam	25%	80% correct (32 of 40 questions); the weld-symbol section (10 questions) requires at least 7 correct independently of the overall score.	A 40-question timed written exam combining trade math problems (fraction conversion, area, volume, angle, unit conversion, and material takeoff) with drawing-reading questions (dimension extraction, AWS A2.4 weld symbol interpretation, and work-order analysis) representative of the math and print-reading content assessed in both NCCER Shipfitting and NCCER Maritime Welding written tests. Students use only a basic scientific calculator, as permitted in credentialing exams. Accuracy · Safety · Communication · Professionalism
Integrated Safety and Documentation Project	Project	25%	Score of 75% or higher on the rubric (30 of 40 points); the near-miss report and pre-task safety checklist sections are each required to score at least 70% independently.	Students receive a scenario packet describing a planned hot-work operation inside a double-bottom tank on a vessel under construction; they must produce a complete confined-space entry permit, a hot-work permit, a near-miss report for a described earlier incident, a personal PPE selection list with justification, and a one-page toolbox-talk outline for the crew. Each document is scored on accuracy, completeness, and professional format using a detailed rubric that mirrors the documentation standards used in a commercial shipyard. Accuracy · Safety · Communication · Professionalism
Career and Safety Oral Defense	Oral / panel	25%	Pass on all four evaluation criteria: safety rationale (correct and complete), math or drawing question answered correctly within three minutes, credential plan defensible, and professional communication rating of satisfactory or above.	In a 10-minute one-on-one oral session with the instructor, each student explains their personal credential plan and defends one randomly drawn safety scenario (for example, responding to an unconscious worker found in a void space), answers one trade math or drawing-reading question drawn at random from the course problem bank, and describes one realistic career goal and the steps needed to reach it. The instructor uses a four-criterion rubric; all four criteria must be rated passing for the student to earn credit for this assessment and advance to Course 2. Accuracy · Safety · Communication · Professionalism

MFG-SHIP13-02 Trade course

Hull Construction

205 hr · ~~$4,000~~ COMPLIMENTARY

Students learn to interpret naval architectural drawings and construct steel and aluminum ship hull structures from keel to deck, following American Bureau of Shipping (ABS) rules and industry-standard fabrication sequences. Lessons progress from reading lines plans and structural drawings through plate layout, frame fabrication, erection, and fairness inspection. Work is performed to ABS/USCG weld-quality standards and NCCER Shipfitting competency areas.

Outcomes

Interpret hull structural drawings, including lines plans, frame schedules, and bill-of-materials tables, to extract fabrication and erection data.
Lay out, mark, and cut steel and aluminum hull plates and structural members to dimensional tolerances acceptable under ABS rules.
Fabricate and erect transverse frames, longitudinal stringers, floors, girders, and bulkheads in correct sequence using approved fit-up and tack-weld practices.
Apply lockout/tagout, confined-space entry, and fall-protection procedures specific to hull erection environments before each evolution.
Perform dimensional and fairness checks on erected hull structure using straight-edges, fairing battens, templates, and levels, and document nonconformances on a punch list.
Produce a complete set of fabrication records—cutting lists, fit-up inspection reports, and a weld map—meeting program quality-control requirements.

Course text

How the course runs. 12 blocks: Ship Structure Fundamentals and Drawing Interpretation; Hull Safety: Confined Spaces, Heights, and Hazardous Energy; Blueprint Reading for Hull Fabrication; Material Identification, Handling, and Storage; Layout and Marking of Hull Plates; Plate Cutting: Plasma, Oxy-Fuel, and Mechanical Methods; Frame Fabrication: Transverse Frames and Floors; Keel, Girder, and Longitudinal Installation; Shell Plating Fit-Up and Tacking; Bulkhead Fabrication and Installation; Fairness Inspection, Punch List, and Dimensional Survey; Hull Construction Documentation and Quality Records.

What competent looks like. Interpret hull structural drawings, including lines plans, frame schedules, and bill-of-materials tables, to extract fabrication and erection data. Lay out, mark, and cut steel and aluminum hull plates and structural members to dimensional tolerances acceptable under ABS rules. Fabricate and erect transverse frames, longitudinal stringers, floors, girders, and bulkheads in correct sequence using approved fit-up and tack-weld practices. Apply lockout/tagout, confined-space entry, and fall-protection procedures specific to hull erection environments before each evolution. Perform dimensional and fairness checks on erected hull structure using straight-edges, fairing battens, templates, and levels, and document nonconformances on a punch list. Produce a complete set of fabrication records—cutting lists, fit-up inspection reports, and a weld map—meeting program quality-control requirements.

Lessons · 12 blocks

#	Lesson	Hr	Type	Objective	Activities	Materials	Check
1	Ship Structure Fundamentals and Drawing Interpretation	18	theory	Given a set of structural drawings for a steel hull, the student identifies and describes the function of every major structural element—keel, frames, floors, girders, stringers, longitudinals, deck beams, bulkheads, and shell plating—and locates each on plan, profile, and body-plan views.	Instructor-led walkthrough of a three-view lines plan and structural general arrangement drawing; students annotate a printed copy labeling 20 named components. Small-group matching exercise: each group receives a set of structural element cards and places them on a scaled hull cross-section poster in correct position and orientation. Individual written response: given a frame-spacing schedule and midship section drawing, students calculate the longitudinal position of five specified frames from the forward perpendicular and check answers against a provided key.	ABS Rules for Building and Classing Steel Vessels (current edition, relevant structural chapters); NCCER Shipfitting Level 1 trainee guide; sample structural GA drawings and lines plans (instructor-supplied); pencils, scales, colored highlighters	10-question drawing-identification quiz; students must correctly name and locate at least 18 of 20 labeled structural elements (90% pass mark). Mapped to NCCER Shipfitting core knowledge area: ship structure nomenclature.
2	Hull Safety: Confined Spaces, Heights, and Hazardous Energy	14	theory	The student correctly applies OSHA permit-required confined-space entry procedures, lockout/tagout sequences, and fall-protection requirements as they apply to tank and void spaces, staging inside a hull, and powered cutting equipment before any hands-on hull work begins.	Case-study analysis: students read a summary of a shipyard confined-space incident, identify the failed control measures, and rewrite the permit to correct each deficiency. Instructor demonstration of a complete LOTO sequence on a plasma cutting table power supply; students then perform the sequence in pairs, with instructor sign-off on each step before re-energizing. Scenario walk-through in the shop: instructor marks three 'hazard zones' (simulated open tank, elevated staging, and pinch-point area); students verbally describe required PPE, permits, and controls for each zone before entering.	OSHA 29 CFR 1910.146 (confined spaces) and 29 CFR 1926 Subpart M (fall protection) quick-reference cards; employer LOTO procedure template; hard hats, safety glasses, harnesses, and lanyards for demonstration; gas monitor (four-gas) for confined-space demo	Written OSHA 10-aligned safety quiz covering confined-space, LOTO, and fall protection; minimum 80% correct. Students also complete a practical LOTO demonstration on assigned equipment without prompting; any missed step is an automatic fail requiring repeat. Mapped to NCCER Shipfitting safety competency.
3	Blueprint Reading for Hull Fabrication	16	theory	Given a hull structural drawing package including a shell-expansion plan, frame drawing, and detail sheets, the student extracts plate dimensions, material specifications, weld symbols, and erection notes with no more than one error per drawing.	Instructor-led review of standard marine drafting conventions: title block, revision blocks, drawing scales, AWS weld symbols as used in marine drawings, and material call-outs for ABS-grade steel and marine-grade aluminum. Students work in pairs to complete a drawing-takeoff worksheet: they list every plate on a shell-expansion plan, record its thickness, grade, and dimensions, and calculate the total steel tonnage using a provided steel-weight formula. Individual exercise: students read a frame detail drawing and sketch the cross-section of the frame at a specified station, labeling all weld joints with correct AWS symbols.	Shell-expansion plan and frame detail drawings (instructor-supplied, based on a small commercial vessel or workboat); AWS A2.4 Standard Symbols for Welding (reference copy); architect's scale and engineer's scale; blank drawing-takeoff worksheets	Drawing-takeoff assignment graded by instructor; students must correctly extract all plate dimensions and material grades with no more than one error per drawing sheet and achieve an overall score of 85% or higher. Mapped to NCCER Shipfitting Level 1: blueprint reading.
4	Material Identification, Handling, and Storage	10	demo	The student correctly identifies ABS-grade structural steel and marine-grade aluminum alloys by mill certificate, heat number, and marking, and demonstrates safe material handling and storage practices that prevent distortion and contamination.	Instructor demonstrates how to read a certified mill test report (CMTR), locate the heat number on the plate, and verify the material grade meets the drawing call-out; students then match five sample CMTRs to five marked plate coupons. Demonstration and student practice of proper plate and structural member storage: steel segregated from aluminum, proper dunnage spacing to prevent warping, and color-coded tags for material traceability. Students use a wire brush, grinder with flap disc, and solvent wipe to prepare a steel plate and an aluminum plate surface for layout, following manufacturer safety data sheet (SDS) guidance for the solvent.	Sample CMTRs for ASTM A36, ABS Grade A steel, and 5083/6061 aluminum; marked plate coupons; dunnage lumber; color-coded material tags; wire brushes, angle grinders with flap discs; SDS for acetone or comparable surface prep solvent; PPE: gloves, safety glasses, face shield	Instructor observation checklist: student correctly reads CMTR and matches to plate (pass/fail, all five must match); storage setup evaluated against a 10-point checklist with a minimum score of 8/10. Mapped to NCCER Shipfitting: material identification.
5	Layout and Marking of Hull Plates	20	lab	Using a structural drawing and a cutting list, the student lays out the shape of a hull plate on flat stock to within 1/16-inch dimensional tolerance using scribers, soapstone, combination squares, tape measures, and straight-edges.	Instructor demonstrates full-scale layout of a simple rectangular plate and then a plate with a curved edge, using a batten and offset table to develop the curve; students replicate the curved-plate layout on a fresh piece of flat stock. Each student is given a two-plate cutting list derived from the course hull project drawings and independently lays out both plates, including all hole locations, cutouts, and bevel marks indicated on the drawing. Peer inspection: students swap laid-out plates and measure all dimensions against the cutting list, recording any discrepancy on an inspection form; items outside tolerance are corrected before the next lesson.	Flat steel plate (A36, 3/16" and 1/4") and aluminum sheet (5083, 3/16"); scribers, soapstone, silver pencils; steel tape measures, combination squares, framing squares; flexible batten (wood or aluminum); offset tables from course hull project; safety glasses, gloves	Instructor measures each laid-out plate against the cutting list; all dimensions must be within 1/16 inch and all bevel marks correct; 100% of critical dimensions must pass before student proceeds to cutting. Mapped to NCCER Shipfitting: layout and fabrication.
6	Plate Cutting: Plasma, Oxy-Fuel, and Mechanical Methods	20	lab	The student cuts steel and aluminum hull plates to the laid-out lines using plasma arc cutting and, for steel, oxy-fuel cutting, achieving cut edges within 1/8-inch dimensional tolerance and surface quality acceptable for fit-up without excessive grinding.	Instructor demonstrates plasma arc torch setup, consumable selection, travel speed, and standoff distance on a steel plate and then on an aluminum plate; students each make a straight cut and a curved cut on scrap material before cutting production plates. Students cut their two laid-out plates from the previous lesson using the plasma table or hand-held plasma torch; all cuts are made to the scribed lines, and each student grinds or files cut edges to remove dross and achieve the correct bevel angle per the drawing. Oxy-fuel demonstration on steel only: instructor cuts a 3/8\" steel plate using an oxy-fuel torch, explaining tip selection and preheat; students practice straight oxy-fuel cuts on scrap steel and compare edge quality to plasma cuts.	Plasma cutting machine with appropriate consumables; oxy-fuel cutting outfit with cutting torch and correct tips; angle grinders with cutting and grinding discs; ear protection, face shields, leather gloves, leather apron, safety glasses; marked plates from Lesson 5; fire extinguisher; welding curtains	Instructor measures cut plates against cutting list; dimensional tolerance within 1/8 inch on all edges; no undercut or excessive dross that cannot be remediated by grinding; instructor signs cut-plate inspection form. Mapped to NCCER Shipfitting: cutting and beveling; supports ABS/USCG weld test preparation (edge preparation).
7	Frame Fabrication: Transverse Frames and Floors	22	lab	The student fabricates a transverse web frame and a floor plate from cut components, fitting and tacking all parts to dimensional tolerances specified on the frame drawing, with all joints prepared for welding per the applicable weld symbol.	Instructor demonstrates layout of a web frame on a strongback or layout table, including use of a plumb bob, level, and angle blocks to set web and flange alignment; students observe and then set up their own frame components on the strongback. Each student fits and tack-welds a transverse web frame assembly—web plate, face bar or flatbar flange, and lightening holes if specified—verifying squareness and camber against the drawing before instructor checks fit-up. Floor plate fabrication: students cut, fit, and tack a floor plate with a limber hole and a drain hole to the bottom shell plate mock-up on the strongback, checking alignment with a straightedge and level.	Structural steel shapes (flatbar, angle, T-bar per cutting list); floor plate blanks; strongback or layout table; plumb bob, torpedo level, angle blocks, clamps, dogs, wedges; tack-weld capable MIG or SMAW equipment; angle grinder; frame drawing from course hull project; steel tape, combination square	Instructor checks completed frame assembly against drawing using tape measure and square; web height, flange width, and overall frame squareness must each be within 1/8 inch of nominal; all tack welds visually acceptable (no cracks, proper size); instructor signs frame inspection report. Mapped to NCCER Shipfitting: frame fabrication.
8	Keel, Girder, and Longitudinal Installation	18	lab	The student correctly positions and tack-welds a keel plate or bar keel, center girder, and at least two longitudinal members onto a hull bottom mock-up, maintaining baseline reference and longitudinal alignment within 1/8-inch tolerance.	Instructor explains the erection sequence for a typical bottom structure—keel first, then center girder, then frames, then longitudinals—and demonstrates how a chalk baseline and plumb lines are used to control alignment throughout erection. Students set the keel plate on the mock-up blocks, establish baseline references with chalk lines and a laser level, and tack the keel in position; instructor verifies alignment before students proceed to the center girder. Students install two longitudinal stiffeners on either side of the keel, using the frame spacing from the drawing, and verify that each longitudinal is fair (no humps or hollows) by laying a batten along the top edge.	Keel plate and center girder sections (from cutting list); longitudinal bar stock; erection blocks or horses; chalk line; laser level or transit level; batten (wood or aluminum, 8 ft minimum); clamps, dogs, strongbacks; MIG tack-weld setup; hull bottom mock-up framing from previous lessons	Instructor measures keel offset from baseline and checks longitudinal fairness with batten; maximum allowable deviation from straight is 1/8 inch in any 10-foot run; instructor signs erection inspection sheet. Mapped to NCCER Shipfitting: hull erection and alignment.
9	Shell Plating Fit-Up and Tacking	22	lab	The student fits and tacks a strake of shell plating to a framed hull section, achieving a root gap and land dimension within the tolerances specified by the applicable weld procedure, and a fair exterior surface verified by batten.	Instructor demonstrates shell plate fit-up on a curved section using jacks, clamps, and hydraulic dogs to pull the plate fair; students observe the sequence of clamping from centerline outward and the use of a strongback to hold plates in position. Each student fits one shell plate to the bottom section mock-up, achieving the root gap specified on the weld procedure specification (WPS) used for the joint, and places tack welds at intervals per the WPS. Students run a fairing batten along the outside of the tacked shell strake and mark any high or low spots; they then adjust tacks or use a hydraulic jack to correct fairness defects before instructor final check.	Shell plate blanks (cut in Lesson 6); hydraulic or mechanical clamps, dogs, jacks, strongbacks; fairing batten; root-gap gauges; WPS (instructor-issued, matching the joint type); MIG welding setup; soapstone for marking; safety glasses, gloves, hearing protection	Instructor measures root gap at five equally spaced points along the joint using a feeler gauge or root-gap gauge; all five readings must be within the WPS tolerance; batten fairness check must show no deviation greater than 1/8 inch. Mapped to NCCER Shipfitting: shell plating; supports ABS/USCG weld test fit-up requirements.
10	Bulkhead Fabrication and Installation	18	lab	The student fabricates a transverse watertight bulkhead panel with vertical stiffeners, installs it in the hull mock-up plumb and square, and prepares all perimeter weld joints to drawing and WPS requirements.	Instructor explains the structural and watertight function of bulkheads, the USCG/ABS requirements for watertight integrity, and the consequences of out-of-plumb installation; students read the relevant section of the ABS rules summary provided by instructor. Students lay out, cut, and fit stiffeners to a bulkhead panel on the layout table, tacking stiffeners at correct spacing per the drawing, then lifting the panel into position in the hull mock-up using the shop overhead crane (instructor-supervised lift). Students plumb the bulkhead in both planes using a digital level, shim and dog it into position, tack the perimeter, and complete a pre-weld inspection form documenting joint preparation, gap, and alignment measurements.	Bulkhead plate and stiffener stock; layout table; overhead crane (instructor-supervised); digital level; dogs, shims, clamps; pre-weld inspection forms; ABS Rules summary (instructor-provided excerpt); MIG setup; tape measure, combination square	Bulkhead plumb checked with digital level in both planes: must be within 1/8 inch per 4 feet; perimeter gap within WPS tolerance at all measured points; pre-weld inspection form complete and signed; instructor signs off before welding begins. Mapped to NCCER Shipfitting: bulkhead installation.
11	Fairness Inspection, Punch List, and Dimensional Survey	17	field	The student conducts a complete dimensional and fairness survey of the assembled hull mock-up, documents all nonconformances on a punch list using industry-standard terminology, and prioritizes corrections in the sequence a production shipyard would follow.	Instructor demonstrates a shipyard dimensional survey: running a baseline, checking frame spacing with a tape against the frame schedule, using a plumb bob or laser to check perpendicularity, and using a batten for fairness; students shadow and record measurements. Each student independently surveys an assigned hull section, completing a dimensional check sheet that records actual versus nominal dimensions for frame spacing, bulkhead position, keel straightness, and shell fairness at specified stations. Students compile their data into a written punch list using standard terms (e.g., 'Frame 6 web height 1/4\" low — grind and refit,' 'Shell strake B, port, humped 3/16\" at Frame 4 — jack and re-tack'); punch lists are reviewed by instructor for completeness and correct terminology.	Assembled hull mock-up from Lessons 7–10; steel tape measures; digital level; laser level or transit; plumb bob; fairing battens; dimensional check sheets (instructor-issued); punch list forms; pencils	Dimensional check sheet scored by instructor against the instructor's own survey of the same section; student measurements must agree with instructor measurements within 1/16 inch on all critical dimensions; punch list must capture all nonconformances found by instructor (no missed items allowed for a pass). Mapped to NCCER Shipfitting: inspection and quality control; supports ABS/USCG inspection preparation.
12	Hull Construction Documentation and Quality Records	10	theory	The student assembles a complete fabrication record package—including a material traceability log, weld map, fit-up inspection reports, and punch list close-out sheet—that meets a stated quality-management requirement and would satisfy an ABS surveyor's documentation review.	Instructor presents examples of actual shipyard quality records (sanitized): material traceability log, weld map, non-conformance report (NCR), and inspector sign-off sheet; students compare these to the partial records they generated during the course and identify gaps. Each student completes a weld map for the hull mock-up, marking each joint with a weld joint number, the WPS that applies, the welder ID, and the inspection result (accepted/rejected); weld maps are drawn on a reduced-scale GA drawing provided by instructor. Students write a one-page close-out memo summarizing the hull section's dimensional survey results, listing all punch list items, noting which are closed, and recommending the section for next-phase work or further rework—using professional written language appropriate for a shipyard QC file.	Sanitized sample quality records from instructor; blank weld map forms; reduced-scale GA drawing; students' own inspection reports and punch lists from earlier lessons; word processor or lined paper for memo; pen	Weld map graded for completeness: all joints numbered, all WPS numbers correctly assigned, all inspection results recorded—must be 100% complete to pass; close-out memo graded on a 10-point rubric (accuracy, completeness, professional language) with a minimum score of 8/10. Mapped to NCCER Shipfitting: documentation; supports ABS/USCG surveyor documentation requirements.

Assessments

Assessment	Type	Weight	Pass standard	Method & rubric
Hull Structures and Drawing Reading Knowledge Exam	Written exam	25%	75% correct (minimum 38 of 50 questions)	A 50-question written exam covering ship structure nomenclature, blueprint reading conventions, material identification, ABS-grade material designations, weld symbols, and hull erection sequence. Questions are aligned to NCCER Shipfitting core knowledge areas and ABS/USCG documentation concepts introduced throughout the course. Standard met · Safety · Time · Quality/finish · Documentation
Frame Fabrication and Shell Plating Skills Demonstration	Skills demonstration	45%	All critical dimensions within tolerance and all safety steps performed without prompting; instructor signs competency checklist	The student independently fabricates a transverse web frame and fits one shell plate to a framed section within a timed window, demonstrating layout, cutting, fit-up, and tacking without instructor assistance. The instructor evaluates dimensional accuracy (all critical dimensions within 1/8 inch), joint preparation per WPS, safe equipment operation, and correct PPE use throughout; any unsafe act or missed LOTO step is an automatic fail requiring a full repeat. Mapped to NCCER Shipfitting fabrication competencies and ABS/USCG weld fit-up standards. Standard met · Safety · Time · Quality/finish · Documentation
Fabrication Lab Log	Log	15%	All required entries present and legible; dimensional data accurate to within 1/16 inch of instructor reference measurements; overall score 80% or higher on completeness rubric	Students maintain a cumulative lab log throughout the course that includes: dated entries for every lab session, sketches or photographs of work at each stage, completed dimensional check sheets from Lessons 5–11, all inspection forms, the weld map, and the punch list with close-out status. The log is submitted at course end and graded against a 20-item completeness and accuracy rubric. Standard met · Safety · Time · Quality/finish · Documentation
Hull Construction Safety Check	Safety audit	15%	100% on critical safety items (confined-space permit, LOTO, fall protection) and 80% overall on the full checklist; any critical item scored 0 requires a safety remediation session and recheck before the student may continue	An unannounced practical safety observation is conducted once during the lab phase of the course: the instructor observes the student setting up for a hull erection task and scores performance against a 15-item checklist covering confined-space permit requirements, LOTO procedure, PPE selection and donning, housekeeping, and tool inspection. Mapped to NCCER Shipfitting safety competencies and OSHA 29 CFR 1910/1926 requirements reviewed in Lesson 2. Standard met · Safety · Time · Quality/finish · Documentation

MFG-SHIP13-03 Trade course

Steel & Aluminum Welding for Marine Fabrication

205 hr · ~~$4,000~~ COMPLIMENTARY

Students develop hands-on proficiency in shielded metal arc welding (SMAW), flux-cored arc welding (FCAW), gas metal arc welding (GMAW), and gas tungsten arc welding (GTAW) on carbon steel and marine-grade aluminum alloys used in shipbuilding. Instruction integrates AWS D1.1 structural steel and AWS D1.2 aluminum welding codes, ABS/USCG qualification requirements, and NCCER Maritime Welding competency areas throughout every lesson. Safe shop practices, distortion control, and weld inspection are embedded in all lab and practice sessions.

Outcomes

Set up and operate SMAW, FCAW, GMAW, and GTAW equipment safely to produce sound welds on carbon steel plate and pipe in multiple positions per AWS D1.1 workmanship requirements.
Set up and operate GMAW and GTAW equipment to weld marine-grade aluminum alloys per AWS D1.2, controlling heat input to prevent distortion and burn-through.
Interpret welding symbols, joint-detail drawings, and weld procedure specifications (WPS) used in shipyard production to select correct process, filler, and parameters.
Perform visual weld inspection using AWS acceptance criteria and conduct basic nondestructive examination (NDE) tasks including visual testing (VT) and guided-bend test interpretation.
Apply lockout/tagout, hot-work permit procedures, ventilation controls, and PPE selection specific to marine welding environments including confined spaces and coated steel.
Qualify a weld test coupon to ABS/USCG and AWS Certified Welder requirements by demonstrating consistent technique, acceptable visual appearance, and passing guided-bend results.

Course text

How the course runs. 12 blocks: Marine Welding Safety, Hot-Work Permits, and Weld Shop Orientation; Reading Welding Symbols, WPS Documents, and AWS/ABS Code Basics; SMAW Fundamentals on Carbon Steel — Flat and Horizontal; SMAW Vertical and Overhead Positions — Structural Steel; FCAW-G and FCAW-S on Shipbuilding Steel — Production Techniques; GMAW on Carbon Steel and Transition to Aluminum Alloys; GTAW on Carbon Steel and Marine Aluminum; Weld Distortion Control and Thermal Management in Marine Structures; Weld Inspection: Visual Testing, NDE Introduction, and AWS Acceptance Criteria; Pipe and Tubular Welding for Marine Outfitting Applications; ABS/USCG and AWS Certified Welder Qualification Test Preparation; Integrated Welding Project: Marine Panel Assembly with Full QA Documentation.

What competent looks like. Set up and operate SMAW, FCAW, GMAW, and GTAW equipment safely to produce sound welds on carbon steel plate and pipe in multiple positions per AWS D1.1 workmanship requirements. Set up and operate GMAW and GTAW equipment to weld marine-grade aluminum alloys per AWS D1.2, controlling heat input to prevent distortion and burn-through. Interpret welding symbols, joint-detail drawings, and weld procedure specifications (WPS) used in shipyard production to select correct process, filler, and parameters. Perform visual weld inspection using AWS acceptance criteria and conduct basic nondestructive examination (NDE) tasks including visual testing (VT) and guided-bend test interpretation. Apply lockout/tagout, hot-work permit procedures, ventilation controls, and PPE selection specific to marine welding environments including confined spaces and coated steel. Qualify a weld test coupon to ABS/USCG and AWS Certified Welder requirements by demonstrating consistent technique, acceptable visual appearance, and passing guided-bend results.

Lessons · 12 blocks

#	Lesson	Hr	Type	Objective	Activities	Materials	Check
1	Marine Welding Safety, Hot-Work Permits, and Weld Shop Orientation	12	theory	Students will correctly identify all hazards specific to shipyard welding environments and apply the appropriate controls, PPE, lockout/tagout, and hot-work permit procedures before performing any welding task.	Hazard walk-through of the weld shop: students identify fire, fume, electrical, UV radiation, compressed-gas, and confined-space hazards on a printed shop diagram and record corrective controls for each. Complete a simulated hot-work permit as a team, identifying fire watch duties, ventilation requirements, combustible clearance distances, and permit sign-off chain per OSHA general industry and NFPA 51B guidance. Demonstrate correct donning sequence for welding PPE (auto-darkening helmet shade selection per AWS/ANSI Z49.1, leather gloves, FR sleeves, steel-toed boots) and perform a LOTO exercise on a welding machine per OSHA 29 CFR 1910.147.	OSHA 29 CFR 1910.147 LOTO standard excerpt, ANSI Z49.1 Safety in Welding Cutting and Allied Processes, NFPA 51B excerpt, shop hazard diagram, blank hot-work permit forms, welding PPE sets, welding machine with lockout tags and hasp, fire extinguisher (training unit)	Students complete a 20-question written safety quiz (70% pass) and demonstrate LOTO and PPE donning with zero critical errors as observed on a pass/fail instructor checklist.
2	Reading Welding Symbols, WPS Documents, and AWS/ABS Code Basics	10	theory	Students will decode standard AWS welding symbols on shipbuilding drawings and extract joint type, process, filler, position, and preheat requirements from a weld procedure specification (WPS) without assistance.	Symbol decoding exercise: students receive ten shipbuilding detail drawings and complete a worksheet identifying groove type, weld size, finish symbol, reference line elements, and tail notes for each weld callout. WPS scavenger hunt: students are given a prequalified SMAW WPS and answer a structured question set identifying base metal P-number, filler metal classification, preheat minimum, interpass temperature limit, and essential variables. Small-group comparison of an AWS D1.1 visual acceptance table against an ABS welder qualification requirement sheet, listing three similarities and three differences on a T-chart and presenting findings to the class.	AWS A2.4 Standard Symbols for Welding, AWS D1.1 current edition (instructor copy and student excerpts), sample prequalified WPS documents, shipbuilding structural drawings (scantling plans), ABS Rules for Materials and Welding excerpts, ruler, pencils	Students correctly decode 8 of 10 welding symbols on a timed drawing quiz and answer 7 of 10 WPS interpretation questions correctly; both 70% thresholds must be met.
3	SMAW Fundamentals on Carbon Steel — Flat and Horizontal	20	lab	Students will run stringer and weave beads with E6010 and E7018 electrodes in flat (1G/1F) and horizontal (2G/2F) positions, producing welds that meet AWS D1.1 visual acceptance criteria for reinforcement, uniformity, undercut, and overlap.	Instructor-led demo of machine setup (polarity, amperage selection per electrode manufacturer data sheet), arc striking, and bead restart technique on flat plate; students then run ten consecutive 6-inch stringer beads and self-evaluate against a printed AWS visual checklist. Fillet weld practice on T-joint coupons in 1F and 2F: students weld a minimum of four coupons per position, varying travel speed to observe and document the effect on bead profile in their lab log. Structured peer review: students exchange coupons, measure fillet leg size with a fillet weld gauge, check undercut with a dial-type undercut gauge, and record accept/reject decisions against AWS D1.1 visual criteria on a standardized inspection form.	CC/DC welding machines, E6010 and E7018 electrodes (rod oven for E7018), 3/8-inch and 1/2-inch carbon steel plate coupons, angle grinder, wire brush, chipping hammer, fillet weld gauges, undercut gauges, AWS D1.1 visual acceptance table (laminated reference cards), lab log notebooks, PPE	Instructor visually inspects two graded coupons per student (one 1F fillet, one 2G groove) against AWS D1.1 Table 6.1 criteria; all six visual criteria must pass, and fillet leg size must be within +1/4 inch / -0 inch of specified size.
4	SMAW Vertical and Overhead Positions — Structural Steel	16	lab	Students will produce E7018 fillet and groove welds in vertical-up (3F/3G) and overhead (4F/4G) positions that meet AWS D1.1 visual acceptance criteria, demonstrating control of molten pool and correct electrode angle adjustments for each position.	Instructor demo of vertical-up technique with emphasis on keyhole management, electrode angle, and pause-at-toes technique for preventing undercut; students practice on 3F fillet coupons for the first hour before progressing to 3G groove. Overhead welding station rotation: students weld 4F fillet coupons on a fixed overhead fixture for 45-minute blocks, rotating through three stations so all students accumulate equivalent arc-on time; instructor circulates and provides real-time technique coaching. Students break two 3G groove coupons using a workshop-grade guided-bend fixture (root and face bends), photograph results, and record whether each meets AWS bend acceptance criteria (no discontinuity greater than 1/8 inch) in their lab log.	CC/DC welding machines, E7018 electrodes (rod oven), 3/8-inch carbon steel groove and fillet coupons pre-tacked in 3G and 4G fixtures, overhead welding positioners/fixtures, guided-bend test fixture (plunger-type), band saw or press for coupon sectioning, fillet gauges, lab log notebooks, PPE including overhead-appropriate ear and neck protection	One 3G groove coupon per student is bend-tested (root and face); both bends must pass AWS bend acceptance. One 4F fillet is visually inspected by the instructor against D1.1 criteria. Both assessments must pass for lesson completion credit.
5	FCAW-G and FCAW-S on Shipbuilding Steel — Production Techniques	18	lab	Students will set up and operate both gas-shielded (FCAW-G) and self-shielded (FCAW-S) flux-cored processes on carbon steel in flat, horizontal, and vertical-up positions, selecting wire classification and parameters from the WPS to produce welds meeting ABS workmanship standards.	Wire and shielding gas selection exercise: students match three FCAW wire classifications (E70T-1C, E71T-1C, E71T-8) to their shielding gas requirements, polarity, and typical shipyard application using AWS A5.20 filler metal specification and record findings in a comparison table. Machine parameter optimization drill: working in pairs, students run test beads at three different wire-feed speeds and two voltage settings, measure bead width and height with a weld profile gauge, and identify the parameter set producing the flattest, most uniform bead with minimal spatter. Production simulation: students complete a multi-pass fillet weld joining 1/2-inch plate T-joint using FCAW-G with specified root and fill passes per a provided WPS, then self-inspect using the ABS workmanship checklist and submit the coupon with a completed inspection report.	CV welding machines with wire feeders, E70T-1C wire (gas-shielded), E71T-8 wire (self-shielded), 75/25 Ar/CO2 shielding gas cylinders with regulators, 1/2-inch carbon steel plate, weld profile gauges, spatter chippers, wire brush, ABS Rules for Materials and Welding Part 2 Section 4 excerpt, WPS documents, lab log notebooks, PPE	Students submit a completed 1/2-inch multi-pass T-joint fillet coupon with a self-inspection report; instructor confirms visual acceptance per ABS criteria and verifies lab log entries for parameter sets are complete. Both required for credit.
6	GMAW on Carbon Steel and Transition to Aluminum Alloys	16	demo	Students will distinguish GMAW transfer modes (short-circuit, spray, pulsed spray) and correctly configure equipment to produce sound GMAW welds on both A36 carbon steel and 5083/6061 marine-grade aluminum in flat and horizontal positions.	Transfer-mode demonstration: instructor runs short-circuit, spray, and pulsed spray on steel at the front of the class while students record amperage, voltage, wire-feed speed, and audible characteristics for each mode on a structured observation sheet, then discuss which modes are acceptable for which marine applications. Equipment changeover drill: working in teams, students swap out the wire spool, drive rolls, contact tip, and gun liner from steel configuration to aluminum configuration following a printed changeover checklist, then verify settings with a digital multimeter before running a test bead. Students weld a series of lap and butt joints on 1/4-inch 5083 aluminum plate in flat position using ER5356 filler, immediately after the changeover drill; each student runs at least four joints and grades them for porosity, crater cracks, and bead continuity using a hand-held magnifier and the AWS D1.2 visual table.	CV/pulsed GMAW machines, ER70S-6 wire (steel), ER5356 wire (aluminum), aluminum drive rolls (U-groove), Teflon or Nylon gun liners, 100% argon shielding gas for aluminum, 75/25 Ar/CO2 for steel, 1/4-inch A36 plate, 1/4-inch 5083 aluminum plate, digital multimeter, hand-held magnifier (10x), AWS D1.2 current edition excerpts, equipment changeover checklist, lab log notebooks, PPE (clean gloves for aluminum)	Students correctly complete the equipment changeover checklist with zero errors (instructor verifies) and produce two aluminum lap joints in flat position that pass AWS D1.2 visual acceptance criteria checked by instructor; both required.
7	GTAW on Carbon Steel and Marine Aluminum	22	lab	Students will set up a GTAW machine with correct polarity, tungsten type, and shielding gas for both carbon steel (DCEN) and aluminum (AC) and produce full-penetration butt welds on thin-gauge material that meet AWS D1.1 and D1.2 visual acceptance criteria respectively.	Tungsten preparation station: students grind pointed tungstens (2% ceriated for steel DCEN) and prepare balled tungstens (pure or zirconiated for aluminum AC), then photograph both under a bench magnifier and annotate images in their lab log explaining why tungsten geometry differs between processes. GTAW on 3/16-inch carbon steel: each student completes a minimum of six butt weld coupons in flat position using ER70S-2 filler, focusing on consistent arc length, torch angle, and filler addition rhythm; instructor uses a timing approach (one coupon per 20-minute block) to maintain pace. GTAW on 1/8-inch 5052 aluminum: students practice AC welding with ER4043 filler on butt joints, paying specific attention to cleaning action (etching zone), puddle width control to avoid burn-through, and post-weld crater fill technique; at least four coupons per student are produced and self-graded against AWS D1.2 criteria.	AC/DC GTAW machines, 2% ceriated tungsten (3/32 and 1/8 inch), pure or zirconiated tungsten, ER70S-2 filler rods, ER4043 filler rods, 100% argon shielding gas, 3/16-inch carbon steel plate, 1/8-inch 5052 aluminum plate, tungsten grinder with diamond wheel, bench magnifier, AWS D1.1 and D1.2 visual acceptance table cards, lab log notebooks, PPE (clean cotton gloves for GTAW aluminum)	One steel butt weld and one aluminum butt weld per student are inspected by the instructor against respective AWS visual criteria; additionally, one aluminum coupon is face-bent in the guided-bend fixture and must show no cracks greater than 1/8 inch. All three checks must pass.
8	Weld Distortion Control and Thermal Management in Marine Structures	14	theory	Students will predict distortion types (angular, longitudinal, transverse, buckling) produced by welding sequences on a given joint configuration and select proven distortion-control methods — presetting, backstep, skip welding, and clamping — appropriate for a shipyard production scenario.	Case-study analysis: students examine three photographs of distorted ship panels (one angular distortion on a deck plate, one buckling on a thin shell plate, one longitudinal shrinkage on a keel bar), identify the distortion type, and write a one-paragraph root-cause explanation using thermal contraction principles. Welding sequence lab: in pairs, students weld an identical 12-inch T-joint twice — once with a single continuous weld and once using a backstep sequence — measure angular distortion of each result with a digital angle gauge, and record the quantitative difference in their lab log. Group problem-solving: teams receive a simplified ship frame drawing with ten welds and must write a weld sequence (numbered weld order, direction arrows) that minimizes distortion, then present their sequence rationale to the class for critique and instructor scoring.	Digital angle gauges, 12-inch carbon steel T-joint coupons (pre-tacked), SMAW or FCAW machines, distortion case-study photograph set (printed), ship frame drawing with weld callouts, straightedges, clamps and strongbacks, Lincoln Electric Welding Handbook or equivalent reference chapter on distortion, lab log notebooks	Students submit a lab log entry with measured angular distortion values from both weld sequences and a written comparison; they also score 70% or higher on a 10-question written distortion-control quiz administered at the end of the lesson.
9	Weld Inspection: Visual Testing, NDE Introduction, and AWS Acceptance Criteria	14	theory	Students will perform a thorough visual weld inspection (VT) per AWS D1.1 acceptance criteria, correctly classify discontinuities as acceptable or rejectable, and describe the purpose and basic principles of liquid penetrant (PT), magnetic particle (MT), and ultrasonic (UT) testing methods used in shipyard QA.	Visual inspection station rotation: students rotate through eight pre-welded sample coupons containing seeded defects (undercut, overlap, porosity, cracks, incomplete fusion, excessive reinforcement) and complete a standardized inspection form for each, recording accept/reject and the specific criterion violated. NDE methods comparison: students watch instructor-led demonstrations of liquid penetrant and magnetic particle testing on prepared samples, then complete a T-chart comparing each method's capabilities, limitations, base material compatibility, and USCG/ABS relevance. Mock inspector role play: each student receives an unmarked coupon, performs a full VT using gauges and a 10x magnifier, completes an ABS-style inspection report, and submits it; instructor reveals actual defect list and students score their own detection rate.	Set of 8 seeded-defect weld coupons, fillet weld gauges, undercut gauges, ruler, 10x magnifier, AWS D1.1 Table 6.1 visual acceptance criteria (laminated), liquid penetrant testing kit (penetrant, developer, cleaner), magnetic particle yoke with iron powder, ABS inspection report forms, NDE reference posters or Lincoln Electric NDE reference guide excerpts	Students correctly classify at least 12 of 16 accept/reject decisions across the coupon rotation (75%) and submit a complete mock inspection report with all required fields filled; incomplete reports are returned for correction before credit is granted.
10	Pipe and Tubular Welding for Marine Outfitting Applications	18	lab	Students will weld carbon steel pipe coupons in 2G (horizontal-fixed) and 5G (horizontal-rolled and fixed vertical) positions using SMAW with E6010 root and E7018 fill/cap, producing full-penetration welds that pass visual inspection and a guided-bend test.	Root pass technique clinic: instructor demonstrates E6010 keyhole root pass technique on a 3-inch Schedule 40 carbon steel pipe coupon in 5G position; students then each complete three root-pass-only coupons and have the root visually checked by the instructor before advancing to fill passes. Full weld completion: each student completes at least two full pipe coupons (root, fill, cap) in 2G position and one in 5G position over the practice block, recording interpass temperatures with a contact thermometer and logging readings in their lab log. Coupon sectioning and bend test: one 2G coupon per student is cut, prepared, and bent (root and face) in the guided-bend fixture; students photograph results and document pass/fail against AWS acceptance criteria in their lab log.	CC/DC welding machines, E6010 and E7018 electrodes (rod oven), 3-inch Schedule 40 carbon steel pipe (pre-beveled and pre-tacked in 2G and 5G fixtures), pipe positioners/clamps, contact thermometer, angle grinder, band saw or pipe cutter for coupon sectioning, guided-bend test fixture, fillet/profile gauges, lab log notebooks, PPE	Guided-bend test on the 2G coupon must show no cracks or open discontinuities greater than 1/8 inch; the 5G coupon must pass visual inspection per AWS D1.1. Instructor signs off lab log entries for temperature readings. Both bend and visual checks required.
11	ABS/USCG and AWS Certified Welder Qualification Test Preparation	22	practice	Students will produce welder qualification test coupons following ABS/USCG and AWS Certified Welder procedural requirements for the process and position relevant to their intended qualification, demonstrating consistent pre-weld, in-process, and post-weld practices that an independent examiner would observe.	Test documentation drill: students complete all pre-test paperwork including welder qualification record (WQR) blank forms, identify the essential variables for their test (process, position, base metal thickness range, filler classification) from the applicable AWS or ABS standard, and have the instructor review for accuracy before welding begins. Timed qualification coupon practice: each student performs a complete simulated qualification weld (SMAW 3G or FCAW 2G, per student's target credential) under test-like conditions — no instructor coaching during the weld, standard coupon dimensions, no restarts except at permitted locations — to build test-day composure. Bend test debrief: coupons are bent in the fixture and results are analyzed as a group; students whose coupons show discontinuities diagnose the likely cause (lack of fusion, slag inclusion, excessive travel speed) using a defect-cause reference card and write a corrective action statement in their lab log.	CC/DC and CV welding machines, E7018 and E70T-1C electrodes/wire per WPS, qualification test coupon blanks (pre-beveled per AWS D1.1 or ABS specification), guided-bend fixture, blank WQR forms, AWS D1.1 Annex I welder qualification tables (excerpts), ABS Rules for Materials and Welding welder qualification section (excerpts), defect-cause reference cards, lab log notebooks, PPE	Each student produces at least one complete practice qualification coupon; the guided-bend test result is documented. Students must correctly complete the pre-test WQR form with all required fields (100% completion) and articulate in writing the cause and correction for any bend failure. Progress is tracked on instructor's qualification readiness matrix.
12	Integrated Welding Project: Marine Panel Assembly with Full QA Documentation	23	lab	Students will independently plan, fabricate, and inspect a multi-material marine panel assembly (carbon steel frame with aluminum insert or deck fitting) using at least two welding processes, completing all production, inspection, and QA documentation to shipyard standards.	Pre-production planning: each student writes a brief welding plan identifying joint types, process and filler selections, weld sequence to minimize distortion, required PPE and ventilation, and a materials cutlist; plan is reviewed by the instructor and approved before fabrication begins. Panel fabrication: students fabricate the assembly over multiple work sessions using SMAW or FCAW for the steel frame and GMAW or GTAW for the aluminum insert/fitting, logging all interpass temperatures, parameter settings, and any non-conformances in a production traveler document. Final inspection and QA package: students perform a complete VT of the finished assembly using gauges and the AWS D1.1/D1.2 criteria, complete an ABS-style inspection report, photograph and annotate four critical weld zones, and submit the full QA package (plan, traveler, inspection report, photos) for instructor grading.	Assorted carbon steel plate and structural shapes (3/8 and 1/2 inch), 5083 or 6061 aluminum plate and extrusions, SMAW/FCAW/GMAW/GTAW equipment as selected, full consumables per WPS, contact thermometer, fillet and undercut gauges, 10x magnifier, digital camera or phone, ABS inspection report forms, production traveler template, AWS D1.1 and D1.2 visual acceptance criteria cards, PPE	QA package graded on a four-category rubric (fabrication quality, visual inspection accuracy, documentation completeness, distortion control); students must achieve 70% overall with no category below 60%. Panels with rejectable unrepaired weld defects are returned for correction before final grading.

Assessments

Assessment	Type	Weight	Pass standard	Method & rubric
Welding Theory and Code Knowledge Exam	Written exam	25%	70% correct (35 of 50 questions)	A 50-question written exam covering AWS D1.1 and D1.2 code provisions, welding symbol interpretation, WPS reading, GMAW/FCAW/SMAW/GTAW process fundamentals, defect identification, NDE method selection, and marine welding safety requirements aligned to NCCER Maritime Welding and AWS Certified Welder knowledge areas. Questions are multiple-choice and short-answer; students have 90 minutes to complete. Standard met · Safety · Time · Quality/finish · Documentation
Welder Qualification Skills Demonstration	Skills demonstration	45%	Guided-bend test passes AWS acceptance criteria (no linear discontinuity greater than 1/8 inch on any bend); visual inspection passes all six AWS D1.1 Table 6.1 criteria	Each student welds a designated qualification coupon (SMAW E7018 in 3G position on 3/8-inch carbon steel or FCAW in 2G per instructor assignment) under test conditions matching ABS/USCG and AWS Certified Welder procedural requirements; the coupon undergoes guided-bend testing and full visual inspection by the instructor acting as examiner. This demonstration directly prepares students for the actual ABS/USCG and AWS D1.1 Certified Welder performance qualification. Standard met · Safety · Time · Quality/finish · Documentation
Welding Lab Log Portfolio	Log	15%	All 12 lesson lab log entries present and complete; at least 10 of 12 entries rated Meets Standard on the four-point rubric (data accuracy, observations, accept/reject decisions, corrective actions)	Students maintain a chronological lab log throughout the course recording equipment settings, coupon results, measured dimensions, inspection findings, bend test outcomes, and corrective actions for every hands-on lesson; the completed log is submitted as a portfolio at the end of the course and graded against a four-point rubric aligned to NCCER Maritime Welding documentation competencies. Standard met · Safety · Time · Quality/finish · Documentation
Hot-Work and Welding Safety Compliance Check	Safety audit	15%	Zero critical errors; all items on the safety checklist marked Satisfactory by the instructor	A live unannounced safety observation conducted once during a lab session: the instructor uses a standardized 15-item checklist to verify correct PPE, machine grounding, electrode storage, ventilation operation, fire-watch readiness, and LOTO compliance; any critical error (defined as an item posing immediate injury risk) requires the student to stop work, correct the deficiency, and repeat the full check before continuing. This check is directly aligned to OSHA 29 CFR 1910.252 electric welding requirements and ABS hot-work expectations. Standard met · Safety · Time · Quality/finish · Documentation

MFG-SHIP13-04 Trade course

Shipfitting Layout

204 hr · ~~$3,980~~ COMPLIMENTARY

Students develop the geometric layout, measurement, and marking skills required to position, fit, and fair structural ship components from working drawings and lofting data. The course covers flat-plate layout, curved-surface development, template making, and the use of precision measuring tools on both steel and aluminum structure. Lessons map directly to NCCER Shipfitting credential competency areas covering layout, fit-up, and structural assembly.

Outcomes

Interpret shipbuilding structural drawings, including frame tables, offsets, and bill of materials, and transfer dimensions to the shop floor or plate with an accuracy of ±1/16 inch.
Apply geometric construction and basic trigonometry to lay out straight frames, curved frames, bulkheads, and deck camber using chalk lines, trammel points, and optical or laser levels.
Develop flat-pattern templates and spiling boards for curved hull plating and pipe penetrations, and verify template accuracy against the original drawing before cutting.
Use precision measuring tools—combination squares, bevel gauges, contour gauges, plumb bobs, laser levels, and digital angle finders—to check fairness, plumb, and alignment of fitted assemblies.
Execute a complete plate-to-assembly fit-up sequence, including tacking, temporary shoring, and checking for distortion, following shipyard safety rules and applicable NCCER Shipfitting standards.
Produce required fit-up documentation—sketch, material take-off, inspection checklist—that satisfies a sample shipyard quality-assurance sign-off.

Course text

How the course runs. 12 blocks: Shipbuilding Drawings and Notation; Precision Measurement Tools and Their Use; Lines, Offsets, and the Lofting Process; Geometric Construction for Layout; Template Making — Flat Plate and Brackets; Spiling and Curved-Surface Template Development; Frame Layout — Straight and Cambered; Bulkhead and Longitudinal Fit-Up; Fairness and Distortion Control; Laser and Digital Layout Tools; Material Take-Off and Fit-Up Documentation; Integrated Layout and Fit-Up Practical.

What competent looks like. Interpret shipbuilding structural drawings, including frame tables, offsets, and bill of materials, and transfer dimensions to the shop floor or plate with an accuracy of ±1/16 inch. Apply geometric construction and basic trigonometry to lay out straight frames, curved frames, bulkheads, and deck camber using chalk lines, trammel points, and optical or laser levels. Develop flat-pattern templates and spiling boards for curved hull plating and pipe penetrations, and verify template accuracy against the original drawing before cutting. Use precision measuring tools—combination squares, bevel gauges, contour gauges, plumb bobs, laser levels, and digital angle finders—to check fairness, plumb, and alignment of fitted assemblies. Execute a complete plate-to-assembly fit-up sequence, including tacking, temporary shoring, and checking for distortion, following shipyard safety rules and applicable NCCER Shipfitting standards. Produce required fit-up documentation—sketch, material take-off, inspection checklist—that satisfies a sample shipyard quality-assurance sign-off.

Lessons · 12 blocks

#	Lesson	Hr	Type	Objective	Activities	Materials	Check
1	Shipbuilding Drawings and Notation	14.5	theory	Students will correctly read and extract dimensions, weld symbols, material specifications, and part marks from a set of structural shipbuilding drawings with zero critical errors on a graded interpretation exercise.	Instructor walks through a sample midship-section drawing, pointing out the lines plan, structural profile, deck plan, and frame sections while students annotate a personal copy. Students work in pairs to complete a scavenger-hunt worksheet requiring them to locate and record 20 specific data points—frame spacing, plate thickness, stiffener size, weld symbol, and material grade—from a three-sheet drawing package. Individual written exercise: students sketch a simple bracket from a detail drawing, label all dimensions and weld symbols, and list the bill of materials for the part.	Full-size sample structural drawings (frame sections, deck plan, shell expansion), weld symbol reference chart per AWS A2.4, NCCER Shipfitting Module 1 textbook, pencils, ruler, highlighters	Graded interpretation worksheet: students must correctly answer at least 80% of 25 questions covering drawing views, notation, weld symbols, and material callouts to pass.
2	Precision Measurement Tools and Their Use	13	demo	Students will select and correctly use combination squares, bevel gauges, trammel points, digital angle finders, contour gauges, and measuring tapes to take and record six assigned measurements within the tolerance specified on the drawing.	Instructor demonstrates each tool in turn on a tabletop steel assembly, narrating proper zeroing, calibration checks, and reading technique while students observe and take notes. Students rotate through six measurement stations set up on the shop floor—each requiring a different tool and a specific tolerance—recording measurements on a structured data sheet. Pairs check each other's readings, calculate deviation from the nominal, and flag any reading outside tolerance for discussion with the instructor.	Combination squares, bevel gauges (analog and digital), contour gauges, trammel points, 25-ft and 100-ft steel tapes, plumb bobs, laser level, digital angle finder, scrap plate assemblies, measurement data sheet	All six station measurements recorded and compared to nominal; students must achieve four of six readings within the drawing tolerance and correctly identify the two that are out of tolerance to pass.
3	Lines, Offsets, and the Lofting Process	16.5	theory	Students will explain the purpose of a lines plan and offset table and manually plot at least eight hull-form points onto a full-size lofting grid, producing a faired curve that deviates no more than 1/8 inch from the instructor's reference curve.	Lecture and slide presentation covering the three views of a ship's lines plan—body plan, sheer plan, waterlines plan—with labeled examples; students complete a guided notes sheet. Instructor demonstrates reading an offset table and plotting the first four points on a full-size paper lofting grid on the shop floor, then students continue to plot the remaining points for one frame station. Students use a flexible batten and ducks (or weights) to fair a smooth curve through the plotted points, then trace the faired line and compare it to the instructor's pre-drawn reference using a tick strip.	1:1 paper lofting grid (minimum 4 ft × 8 ft kraft paper), sample offset table, flexible battens, batten weights or ducks, chalk line, steel tape, pencils, NCCER Shipfitting lofting chapter	Faired curve plotted and traced; checked at eight stations—curve must be within 1/8 inch of reference at six of eight stations to pass.
4	Geometric Construction for Layout	14.5	lab	Students will construct perpendicular lines, bisect angles, divide a line into equal parts, and lay out a 3-4-5 right angle on a shop floor using only chalk lines and a steel tape, with all constructed angles within 1/8 inch of true over a 10-foot run.	Instructor reviews the geometric principles on a whiteboard, then demonstrates each construction on the shop floor using chalk lines, steel tape, and a plumb bob while students follow along on a mini floor-chalk area. Students work independently to complete a floor-layout exercise: establish a baseline, erect a perpendicular using the 3-4-5 method, bisect the 90° angle, and divide the baseline into five equal segments. Students use a digital angle finder and tape to self-check all constructed elements, record deviations on a data sheet, and adjust until within tolerance.	Shop floor (concrete), chalk lines and chalk, 100-ft steel tape, 25-ft steel tape, plumb bobs, digital angle finder, knee pads	Instructor measures all five constructed elements; all must be within 1/8 inch of true per 10-foot run, and the 3-4-5 right angle must be within 0.5° to pass.
5	Template Making — Flat Plate and Brackets	16.5	lab	Students will fabricate a flat-pattern cardboard template for an assigned structural bracket, mark all bend lines and reference points, and verify the template against the drawing so that the actual part cut from the template will be within ±1/16 inch in all dimensions.	Instructor demonstrates allowances for bend deduction, grain direction, and part marking on a simple bracket template, then shows how to verify the template by overlaying it on the drawing. Each student receives a bracket detail drawing and fabricates a full-size cardboard template, marking part number, material, thickness, heat number block, and all reference lines. Students check their template against the drawing using a rule and digital calipers, record all dimensions on a fit check sheet, and revise the template until all dimensions are within ±1/16 inch.	Bracket detail drawings (min. three different designs), cardboard sheets, straight-edge, compass, combination square, digital calipers, marking pens, scissors or snips, template fit-check sheet	Fit-check sheet reviewed by instructor; all critical dimensions must be within ±1/16 inch and part marking must be complete and legible to pass.
6	Spiling and Curved-Surface Template Development	16.5	lab	Students will use spiling technique to develop a template for a curved hull strake segment on a mock-up frame assembly, achieving a fit with a gap of no more than 3/16 inch at any point around the perimeter when test-fitted to the frame.	Instructor demonstrates spiling board setup, transfer of points from frame to template material, and how to fair the resulting curve with a batten on a pre-built curved frame mock-up. Students develop their own spiled template using Masonite or heavy cardboard, transfer the curve, fair it, and cut the template. Students test-fit the template to the frame mock-up, mark any high spots with a china marker, trim, and refit until the gap standard is met; they document the number of fit-and-trim cycles on a process log.	Curved hull-section mock-up (wood or steel frame), Masonite or heavy cardboard, flexible batten, compass (spiling compass), jigsaw or snips, china markers, tape measure, process log sheet, NCCER Shipfitting template chapter	Instructor measures gap around the full perimeter of the fitted template with a feeler gauge or ruler; maximum 3/16-inch gap at any point to pass.
7	Frame Layout — Straight and Cambered	16.5	lab	Students will lay out a transverse flat-bar frame and a deck beam with the correct camber from a given deck-camber table, tack the assembly to the layout marks, and verify plumb and camber within the tolerances specified in the assignment.	Instructor demonstrates calculating camber ordinates from a parabolic camber formula (rise = camber × (1 − (2x/B)²)) and laying out the camber curve on a plate table using a batten. Students calculate ordinates for their assigned beam span and camber, lay out the curve on a marked plate table or steel layout floor, and set the deck beam to the line. Students check camber with a straight edge and taper gauge at five stations along the beam, and check plumb with a digital level; results are recorded on a layout inspection form.	Steel layout floor or plate table, flat-bar and angle stock for frame mockup, chalk lines, flexible batten, straight edge, taper gauge, digital level, clamps, MIG welder for tacking, layout inspection form, calculator	Layout inspection form reviewed: camber must be within ±1/8 inch at all five stations and assembly must be plumb within 1/8 inch per 10-foot height to pass.
8	Bulkhead and Longitudinal Fit-Up	18	lab	Students will position and tack a transverse bulkhead and at least two longitudinal stiffeners in a simulated hull-section jig, achieving plumb, fair, and spacing within tolerances and completing the required fit-up inspection checklist.	Instructor walks students through a shipyard fit-up procedure, emphasizing the sequence: set keel baseline, establish frame stations, plumb each frame, fair longitudinals, then fit the bulkhead. Students work in teams of two in a mock hull jig to position a pre-cut bulkhead plate, establish plumb using a plumb bob and digital level, tack it in place, then measure and set two longitudinal flat bars to their marked positions. Teams complete a fit-up inspection checklist—checking spacing, plumb, fairness (using a batten), and tack-weld spacing—and have the instructor sign off each item before proceeding to the next.	Mock hull jig with keel bar and frame brackets, pre-cut mild-steel plate bulkhead, flat-bar longitudinals, clamps, strong-backs, MIG welder for tacking, plumb bob, digital level, 25-ft tape, straight-edge batten, fit-up inspection checklist	Completed and signed fit-up inspection checklist: all critical dimensions (plumb ±1/8 inch per 10 ft, spacing ±1/8 inch, tack spacing within specification) must pass before sign-off; all items must be green to pass the lesson.
9	Fairness and Distortion Control	14.5	theory	Students will identify at least four causes of weld distortion in ship structure and describe one appropriate pre-fit or post-fit corrective method for each, scoring 80% or higher on a written scenario quiz.	Lecture with photographs and diagrams covering angular distortion, longitudinal shrinkage, transverse shrinkage, and buckling; students annotate a distortion reference chart. Small-group case studies: each group receives a photograph and description of a distorted assembly and must diagnose the cause, rank the contributing factors, and propose a corrective sequence; groups present findings to the class. Written scenario quiz: students are given five distortion situations and must identify the cause, select a correction method (pre-setting, strongbacks, backstep welding, peening, heat straightening), and justify the choice.	Slide presentation, distortion reference chart, photographs of distorted assemblies, case study packets, NCCER Shipfitting distortion chapter, AWS D1.1 reference sections on distortion control	Written scenario quiz scored by instructor; students must correctly address four of five scenarios with correct cause identification and a defensible corrective method—80% or higher to pass.
10	Laser and Digital Layout Tools	13	demo	Students will set up and use a rotating laser level and a digital theodolite (or total station) to establish a baseline, transfer a reference elevation, and check the plumb of a vertical structural member, with all readings within 1/8 inch of true.	Instructor demonstrates setup, calibration, and safety precautions (laser class and eye-protection requirements) for the rotating laser level and digital instrument, then transfers a reference elevation to four corners of the shop. Students take turns setting up the laser level, shooting grades to five marked targets, and recording readings; partners verify using a conventional level and rod. Students use the digital angle-measuring function to check the plumb of a vertical post at two axes, record results, and calculate deviation from plumb.	Rotating laser level with receiver, digital theodolite or total station (or digital level), laser safety glasses (appropriate class), tripods, grade rod, vertical post setup, data recording sheet	Data recording sheet reviewed; all five elevation transfers must be within 1/8 inch of the reference and plumb readings must be within 1/8 inch per 10-foot height to pass.
11	Material Take-Off and Fit-Up Documentation	16.5	theory	Students will produce a complete material take-off list and a fit-up sketch for a given structural assembly, including all part marks, quantities, material grades, and dimensions, with the take-off matching the drawing to within a 5% quantity error.	Instructor demonstrates reading a bill of materials block and completing a standard shipyard material take-off form from a sample assembly drawing, highlighting common errors. Students individually complete a material take-off for a five-part weld assembly drawing, listing each part with part mark, material designation, quantity, size, length, and mass. Students produce a freehand fit-up sketch of the same assembly showing part orientation, weld symbols, and assembly sequence, then exchange with a peer for a blind review against the drawing.	Multi-part assembly drawings, shipyard material take-off forms, fit-up sketch worksheet, pencils, ruler, AWS A2.4 weld symbol reference, NCCER Shipfitting documentation chapter	Material take-off form and fit-up sketch graded by instructor: take-off must have all parts listed with correct data and total quantity within 5% of drawing; sketch must show correct orientation, weld symbols, and sequence—80% score to pass.
12	Integrated Layout and Fit-Up Practical	34	practice	Students will independently complete the full layout, template development, and fit-up sequence for an assigned multi-part hull-section assembly, satisfying all dimensional tolerances and producing a complete documentation package, which serves as the primary skills assessment for the course.	Each student receives a drawing package for a small hull section (keel bar, two transverse frames, one longitudinal, one bracket); they independently lay out the assembly on the shop floor, develop any required templates, cut or request pre-cut material, and fit the parts in correct sequence over the allotted hours. Students complete all required documentation in parallel with the build: material take-off, layout record, fit-up inspection checklist, and a brief written description of any corrections made and why. Instructor conducts a progressive check at three milestones—layout complete, templates approved, tack fit-up complete—signing off at each gate before the student advances; final assembly is measured against the drawing at the end.	Full drawing package (unique per student), steel layout floor or plate table, full precision-tool kit, cardboard or Masonite for templates, clamps, strongbacks, MIG welder for tacking, full documentation forms, safety PPE (hard hat, safety glasses, leather gloves, steel-toed boots)	Final assembly measured at all critical dimensions by instructor using calibrated tools; all primary dimensions must be within ±1/8 inch, all templates must have been approved before cutting, documentation package must be complete—all three gate sign-offs required and final dimensional check must pass to receive a passing grade on this lesson.

Assessments

Assessment	Type	Weight	Pass standard	Method & rubric
Shipfitting Layout Knowledge Exam	Written exam	25%	75% correct (38 of 50 questions)	A 50-question written exam covering drawing interpretation, lofting principles, geometric construction, offset tables, camber calculations, distortion causes and corrections, material take-off, and tool selection, mapped to NCCER Shipfitting written-test competency areas. Questions are a mix of multiple-choice and short-answer; students may use a calculator and a weld symbol reference card. Standard met · Safety · Time · Quality/finish · Documentation
Integrated Layout and Fit-Up Skills Demonstration	Skills demonstration	45%	All three milestone gates signed off; all primary dimensions within ±1/8 inch; documentation package complete and accepted	Students independently execute the Lesson 12 practical assignment—laying out, templating, and tacking a multi-part hull-section assembly from a drawing package—under instructor observation. Performance is evaluated against an NCCER-aligned skills verification checklist covering layout accuracy, template quality, fit-up sequence, tack placement, and documentation; this assessment directly mirrors NCCER Shipfitting performance-test task requirements. Standard met · Safety · Time · Quality/finish · Documentation
Lab Log and Documentation Portfolio	Log	15%	Eight of twelve lesson documentation packages submitted, complete, and scoring 80% or higher on the standard review rubric	Students maintain a running lab log throughout the course, submitting a structured documentation package for each hands-on lesson: measurement data sheets, layout records, template fit-check sheets, fit-up inspection checklists, and material take-off forms. The portfolio is reviewed at mid-course and again at course end; completeness, accuracy, and legibility are scored against a standard rubric aligned to shipyard quality-assurance expectations. Standard met · Safety · Time · Quality/finish · Documentation
Safety and PPE Compliance Check	Safety audit	15%	Zero critical violations observed across the full course; any single critical violation requires a documented corrective action and re-check before the student may continue lab work	The instructor conducts unannounced safety walk-throughs during every lab and practice lesson, using a standardized shipyard safety observation form that checks for correct PPE (hard hat, safety glasses or face shield, leather gloves, steel-toed boots, hearing protection in noisy areas), proper housekeeping, correct tool handling, adherence to shipyard lockout/tagout procedures when applicable, and safe material-handling practices. Results are logged for each student and form part of the final course grade. Standard met · Safety · Time · Quality/finish · Documentation

MFG-SHIP13-05 Trade course

Marine Coatings: Surface Preparation and Protective Coating Application

204 hr · ~~$3,980~~ COMPLIMENTARY

This course covers the complete protective coating process used in shipbuilding and marine repair, from surface preparation through final topcoat application, in compliance with SSPC, NACE, and shipyard quality standards. Students learn to read and apply coating specifications, operate blasting and spray equipment, identify and document coating defects, and work safely with flammable and toxic coating materials. Lessons map to NCCER Shipfitting core competencies related to surface protection and to the quality-control knowledge tested in ABS/USCG weld and fabrication qualification contexts.

Outcomes

Select and apply the correct personal protective equipment and ventilation controls for each phase of surface preparation and coating application in compliance with OSHA standards and SDS requirements.
Prepare steel and aluminum marine surfaces to specified SSPC cleanliness grades using hand tools, power tools, and abrasive blasting, and verify results with visual comparator standards.
Read and execute a coating system specification sheet, mixing multi-component coatings to correct ratio, applying each coat within the documented overcoat window, and achieving specified dry-film thickness.
Operate airless spray, conventional spray, and roller/brush application equipment, performing basic maintenance and troubleshooting to minimize defects such as runs, sags, pinholes, and holidays.
Inspect coated surfaces using wet-film and dry-film thickness gauges, holiday detectors, and adhesion test equipment, and document results on a standard inspection record.
Explain the purpose and requirements of common marine coating systems including anti-corrosion primers, intermediate coats, antifouling bottom paints, and tank linings, and relate proper application to vessel service life.

Course text

How the course runs. 12 blocks: Corrosion, Coating Fundamentals, and the Marine Environment; Hazard Recognition, SDS Interpretation, and Coating-Area PPE; Surface Cleanliness Standards and Visual Inspection; Hand-Tool and Power-Tool Surface Preparation; Abrasive Blasting: Equipment, Media, and Safety; Abrasive Blasting Practice and Surface Profile Measurement; Reading Coating Specifications and Mixing Multi-Component Coatings; Coating Application Methods: Brush, Roller, and Airless Spray; Dry-Film Thickness Measurement and Holiday Detection; Antifouling and Bottom Paint Systems; Tank Coatings and Confined-Space Coating Operations; Coating Inspection, Quality Documentation, and Defect Remediation.

What competent looks like. Select and apply the correct personal protective equipment and ventilation controls for each phase of surface preparation and coating application in compliance with OSHA standards and SDS requirements. Prepare steel and aluminum marine surfaces to specified SSPC cleanliness grades using hand tools, power tools, and abrasive blasting, and verify results with visual comparator standards. Read and execute a coating system specification sheet, mixing multi-component coatings to correct ratio, applying each coat within the documented overcoat window, and achieving specified dry-film thickness. Operate airless spray, conventional spray, and roller/brush application equipment, performing basic maintenance and troubleshooting to minimize defects such as runs, sags, pinholes, and holidays. Inspect coated surfaces using wet-film and dry-film thickness gauges, holiday detectors, and adhesion test equipment, and document results on a standard inspection record. Explain the purpose and requirements of common marine coating systems including anti-corrosion primers, intermediate coats, antifouling bottom paints, and tank linings, and relate proper application to vessel service life.

Lessons · 12 blocks

#	Lesson	Hr	Type	Objective	Activities	Materials	Check
1	Corrosion, Coating Fundamentals, and the Marine Environment	14	theory	Students will explain why steel and aluminum corrode in marine service and identify the components and function of a multi-coat protective coating system.	Lecture and annotated diagram exercise: students label the electrochemical corrosion cell and identify anodic and cathodic zones on a corroded hull photo set, then write a short explanation in their own words. Group analysis of three real coating system specification sheets (one anti-corrosion primer system, one antifouling system, one tank lining); students extract and compare DFT ranges, recoat windows, and substrate requirements. Case-study discussion: instructor presents two documented coating failures (delamination and osmotic blistering) from published NACE/SSPC failure analysis examples; students identify likely root causes using a guided worksheet.	Whiteboard, projector, sample coating spec sheets from major marine coating manufacturers (e.g., Jotun, Sherwin-Williams Marine, Hempel), SSPC Painting Manual Vol. 1, corroded steel coupon samples for visual reference.	10-question written quiz covering corrosion mechanisms, coating layer terminology (primer, intermediate, topcoat, DFT, WFT), and spec sheet reading; pass mark 70%.
2	Hazard Recognition, SDS Interpretation, and Coating-Area PPE	16	theory	Students will identify health and physical hazards associated with marine coating materials, select correct PPE for each task, and extract required safety information from a Safety Data Sheet.	SDS scavenger hunt: each student receives an SDS for a different marine coating product (epoxy primer, polyurethane topcoat, coal tar epoxy) and completes a structured extraction form covering flammability, exposure limits, required PPE, first-aid measures, and spill response. PPE selection drill: instructor describes five coating scenarios (spray painting in a confined tank, brush-applying antifouling paint on open deck, abrasive blasting, sanding, solvent wiping) and students select the correct respirator type, glove material, and eye protection from a tray of options, justifying each choice aloud. Confined-space entry pre-task planning exercise: students complete a simulated permit form for painting inside a ballast tank, identifying atmosphere testing requirements, ventilation needs, rescue provisions, and communication procedures, referencing OSHA 29 CFR 1915 Subpart B.	Printed SDS packets for at least five coating products, PPE sample kit (half-face and full-face respirators with organic vapor cartridges, supplied-air apparatus for demonstration, nitrile and neoprene gloves, chemical splash goggles, Tyvek coveralls), OSHA 29 CFR 1915 Subpart B reference handout.	Students must correctly match PPE to all five scenarios without instructor prompting and correctly identify all four critical SDS sections on an oral check; 100% accuracy required on PPE selection before advancing to hands-on lessons.
3	Surface Cleanliness Standards and Visual Inspection	14	theory	Students will identify and distinguish SSPC surface preparation grade descriptors for hand-tool, power-tool, and blast-cleaned steel, and match visual conditions to the correct SSPC/NACE standard using comparator cards.	Side-by-side comparison exercise: instructor presents steel coupons prepared to SSPC-SP 2, SP 3, SP 6, SP 10, and SP 5; students examine each under good lighting and record descriptive notes, then compare their descriptions to the SSPC Visual Standard text. SSPC comparator card practice: using the SSPC VIS 1 photographic standard booklet, students independently grade ten photographed coupon images, then check their grades against the answer key and discuss disagreements as a class. Salt contamination and soluble-salt testing demonstration: instructor demonstrates a Bresle patch test and a conductivity meter reading on a prepared coupon; students record the procedure steps and the acceptance threshold referenced in a generic specification.	SSPC VIS 1 visual standard booklet (one per student or shared set), steel coupons prepared to multiple SP grades, Bresle patch test kit for demonstration, conductivity meter, SSPC Painting Manual Vol. 2.	Students grade a blind set of eight coupon photos using SSPC VIS 1; at least six of eight must match the key grade within one grade level, and all must be within the correct SP category (hand tool vs. blast); pass mark 75%.
4	Hand-Tool and Power-Tool Surface Preparation	18	lab	Students will prepare a corroded steel test panel to SSPC-SP 3 Power Tool Cleaning using angle grinders, needle scalers, and wire brushes, meeting the visual standard and recording results on an inspection form.	Tool familiarization and safety check: students identify each tool, demonstrate proper guard installation on the angle grinder, and perform a pre-use inspection checklist before the instructor authorizes tool use. Guided preparation sequence: students work individually on assigned 12×12-inch corroded mild-steel coupons, progressing from chipping loose rust and scale with a needle scaler to grinding and wire brushing to SP 3, pausing at each stage for instructor spot-check. Post-prep inspection and documentation: students photograph the finished panel, compare it to the SSPC VIS 1 SP 3 reference, complete a one-page inspection record (panel ID, date, tool used, grade achieved, observations), and present it to the instructor.	Corroded mild-steel coupons (min. 12×12 in.), angle grinders with grinding and flap-disc attachments, needle scalers, wire-brush cups, chipping hammers, SSPC VIS 1, inspection record forms, face shields, hearing protection, leather gloves, dust masks (N95 minimum).	Instructor visually grades the finished panel against SSPC VIS 1 SP 3; panel must reach SP 3 with no more than trace loose rust remaining. Inspection record must be complete and accurate. Both must pass; either failure requires rework and re-check.
5	Abrasive Blasting: Equipment, Media, and Safety	18	demo	Students will describe the components of a dry-abrasive blast system, select appropriate blast media for steel and aluminum substrates, and explain safety controls including pressure vessel inspection, blast suit requirements, and respiratory air quality.	System walk-around demonstration: instructor powers down and locks out the blast pot, then guides students through each component (compressor, moisture separator, blast pot, deadman valve, blast hose, nozzle, blast helmet with supplied air) explaining function and common failure points. Media comparison exercise: students examine and handle samples of steel grit, steel shot, garnet, aluminum oxide, and plastic media; they record hardness, angularity, and recyclability characteristics and match each media to appropriate substrate and desired surface profile. Respiratory air quality discussion and Grade-D air demonstration: instructor explains the OSHA Grade-D breathing air standard for supplied-air blast helmets and demonstrates use of a carbon monoxide monitor; students complete a checklist for pre-blast air quality verification.	Blast pot (properly tagged out for demonstration), blast hose and nozzle samples, deadman valve, blast helmet with supplied-air line, CO monitor, media sample set (labeled jars), surface profile comparator kit, OSHA 29 CFR 1910.134 reference handout on breathing air.	Oral quiz: instructor asks each student to name all major blast system components and their function, identify the correct media for aluminum versus steel, and state the minimum respiratory requirement for blasting; all three must be answered correctly to pass.
6	Abrasive Blasting Practice and Surface Profile Measurement	20	lab	Students will blast-clean assigned steel panels to SSPC-SP 10 Near-White Metal Blast Cleaning and measure the resulting surface profile using a replica tape method, recording results within specification.	Pre-blast checklist: students complete the blast-area setup checklist (ventilation, containment, PPE donned, air quality verified, deadman function confirmed) before instructor authorizes blasting under direct supervision. Supervised blasting sequence: each student blasts a 12×12-inch steel panel to SP 10, with the instructor observing technique (nozzle angle, standoff distance, overlap pattern) and providing real-time coaching; students stop periodically to compare the panel to SSPC VIS 1 SP 10 reference. Profile measurement: students measure anchor profile on the finished panel using Testex Press-O-Film replica tape and a spring micrometer, record two readings, average them, compare to a simulated specification range of 1.5–3.0 mil, and note pass or fail on the inspection form.	Blast pot with garnet media, steel panels (12×12 in., pre-rusted), SSPC VIS 1, Testex replica tape kit (coarse and X-coarse), spring micrometer, inspection record forms, full blast PPE (supplied-air helmet, Tyvek suit, leather gloves, steel-toed boots), containment sheeting.	Panel must be graded SP 10 by instructor using SSPC VIS 1. Profile readings must be recorded correctly and averaged; the average must fall within 1.5–3.0 mil to pass. Inspection form must be complete. Any unsafe act during blasting results in immediate stop and mandatory safety debrief before resuming.
7	Reading Coating Specifications and Mixing Multi-Component Coatings	16	theory	Students will interpret a marine coating product data sheet, calculate mix ratios by volume for two-component coatings, and explain pot-life limitations and their consequences.	Specification interpretation exercise: each student receives a two-component epoxy primer product data sheet and completes a structured worksheet extracting mix ratio, induction time, pot life at 77°F, application temperature range, theoretical coverage rate, DFT range, and minimum/maximum overcoat times. Mix-ratio calculation drill: instructor provides five mixing scenarios (different batch sizes) for a 4:1 volume ratio epoxy; students calculate the correct volumes of Part A and Part B for each batch using dimensional analysis and record results, checking with the instructor. Pot-life consequence role-play: students act out a scenario where a mixed batch is not used within pot life; they identify the visual signs of material degradation, the coating defects that result if applied anyway, and the correct disposal procedure.	Product data sheets for at least two marine epoxy coatings and one polyurethane topcoat, calculators, mixing ratio worksheet handout, sample cured and degraded material samples for visual comparison.	Calculation quiz: five mix-ratio problems; students must answer all five correctly (100%) to proceed to mixing lab — errors in mix ratio can cause coating failures and are treated as a zero-defect skill.
8	Coating Application Methods: Brush, Roller, and Airless Spray	22	lab	Students will apply a two-component epoxy primer to prepared steel panels using brush, roller, and airless spray, achieving the specified wet-film thickness and uniform coverage with no major defects.	Equipment setup and calibration: for airless spray, students install the correct tip, set pressure, and test spray on cardboard, adjusting until a uniform fan pattern without tailing is achieved before touching the panel; for brush and roller, students select the correct nap and width for the coating viscosity. Application practice panels: each student applies primer to three 12×12-inch SP 10-blasted panels using one method each (brush, roller, airless), measuring wet-film thickness with a wet-film gauge at three points per panel during application and adjusting technique as needed. Defect identification debrief: after panels cure, students photograph and annotate defects (runs, sags, pinholes, dry spray, missed areas) on a defect map form, classify each defect type, and propose the corrective action per the product data sheet guidance.	Two-component epoxy primer (properly mixed per prior lesson), SP 10 blasted steel panels, airless spray unit with appropriate tip, brushes (natural bristle and synthetic), 3/8-inch nap rollers, wet-film thickness gauges, mixing sticks, graduated mixing containers, solvent for cleanup, respirators (OV cartridges), chemical-resistant gloves, ventilated spray booth or outdoor application area.	Wet-film thickness readings at three points on each panel must average within the specified range on the product data sheet (±20%); no more than two minor defects (pinhole or light dry spray) per panel allowed; runs or bare areas are automatic rework. Defect map must be complete and accurate.
9	Dry-Film Thickness Measurement and Holiday Detection	16	lab	Students will measure dry-film thickness on cured coating panels using a calibrated magnetic pull-off gauge, and detect holidays (coating voids) on tank-lining panels using a wet-sponge holiday detector, documenting results on an inspection record.	Gauge calibration exercise: students calibrate a magnetic DFT gauge using the base metal reading and certified shim standards, recording zero reading and each calibration point, repeating until two consecutive calibration cycles agree within gauge manufacturer tolerance. DFT survey: students take a five-point DFT reading pattern on six cured epoxy panels representing varied application quality; they record individual readings, calculate the mean, identify any low-spot readings below specification minimum, and indicate on a sketch where remedial coating is required. Holiday detection: instructor demonstrates wet-sponge detector technique on a demonstration panel with pre-drilled pinholes; students then independently survey a 24×24-inch panel, mark all holidays with paint marker, count them, and enter results on the inspection form, comparing to a simulated specification maximum holiday count.	Calibrated magnetic DFT gauge (Type 1 or Type 2 per SSPC-PA 2), certified shim standards, cured epoxy-coated test panels of varied thickness, wet-sponge holiday detector (low-voltage), conductive sponge and water with wetting agent, paint markers, inspection record forms, SSPC-PA 2 reference handout.	DFT survey: all readings recorded, mean calculated correctly, and any out-of-spec readings correctly flagged — 100% accuracy on data recording required. Holiday detection: student must locate at least 90% of seeded holidays on the demonstration panel to pass.
10	Antifouling and Bottom Paint Systems	14	theory	Students will explain how self-polishing copolymer and hard antifouling coatings function, identify environmental and regulatory constraints on antifouling paint selection, and describe the correct surface preparation and application sequence for a bottom paint system.	Comparative product analysis: students read technical data sheets for one self-polishing copolymer antifouling and one hard ablative antifouling and complete a comparison table covering active biocide type, recoat window, maximum out-of-water exposure time, and any documented regulatory restrictions on copper-based products in certain US jurisdictions. Application sequence planning exercise: given a bare steel hull specification requiring SSPC-SP 10 blast, epoxy primer, one intermediate coat, and two coats of antifouling, students create a step-by-step application plan with estimated recoat windows based on product data sheets and a 75°F ambient temperature. Regulatory overview discussion: instructor leads a structured discussion on EPA and state-level restrictions on certain antifouling biocides for small vessels, tributyltin history, and current copper-content rules in specific states, emphasizing that students must always consult current regulations and owner specifications.	Product data sheets for antifouling systems (instructor-sourced from manufacturers), EPA antifouling regulation summary handout, application sequence planning worksheet, projector for regulatory document review.	Completed application sequence plan reviewed by instructor; plan must include all required coats in correct order, correct SSPC surface prep grade, and recoat windows read accurately from the product data sheet — any omission of a required coat or incorrect SP grade requires revision before credit is given.
11	Tank Coatings and Confined-Space Coating Operations	22	lab	Students will apply an epoxy tank-lining coating system to the interior of a simulated tank structure following a confined-space entry plan, achieving specified coverage and documenting the work on a coating log.	Pre-entry confined-space simulation: using a mock enclosed structure (e.g., a portable confined-space trainer or enclosed mockup), students complete a permit form, test atmospheric conditions with a four-gas monitor (O2, LEL, CO, H2S), verify mechanical ventilation flow, and brief the attendant on rescue procedures before any coating materials are introduced. Stripe coat and full application: working in pairs (one applicator inside, one attendant outside with continuous communication), students apply a brush stripe coat to all welds and edges in the simulated tank interior, then apply the full epoxy lining by roller, measuring wet-film thickness at minimum four points. Coating log completion: after exiting and airing out the space, students complete a full coating application log including date, temperature and humidity readings, batch numbers, mix ratios, applicator name, area coated, WFT readings, and any deviations from specification, signing the log as required by quality-control procedures.	Confined-space mock enclosure or tank trainer, four-gas monitor, mechanical air-mover ventilation unit, two-component epoxy tank lining material, brushes and short-nap rollers, wet-film gauges, thermometer and psychrometer or digital hygrometer, coating log forms, full PPE (supplied-air or powered-air purifying respirator appropriate for the coating per SDS, Tyvek suit, chemical-resistant gloves), OSHA 29 CFR 1915 Subpart B reference.	Pre-entry permit and atmospheric test must be approved by instructor before entry is permitted — no exceptions. WFT readings must average within specified range. Coating log must be complete with all required entries signed. Any unauthorized confined-space entry during the exercise results in automatic failure requiring lesson repeat.
12	Coating Inspection, Quality Documentation, and Defect Remediation	14	lab	Students will conduct a complete coating inspection of a multi-coat finished panel, identify and classify all defects, determine correct remediation actions, and produce a finished inspection package meeting a shipyard quality-record standard.	Full-panel inspection: each student receives a 24×24-inch finished multi-coat panel containing seeded defects (one run, one pinhole cluster, one area of insufficient DFT, one holiday); using DFT gauge, holiday detector, and visual inspection, students locate and mark all defects, classify each by type, and note location on a panel sketch. Remediation planning: for each identified defect, students consult the product data sheet and an SSPC coating inspection guide to write the correct remediation procedure (spot blast, feather sand, recoat, etc.) including required surface preparation grade before recoating. Inspection package assembly: students compile all inspection records from Lessons 9 and 12 (calibration records, DFT survey sheets, holiday detection log, coating application log, defect map, remediation plan) into a single organized package and present it to the instructor as if submitting to a QC manager.	Pre-prepared 24×24-inch multi-coat defect panels, DFT gauge, wet-sponge holiday detector, panel sketch forms, SSPC Painting Manual Vol. 2 (inspection sections), inspection record forms, file folders or binders for package assembly.	Student must identify and correctly classify at least 90% of seeded defects. Remediation procedures must be technically correct per product data sheet and SSPC guidance. Inspection package must contain all required documents in legible, complete form. Incomplete packages require revision before final course grade is recorded.

Assessments

Assessment	Type	Weight	Pass standard	Method & rubric
Marine Coatings Written Knowledge Exam	Written exam	25%	75% or higher (must score 100% on confined-space entry and respirator selection questions to pass regardless of overall score)	A 60-question multiple-choice and short-answer exam covering corrosion theory, SSPC surface preparation grades, SDS interpretation, coating system components, mix ratios, pot life, DFT and WFT concepts, antifouling system types, and confined-space coating hazards; questions are drawn from NCCER Shipfitting knowledge domains related to surface protection. Standard met · Safety · Time · Quality/finish · Documentation
Coating Application Skills Demonstration	Skills demonstration	45%	All four criteria must be met: correct PPE worn throughout; mixed coating within ±5% of specified mix ratio; applied coat achieves average DFT within specification range on at least 80% of readings; no runs, bare areas, or major defects on finished panel	Each student independently mixes a batch of two-component epoxy primer, applies it to a blasted 12×12-inch steel panel using airless spray, and completes a DFT survey of the cured panel, with the instructor evaluating safety practices, mixing accuracy, application technique, and final film quality against a scored rubric. Standard met · Safety · Time · Quality/finish · Documentation
Coating Inspection Lab Log	Log	15%	Log must contain all 12 lesson entries; all DFT calibration records, profile measurements, WFT readings, holiday detection results, and application logs must be complete, legible, and signed; at least 85% of recorded measurements must match instructor's concurrent readings within gauge tolerance	Students maintain a bound lab log throughout the course recording all measurements, equipment calibration steps, inspection results, and application parameters from every hands-on lesson; the completed log is submitted at the end of the course and evaluated as a professional quality-control document. Standard met · Safety · Time · Quality/finish · Documentation
Confined-Space and Coating Hazards Safety Check	Safety audit	15%	100% — any single failure to correctly perform a safety-critical step requires an immediate stop, remedial instruction, and full repeat of the check; no partial credit	A practical safety evaluation conducted in the confined-space mock enclosure in which each student must independently complete the pre-entry permit, correctly operate a four-gas monitor and interpret readings, select and don the correct respiratory protection from the SDS, and brief a simulated attendant on emergency procedures before instructor authorization is granted. Standard met · Safety · Time · Quality/finish · Documentation

MFG-SHIP13-06 Trade course

Marine Outfitting: Systems Installation and Interior Fabrication

204 hr · ~~$3,980~~ COMPLIMENTARY

Students install, fit, and secure the mechanical, structural, and interior systems that convert a bare hull into a functional vessel, including pipe systems, HVAC ducting, deck equipment foundations, joiner bulkheads, and access hatches. Work is performed to commercial shipbuilding standards using blueprints, isometric drawings, and equipment manuals. Lessons map directly to NCCER Shipfitting layout and systems modules and reinforce the fabrication quality requirements tested by ABS/USCG weld qualification.

Outcomes

Read and interpret outfitting drawings, piping isometrics, and equipment-arrangement plans to locate, orient, and install shipboard systems within stated tolerances.
Fabricate and install pipe spools, hangers, and penetration sleeves in steel and aluminum to applicable shipbuilding standards, achieving leak-free joints on a hydrostatic pressure test.
Fit and secure deck equipment foundations, bitts, cleats, and fairleads using correct fastener specifications and weld symbols from the design package.
Install and fasten joiner bulkheads, insulation blankets, ceiling panels, and access hatches plumb, level, and square to within accepted shipyard tolerances.
Apply confined-space entry, LOTO, hot-work permit, and fall-protection procedures correctly on every outfitting evolution without a prompted reminder.
Produce and maintain an outfitting work package including material take-offs, inspection records, red-line as-builts, and a completed punch-list cleared to zero.

Course text

How the course runs. 12 blocks: Outfitting Drawings and Work-Package Fundamentals; Outfitting Safety: Confined Spaces, Hot Work, and Fall Protection; Pipe System Fundamentals and Material Identification; Pipe Spool Fabrication: Layout, Cutting, and Fit-Up; Pipe Hanger and Support Fabrication and Installation; Pipe Penetrations, Sleeves, and Stuffing-Box Installations; Deck Equipment Foundations: Bitts, Cleats, and Fairleads; Joiner Bulkheads: Layout, Framing, and Panel Installation; Insulation Installation: Blankets, Spray Foam, and Fire-Rated Systems; Access Hatches, Manholes, and Watertight Closures; Systems Integration: Multi-Trade Coordination and Conflict Resolution; Outfitting Work-Package Completion, As-Built Documentation, and Final Inspection.

What competent looks like. Read and interpret outfitting drawings, piping isometrics, and equipment-arrangement plans to locate, orient, and install shipboard systems within stated tolerances. Fabricate and install pipe spools, hangers, and penetration sleeves in steel and aluminum to applicable shipbuilding standards, achieving leak-free joints on a hydrostatic pressure test. Fit and secure deck equipment foundations, bitts, cleats, and fairleads using correct fastener specifications and weld symbols from the design package. Install and fasten joiner bulkheads, insulation blankets, ceiling panels, and access hatches plumb, level, and square to within accepted shipyard tolerances. Apply confined-space entry, LOTO, hot-work permit, and fall-protection procedures correctly on every outfitting evolution without a prompted reminder. Produce and maintain an outfitting work package including material take-offs, inspection records, red-line as-builts, and a completed punch-list cleared to zero.

Lessons · 12 blocks

#	Lesson	Hr	Type	Objective	Activities	Materials	Check
1	Outfitting Drawings and Work-Package Fundamentals	16	theory	Given a sample outfitting work package, the student correctly identifies every drawing type, locates specified components by zone and frame number, and extracts a complete material list with zero omissions.	Instructor-led walkthrough of a commercial shipyard work package: general arrangement, compartment drawings, piping isometrics, electrical raceways, and equipment-arrangement plans; students annotate a printed set with zone, frame, and centerline references. Small-group exercise: each team receives a different compartment drawing and must produce a written material take-off (MTQ) for all pipe, hangers, foundations, and joiner components listed, then cross-check against instructor answer key. Individual digital exercise using a CAD viewer (Autodesk DWG TrueView or equivalent): students navigate a multi-sheet drawing set, answer ten locating questions, and record answers in a log sheet submitted for grading.	Sample commercial outfitting drawing sets (GA, isometrics, arrangement plans), Autodesk DWG TrueView on lab computers, NCCER Shipfitting Module 3 (Drawings and Plans), blank MTQ forms, drawing scales and triangular scales	Completed MTQ log checked against instructor key; student must achieve 80% accuracy on component identification and material quantities to pass.
2	Outfitting Safety: Confined Spaces, Hot Work, and Fall Protection	14	theory	The student correctly classifies a described shipboard space as permit-required or non-permit confined space, completes a hot-work permit form, and identifies the fall-protection system required for a given work scenario, scoring 80% or better on a written check.	Case-study review of three documented shipyard incidents (confined-space fatality, hot-work fire, fall from staging) drawn from OSHA and USCG investigation reports; students identify each root cause and write one corrective action per case. Role-play exercise: pairs take turns acting as entrant, attendant, and entry supervisor using a real permit-required confined-space entry form and a calibrated 4-gas monitor (O2, LEL, CO, H2S); instructor introduces a simulated alarm mid-drill. Hot-work permit simulation: students receive a scenario card describing compartment, adjacent materials, and nearby fuel lines, then complete a blank hot-work permit form, identify required fire watch duties, and present their completed permit for peer review.	OSHA 29 CFR 1910.146 confined-space standard (reference copy), shipyard hot-work permit blank forms, 4-gas personal atmospheric monitor, OSHA 29 CFR 1926 Subpart M fall-protection reference, PPE samples (harness, lanyard, self-retracting lifeline), dry-erase scenario cards	Written 20-question quiz on confined-space classification, permit completion, and fall-protection selection; pass mark 80%; students scoring below 80% receive remediation and retest before proceeding.
3	Pipe System Fundamentals and Material Identification	14	theory	The student identifies common shipboard pipe materials, schedule ratings, and end-preparation methods, and correctly selects pipe and fitting specifications from a piping class schedule for three given service systems.	Hands-on material station: students examine labeled samples of carbon steel (Schedule 40 and 80), stainless, copper-nickel, and CPVC pipe; they record nominal pipe size, outside diameter measured with calipers, and wall thickness, then compare measured values to ASME B36.10 nominal data in a reference table. Piping class schedule exercise: using a simplified shipboard piping specification sheet, each student selects the correct pipe class, gasket type, and bolt specification for five different service systems (seawater cooling, potable water, diesel fuel, bilge, and compressed air) and defends choices in a brief class discussion. P&ID symbol quiz: students receive a blank P&ID fragment and must label 15 standard symbols (gate valve, check valve, strainer, pressure gauge, expansion loop, flanged joint, screwed joint, reducer) using an ISA/ISO reference sheet, then compare to answer key.	Pipe sample kit (various materials and schedules), vernier calipers, ASME B36.10 nominal pipe size table (reference excerpt), simplified shipboard piping class schedule handout, P&ID symbol reference sheet, ISA-5.1 symbol standard excerpt	Material identification worksheet and P&ID symbol quiz combined score must reach 80%; calipers reading checked by instructor for correct technique before worksheet is accepted.
4	Pipe Spool Fabrication: Layout, Cutting, and Fit-Up	20	lab	The student fabricates a two-offset carbon-steel pipe spool to a given isometric, with each cut square within 1°, end-to-end dimension within ±1/16 inch, and fit-up gap within the applicable welding procedure specification (WPS) range.	Demonstration by instructor: reading the isometric, calculating offsets using pipe-fitting math (45° offset formula), marking cut lines with soapstone on Schedule 40 pipe, cutting with a portable band saw and angle grinder, and checking squareness with a machinist square. Supervised practice: each student lays out, marks, and cuts a simple single-offset spool from 2-inch Schedule 40 carbon steel using the isometric provided; instructor checks each cut for squareness before tack welding is permitted. Fit-up and tack-weld session: students align spool segments in a pipe vise and V-block, check root gap and hi-lo with a fit-up gauge, apply tacks per WPS instructions (minimum three tacks at equal spacing), and measure finished assembly against the isometric dimension.	2-inch Schedule 40 carbon steel pipe cut stock, pipe isometric drawings, portable band saw, angle grinder with cutting and grinding wheels, pipe vise, V-blocks, soapstone, combination square, machinist square, fit-up weld gauge, WPS reference sheet, hearing protection, grinding face shield, welding gloves	Instructor measures finished spool: dimension within ±1/16 inch, squareness within 1°, root gap within WPS tolerance; all three criteria must be met for pass; failed spools are reworked and re-checked once.
5	Pipe Hanger and Support Fabrication and Installation	18	lab	The student fabricates and installs two different hanger types (clevis and U-bolt) at drawing-specified frame locations and heights, with each hanger plumb within 1/8 inch and support spacing not exceeding the drawing requirement.	Instructor demo on a mock hull section: transferring hanger locations from a drawing to structure using a plumb bob and measuring tape, drilling pilot and finish holes in a steel web frame, and installing a threaded-rod clevis hanger to a torque specification using a torque wrench. Hands-on fabrication: each student cuts and drills a mild-steel flat-bar bracket, welds a threaded insert, and assembles a clevis hanger assembly; fit and finish are inspected against a shop drawing before installation. Installation exercise on mock hull section: students install their hanger and a second U-bolt hanger at marked locations, hang a 2-inch spool section, check plumb with a level, and record measured heights on an inspection record form.	Mock hull section (steel web frames), mild steel flat bar, threaded rod, clevis and U-bolt hanger hardware, drill press and portable drill, twist drill set, torque wrench, combination level, plumb bob, tape measure, MIG welder, welding PPE, inspection record forms	Instructor checks plumb (within 1/8 inch using level), installed height within ±1/4 inch of drawing, and hanger torque verified with torque wrench; all three pass criteria required; inspection record must be fully completed and signed.
6	Pipe Penetrations, Sleeves, and Stuffing-Box Installations	16	lab	The student locates, cuts, and fits a welded pipe sleeve through a steel bulkhead to drawing dimensions, achieving a flush inside face, correct annular clearance, and a full-perimeter fillet weld meeting visual inspection criteria.	Instructor demonstration: transferring a penetration center from both sides of a mock bulkhead using a transfer punch and center finder, plasma-cutting the hole, fitting the sleeve with correct standout, and welding the full perimeter fillet on both sides. Student practice on 3/8-inch plate mock bulkhead: each student marks, punches, and plasma-cuts one penetration hole for a 2-inch pipe sleeve, fits the sleeve, tacks in position, and presents to instructor for dimensional check before welding. Visual weld inspection exercise: after welding, students self-inspect their sleeve fillet using an AWS visual weld inspection guide and a weld gauge, documenting any undercut, porosity, or incomplete fusion on an inspection record, then peer-review one classmate's record.	3/8-inch mild steel plate mock bulkhead panels, 2-inch Schedule 40 carbon steel sleeve stock, plasma cutter, angle grinder, MIG welder, transfer punch, center finder, tape measure, combination square, weld fillet gauge, AWS D1.1 visual inspection acceptance criteria excerpt, inspection record forms, full welding PPE	Instructor measures annular clearance (per drawing spec ±1/16 inch) and sleeve standout; performs visual weld inspection to AWS D1.1 visual acceptance criteria; any rejectable discontinuity or out-of-tolerance dimension requires repair and re-inspection before lesson credit is awarded.
7	Deck Equipment Foundations: Bitts, Cleats, and Fairleads	18	lab	The student lays out, fabricates, and welds a deck cleat foundation pad to a structural drawing, with the pad located within ±1/8 inch of the drawing dimension, flat within 1/16 inch across the bolt-hole pattern, and all welds meeting visual inspection criteria.	Instructor-led drawing interpretation session: reading a deck equipment arrangement drawing and a foundation detail, identifying load path, welding symbols for foundation-to-deck and stiffener welds, and required bolt-hole pattern; students mark up their own drawing copies. Foundation fabrication in shop: each student cuts foundation plate and stiffener gussets from mild steel flat bar to cut list, drills the bolt-hole pattern using a drill press and jig, and assembles components with tack welds for instructor check before final welding. Installation simulation on a mock deck panel: students position their foundation to scribed lines, clamp in place, check with a level and straight edge, weld per weld symbol requirements, and complete a dimensional inspection record recording X-Y location, flatness, and bolt-hole spacing.	Mild steel plate and flat bar stock, drill press, jobber drill set, drill jig, MIG welder, angle grinder, combination square, steel rule, level, straight edge, scribe, tap and die set, weld gauge, foundation arrangement and detail drawings, inspection record forms, full welding PPE	Instructor verifies location within ±1/8 inch, flatness within 1/16 inch, bolt-hole spacing to drawing ±1/32 inch, and visual weld quality to AWS D1.1; completed signed inspection record is required; any single criterion failure requires rework.
8	Joiner Bulkheads: Layout, Framing, and Panel Installation	18	lab	The student installs a framed joiner bulkhead panel in a mock compartment plumb within 1/8 inch in any 8-foot run, square to the adjacent structure within 1/4 inch, and fastened with the correct fastener type, spacing, and torque specified on the drawing.	Instructor demo in mock compartment: snapping a chalk line for bulkhead face, installing aluminum extrusion bottom track with adhesive and screws, erecting a stiffener frame, setting a plywood-core panel, shimming to plumb, and driving final fasteners to torque specification. Student practice: in pairs, students snap chalk lines, install bottom and top track, erect the stiffener frame, and fit a full-width panel, checking plumb at multiple points with a torpedo level and 4-foot level before fastening. Inspection and punch-list exercise: each pair swaps stations with another pair, inspects the installed bulkhead using a written inspection checklist (plumb, square, fastener spacing, surface damage), documents all deficiencies on a punch-list form, and returns the form to the installing pair for correction.	Mock compartment frame fixture, plywood-core joiner panels, aluminum extrusion track, stiffeners, appropriate fastener assortment (screws, rivets), adhesive sealant, chalk line, 4-foot level, torpedo level, combination square, tape measure, drill-driver with torque clutch, torque wrench, inspection checklist forms, punch-list forms	Lead instructor measures plumb (±1/8 inch per 8 feet) and squareness (±1/4 inch) independently; fastener spacing verified by count and tape; torque spot-checked with torque wrench on five random fasteners; punch-list must be cleared to zero before pass is recorded.
9	Insulation Installation: Blankets, Spray Foam, and Fire-Rated Systems	14	demo	The student installs mineral wool blanket insulation and a fire-rated foam collar around a pipe penetration to manufacturer instructions and the applicable shipboard specification, with no visible gaps, correct compression, and collar fully seated and fastened.	Instructor demo and safety briefing: respiratory hazards of mineral wool (NIOSH reference), required PPE (N95 or better respirator, gloves, long sleeves), handling and cutting technique, compression limits, fastening with speed clips, and fitting blankets around obstructions without voids. Hands-on installation practice: each student cuts mineral wool blankets to fit a mock hull bay (irregular frame spacing), installs with speed clips at specified spacing, and achieves full coverage with no visible gap greater than 1/4 inch, verified by instructor walk-around. Fire-rated penetration collar installation: students fit a listed intumescent pipe collar around a sleeve penetration in a mock bulkhead following manufacturer's written instructions, fasten per instructions, and photograph the finished installation for their work package.	Mineral wool blanket insulation rolls, intumescent pipe collars (listed product), speed clips and pins, utility knife, straight edge, tape measure, mock hull bay fixture, mock bulkhead with installed pipe sleeves, N95 respirators, safety glasses, nitrile gloves, long-sleeve coveralls, manufacturer installation instructions, shipboard insulation specification excerpt	Instructor inspects blanket installation for gaps (none greater than 1/4 inch) and compression (not over-compressed below manufacturer minimum thickness); collar installation checked against manufacturer instructions step-by-step; both must pass; photograph must be in work package.
10	Access Hatches, Manholes, and Watertight Closures	18	lab	The student lays out and installs a deck access hatch coaming and cover on a mock deck panel, with the coaming located to drawing dimensions within ±1/8 inch, dogging hardware operating without binding, and a hydrostatic/hose test showing no leakage.	Instructor demonstration: transferring hatch centerline from drawing to deck, scribing the cut line, plasma-cutting the opening, fitting and tacking the coaming, welding the full perimeter, grinding flush, and fitting the cover with gasket and dogs. Student hatch installation: each student plasma-cuts an opening in a mock deck plate, fits and tacks a coaming to dimension, presents for instructor dimensional check, welds the coaming, grinds welds to flush with deck, installs the gasketed cover, and adjusts dogs for uniform compression around the perimeter. Leak test exercise: the installed hatch is subjected to a controlled hose test (simulating USCG hose test practice), with a second student inside observing for leaks; any leakage is marked, gasket or dog adjustment is made, and the test is repeated until the hatch passes; results are recorded on an inspection form.	Mock deck plate panels, access hatch kit (coaming, cover, gasket, dogs, hardware), plasma cutter, MIG welder, angle grinder, combination square, tape measure, scribe, torque wrench, garden hose with nozzle for hose test, inspection record forms, full welding PPE, hearing protection	Instructor measures coaming location (±1/8 inch), checks dog operation (no binding, uniform gasket compression), and witnesses hose test with zero leakage for 60 seconds of direct spray; all three criteria must pass; inspection record must be signed by student and instructor.
11	Systems Integration: Multi-Trade Coordination and Conflict Resolution	20	practice	The student identifies and resolves at least three spatial conflicts between pipe, HVAC duct, cable tray, and structural elements in a given compartment drawing set, producing a written conflict-resolution log with proposed solutions and drawing mark-ups.	Instructor-led conflict-identification exercise using a complex compartment drawing set (overlaid piping, HVAC, electrical raceway, and structural plans): class works through two example conflicts together, identifying dimensions, clearances, and which trade has routing priority per the coordination hierarchy used in commercial shipyards. Team design exercise: groups of three receive a compartment drawing package with at least five embedded conflicts; they mark up the drawings in red, log each conflict on a conflict-resolution form (conflict description, affected systems, proposed resolution, required clearance), and present findings to the class for critique. Individual written scenario: each student receives a different single-page compartment cross-section with three conflicts; they must identify all three, propose resolutions, and sketch a corrected cross-section; graded for completeness and technical correctness.	Multi-trade compartment drawing sets (piping, HVAC, electrical raceway, structural overlaid), conflict-resolution log forms, red and blue pencils, drawing scales, NCCER Shipfitting Module reference on drawing coordination, CAD viewer computers for digital review	Conflict-resolution log checked by instructor: all embedded conflicts identified (must find at least 80%), each proposed resolution technically feasible and clearly described, drawing mark-ups legible and dimensionally specific; individual written scenario scored out of 10; pass mark 8/10.
12	Outfitting Work-Package Completion, As-Built Documentation, and Final Inspection	18	practice	The student produces a complete outfitting work package for a designated mock compartment, including updated red-line as-builts, a cleared punch-list, and a signed final inspection record, with no open items remaining.	Red-line as-built session: using a drawing set for the mock compartment completed during earlier lessons, each student walks the installation with their drawing set, marks every field deviation (changed dimension, added hanger, relocated penetration) in red on the drawings, and writes a brief narrative change description for each deviation. Punch-list creation and clearance exercise: instructor pre-seeds the mock compartment with 10 deliberate deficiencies (missing fastener, unground weld spatter, unmarked penetration, over-compressed insulation, and others); students find and document all deficiencies on a punch-list, then correct each item and initial it closed. Final inspection walk-through: in pairs (one as inspector, one as responsible tradesperson), students conduct a formal inspection of a partner's completed mock compartment using the provided multi-point inspection checklist; all items are scored pass or fail; a full pass with zero open items is required for lesson credit.	Completed mock compartment from previous lessons, full drawing set for that compartment, red pencils, black pens, punch-list forms, multi-point final inspection checklist, NCCER Shipfitting quality and documentation reference, camera or phone for photographic documentation	Instructor reviews completed work package: red-line as-builts must capture all pre-seeded deviations (100% required for safety items, 90% overall); punch-list must show all 10 deficiencies found and each one initialed closed; final inspection checklist must show zero open items; any open safety item is an automatic fail requiring immediate correction.

Assessments

Assessment	Type	Weight	Pass standard	Method & rubric
Outfitting Systems Knowledge Exam	Written exam	25%	80% correct (40 of 50 questions)	A 50-question written exam covering pipe material and schedule identification, P&ID and isometric drawing reading, piping class schedule selection, hanger and support types, joiner and insulation specifications, access-hatch and watertight-closure requirements, multi-trade conflict-resolution principles, and outfitting work-package documentation; questions are mapped to NCCER Shipfitting core knowledge areas and administered under closed-book conditions. Standard met · Safety · Time · Quality/finish · Documentation
Pipe Spool and Foundation Installation Skills Demonstration	Skills demonstration	45%	All six pass/fail criteria met on first or second attempt; second attempt requires instructor-supervised remediation between attempts	The student fabricates and installs a two-offset pipe spool to a given isometric (dimension ±1/16 inch, cuts square within 1°, root gap within WPS), installs two hangers at correct locations and heights (plumb within 1/8 inch), and welds a deck equipment foundation pad (location ±1/8 inch, flatness within 1/16 inch, welds passing AWS D1.1 visual criteria); a certified instructor scores each criterion pass/fail using a standardized rubric aligned to NCCER Shipfitting performance profile tasks. Standard met · Safety · Time · Quality/finish · Documentation
Outfitting Work-Package Lab Log	Log	15%	90% of required entries present, accurate, and signed; all safety-hold-point entries must be 100% complete	A cumulative log maintained throughout all lab and practice lessons, containing material take-off sheets, dimensional inspection records, weld visual inspection records, hose-test records, red-line as-builts, punch-list forms, and the final inspection checklist for the mock compartment; the log demonstrates the student's ability to create and maintain the documentation required on a commercial shipyard outfitting package. Standard met · Safety · Time · Quality/finish · Documentation
Outfitting Safety Compliance Check	Safety audit	15%	Zero critical failures (any unsafe act or omission directly affecting life safety); no more than one minor procedural finding; pass/fail overall	An unannounced observational safety audit conducted by the lead instructor during a lab session in lessons 4 through 10, evaluating correct PPE selection and use, hot-work permit compliance, confined-space entry procedures if entered, LOTO application on powered tools, housekeeping, and fall-protection use when working above four feet; any critical failure (e.g., no eye protection while grinding, entry into confined space without atmospheric test) results in immediate work stoppage, remediation, and a mandatory re-audit before the student may continue lab work. Standard met · Safety · Time · Quality/finish · Documentation

MFG-SHIP13-07 Capstone

Capstone Project: Integrated Marine Fabrication Build

216 hr · ~~$2,160~~ COMPLIMENTARY

Students design, fabricate, fit, and finish a multi-material marine structural assembly—such as a small vessel section, watertight compartment mockup, or deck module—integrating shipfitting layout, steel and aluminum welding, outfitting, and marine coatings skills acquired across the program. Each student produces a complete fabrication package including drawings, weld maps, inspection records, and a coating log, then defends the project before a panel of instructors and an industry evaluator. This course serves as the primary evidence of job-readiness and maps directly to NCCER Shipfitting, NCCER Maritime Welding, AWS D1.1, AWS D1.2, and ABS/USCG Weld Test competency areas.

Outcomes

Plan and document a marine fabrication project by producing a bill of materials, weld map, fit-up sequence, and inspection checklist that conform to applicable drawing conventions and project specifications.
Fabricate a structurally sound multi-material assembly (mild steel and aluminum components) using SMAW, GMAW, or FCAW processes, meeting AWS D1.1 and AWS D1.2 dimensional and visual weld quality standards.
Apply surface preparation and a multi-coat marine coating system following manufacturer data sheets and SSPC surface-prep standards, documented in a coating log with DFT readings.
Demonstrate safe work practices throughout the build, including lockout/tagout procedures, confined-space awareness, correct PPE selection, and compliance with OSHA maritime and general industry standards.
Evaluate own work against industry acceptance criteria—visual weld inspection per AWS, fit-up tolerances per NCCER Shipfitting standards, and coating continuity—and produce a nonconformance and corrective-action record.
Present and defend project documentation, fabrication decisions, and quality results clearly before a panel, demonstrating professional communication skills required for shipyard employment.

Course text

How the course runs. 4 blocks: Project Planning, Specifications, and Safety Pre-Task; Structural Fabrication: Fit-Up, Tacking, and Full Welding; Surface Preparation and Multi-Coat Marine Coating Application; Final Inspection, Documentation Package, and Project Defense.

What competent looks like. Plan and document a marine fabrication project by producing a bill of materials, weld map, fit-up sequence, and inspection checklist that conform to applicable drawing conventions and project specifications. Fabricate a structurally sound multi-material assembly (mild steel and aluminum components) using SMAW, GMAW, or FCAW processes, meeting AWS D1.1 and AWS D1.2 dimensional and visual weld quality standards. Apply surface preparation and a multi-coat marine coating system following manufacturer data sheets and SSPC surface-prep standards, documented in a coating log with DFT readings. Demonstrate safe work practices throughout the build, including lockout/tagout procedures, confined-space awareness, correct PPE selection, and compliance with OSHA maritime and general industry standards. Evaluate own work against industry acceptance criteria—visual weld inspection per AWS, fit-up tolerances per NCCER Shipfitting standards, and coating continuity—and produce a nonconformance and corrective-action record. Present and defend project documentation, fabrication decisions, and quality results clearly before a panel, demonstrating professional communication skills required for shipyard employment.

Lessons · 4 blocks

#	Lesson	Hr	Type	Objective	Activities	Materials	Check
1	Project Planning, Specifications, and Safety Pre-Task	36	theory	Given a project brief and set of marine drawings, the student will produce a complete fabrication plan—bill of materials, weld symbol interpretation map, fit-up sequence, hazard identification, and pre-task safety checklist—that an evaluator judges complete and accurate.	Interpret a provided isometric and orthographic drawing set for the assigned assembly; extract all part dimensions, material grades, weld symbols, and joint designations onto a weld map template, then compare results with a partner and resolve discrepancies using the drawing notes. Develop a step-by-step fit-up and welding sequence that minimizes distortion, documenting each step on a sequencing worksheet; justify choices in a written rationale that references NCCER Shipfitting module content on distortion control. Complete a Job Hazard Analysis (JHA) for the entire build—identifying hot-work permits, LOTO points, PPE requirements for each phase (grinding, welding, blasting/painting), fall and confined-space risks—then present the JHA to the instructor for a line-by-line review before any fabrication begins.	Assigned project drawing set (instructor-prepared, isometric + orthographic), weld symbol reference chart (AWS A2.4), NCCER Shipfitting core curriculum, JHA blank form, bill-of-materials template, calculator, pencils, scale rule	Instructor reviews completed weld map, BOM, sequence document, and JHA using a 20-point rubric; student must score 16/20 (80%) with no safety items left blank or incorrect before proceeding to fabrication.
2	Structural Fabrication: Fit-Up, Tacking, and Full Welding	108	lab	Following the approved fabrication plan, the student will cut, fit, tack, and fully weld all steel and aluminum components of the assigned assembly to dimensional tolerances and weld quality standards acceptable under AWS D1.1 (steel) and AWS D1.2 (aluminum), as verified by instructor visual and dimensional inspection.	Set up and operate plasma cutter or oxy-fuel torch and angle grinder to cut mild-steel plate and structural shapes to layout dimensions within ±1/16 in. tolerance; mark and punch all reference lines using layout tools practiced in the Shipfitting Layout course, then dry-fit all pieces in the fixture and record actual versus nominal dimensions on the inspection log. Tack all steel joints in the approved sequence using SMAW or FCAW; perform visual weld inspection (VWI) on each tack for porosity, cracks, and proper fusion before accepting and logging each joint, then repeat the cut-fit-tack process for aluminum components using GMAW (MIG) with the correct filler alloy per AWS D1.2 requirements, using dedicated aluminum tools to prevent contamination. Complete full-penetration and fillet welds on all joints per the weld map; after each weld pass, grind slag (steel) or wire-brush (aluminum) and perform self-VWI using a weld gauge and the AWS visual acceptance criteria checklist, documenting all measurements and any nonconformances with corrective actions taken on the project inspection record.	Mild-steel plate and structural shapes (instructor-specified grade), aluminum plate/extrusions (6061-T6 or equivalent), SMAW power source with E7018 electrodes, FCAW wire feeder, GMAW unit with aluminum-rated liner and ER4043 or ER5356 filler wire, plasma cutter or oxy-fuel cutting outfit, angle grinders with flap discs and grinding wheels, welding table/fixture, clamps and strong-backs, layout tools (soapstone, scribers, combination square, tape measure), weld gauges (fillet and groove), AWS D1.1 and D1.2 visual acceptance criteria reference cards, full PPE (welding helmet auto-darkening min. shade 10, leather gloves, FR clothing, steel-toed boots, hearing protection, respirator rated for welding fume)	Instructor performs dimensional inspection (all critical dimensions within ±1/16 in.) and VWI of all welds against AWS D1.1 and D1.2 visual acceptance criteria; student's own inspection log must match instructor findings within one minor discrepancy. Any weld failing VWI must be repaired and re-inspected; student must achieve 100% VWI-passing welds and ≥80% dimensional conformance score before moving to coatings phase.
3	Surface Preparation and Multi-Coat Marine Coating Application	36	lab	The student will prepare all surfaces of the completed assembly to the cleanliness level specified on the coating system data sheet and apply a minimum two-coat marine coating system, documenting surface profile, ambient conditions, and dry film thickness (DFT) readings in a coating log that meets project specification requirements.	Determine and record ambient conditions (temperature, relative humidity, dew point) using a sling psychrometer or digital meter; confirm conditions fall within the coating manufacturer's application window, then abrasive-blast or power-tool-clean (SSPC-SP 3 or SSPC-SP 6 as specified) all weld seams and base metal, checking and recording surface profile with Testex tape or a replica tape comparator. Apply the primer coat by brush, roller, or spray per the product data sheet, masking any machined surfaces or hardware; after the specified recoat window, apply the topcoat and record batch numbers, application method, time, and temperature in the coating log for each coat. Measure DFT on all coating zones using a calibrated magnetic pull-off or electronic gauge per SSPC-PA 2 measurement frequency guidance; compare readings to the specified DFT range, flag any holidays or thin areas, touch up as needed, and finalize the coating log with a pass/fail entry for each zone.	Abrasive blast equipment or angle grinders with wire cup and flap disc attachments, sling psychrometer or digital dewpoint meter, Testex Press-o-Film replica tape, marine primer (zinc-rich or epoxy, instructor-specified), marine topcoat (polyurethane or epoxy), mixing sticks, graduated mixing cups, brushes and rollers, airless or conventional spray gun (if available), DFT gauge (magnetic and/or electronic), SSPC surface preparation standards reference, coating manufacturer product data sheets, full PPE (supplied-air or half-mask respirator with organic vapor/P100 cartridges appropriate to coating SDS, chemical-splash goggles, nitrile gloves, disposable coveralls)	Instructor reviews completed coating log for all required entries; DFT readings must fall within the manufacturer's specified range on all measured zones; surface preparation record must show correct SSPC level was achieved. Coating log is graded on a 10-point checklist; student must score 8/10 with no DFT zones out of specification accepted without documented repair.
4	Final Inspection, Documentation Package, and Project Defense	36	field	The student will compile a complete project documentation package, present the finished assembly to a panel of instructors and one industry evaluator, and verbally defend fabrication decisions, quality findings, and safety practices to a passing standard on the defense rubric.	Assemble the full project documentation package in order: approved fabrication plan (BOM, weld map, sequence), all completed inspection records (dimensional log, VWI checklist, nonconformance/corrective-action forms), coating log with DFT data, and a one-page written project summary that identifies the most significant technical challenge encountered and how it was resolved, using correct trade terminology. Conduct a self-audit of the finished assembly by walking through every item on the final inspection checklist (dimensional conformance, weld quality, coating integrity, cleanliness, and proper marking) and marking each item pass or fail; present the checklist alongside the assembly to the panel at the start of the defense so the panel can verify findings independently. Deliver a 10-minute structured oral defense to the panel covering: project scope and drawing interpretation, key fit-up and welding decisions (including distortion control measures), a safety highlight (most critical hazard managed during the build and controls used), quality outcomes versus specification, and at least one change the student would make if starting over; answer up to 10 minutes of panel questions drawing on knowledge from all program courses.	Completed assembly, full documentation package (printed and organized in a project binder), final inspection checklist, presentation notes or cue cards (no formal slide deck required but permitted), panel evaluation rubric (provided to student one week before defense), trade references available for consultation during prep (NCCER Shipfitting and Maritime Welding curricula, AWS D1.1 and D1.2 visual criteria cards)	Panel scores the defense on a 30-point rubric: documentation completeness (10 pts), assembly quality against specification (10 pts), and oral defense clarity and technical accuracy (10 pts); student must score 24/30 overall with no sub-category below 7/10. A student who scores below threshold on documentation or assembly may be given one remediation opportunity within five school days; oral defense below threshold requires a full re-defense.

Assessments

Assessment	Type	Weight	Pass standard	Method & rubric
Finished Marine Assembly — Project Assessment	Project	60%	All welds pass AWS D1.1 and/or D1.2 visual acceptance criteria with 100% conforming joints; all critical dimensions within ±1/16 in. on ≥80% of inspection points; all coating zones within specified DFT range with no unrepaired holidays; overall project rubric score ≥ 80%.	The physical assembly is evaluated by the instructor and the industry panel evaluator against the project specification, the weld map, and the coating data sheet using a structured inspection checklist that mirrors the criteria used in NCCER Shipfitting performance verification and ABS/USCG weld acceptance. Any nonconforming weld or coating zone identified during panel inspection that was not already documented and corrected in the student's own inspection record is treated as a critical deficiency and must be resolved before a passing score is awarded. Meets specification · Within estimate · Workmanship · Safety · Documentation
Project Documentation Portfolio	Portfolio	20%	Portfolio graded on a 40-point rubric covering completeness, accuracy, use of trade terminology, and professional organization; minimum passing score is 32/40 (80%) with no required section missing.	The project binder is reviewed by the instructor before the defense date and must contain: the approved fabrication plan (BOM, weld map, sequence), all dimensional and VWI inspection logs with student signatures, the nonconformance and corrective-action record, the coating log with DFT entries, and the one-page project summary. This portfolio maps to the documentation and record-keeping competencies tested in NCCER Registry performance profiles for both Shipfitting and Maritime Welding and demonstrates the record-keeping habits required in AWS- and ABS-certified production environments. Completeness · Organization · Evidence quality
Project Defense — Oral Examination	Oral / panel	20%	Panel rubric score ≥ 24/30 overall, with no individual sub-category (documentation review, assembly quality discussion, or Q&A response) scoring below 7/10.	The student presents the completed project and answers panel questions in a format that mirrors the kind of technical communication expected in shipyard production meetings and quality audits, including explaining code references, justifying process choices, and identifying corrective actions taken. The oral defense is the primary evidence mapped to the career-readiness and professional-communication outcomes of the program and reinforces the verbal explanation of welding procedure and quality rationale required during ABS/USCG weld qualification interviews. Explains decisions · Answers technical questions · Professional communication

MFG-SHIP13-08 Externship / clinical

Externship / Worksite Placement

324 hr · ~~$1,295~~ COMPLIMENTARY

Students complete 324 supervised hours at a licensed shipyard, marine fabrication facility, or boat-manufacturing plant, applying hull construction, fitting, welding, coating, and outfitting skills under journeyman or foreman oversight. Each student is evaluated by their site supervisor against industry performance standards and maintains a structured daily log documenting tasks, safety observations, and credential-relevant skill areas. The externship bridges classroom competency with professional production expectations required for NCCER Shipfitting, NCCER Maritime Welding, AWS D1.1/D1.2, and ABS/USCG weld-test employment contexts.

Outcomes

Perform assigned shipfitting and welding tasks at a host employer's facility to production-quality standards with no more than one corrective intervention per week by Week 6.
Demonstrate consistent compliance with the host site's lockout/tagout procedures, PPE requirements, and confined-space protocols throughout all 324 hours as verified by the site supervisor.
Interpret and execute work from employer-issued blueprints, weld symbols, and cut lists without additional clarification on at least 80 percent of assigned tasks by mid-term.
Complete a structured daily work log that documents task descriptions, safety observations, tools and processes used, and self-assessed NCCER/AWS skill areas, with entries rated satisfactory by the program coordinator.
Receive a final employer evaluation score of at least 75 out of 100 across competency categories including workmanship, safety behavior, communication, and attendance.
Identify at least three specific technical or professional skills developed during the externship and articulate their connection to credentialed exam areas in the exit interview.

Course text

How the course runs. 4 blocks: Site Orientation, Safety Integration, and Work-Log Launch; Production Fitting and Welding: Supervised Task Rotations; Independent Task Performance and Professional Skill Development; Final Hours, Employer Evaluation, and Exit Interview.

What competent looks like. Perform assigned shipfitting and welding tasks at a host employer's facility to production-quality standards with no more than one corrective intervention per week by Week 6. Demonstrate consistent compliance with the host site's lockout/tagout procedures, PPE requirements, and confined-space protocols throughout all 324 hours as verified by the site supervisor. Interpret and execute work from employer-issued blueprints, weld symbols, and cut lists without additional clarification on at least 80 percent of assigned tasks by mid-term. Complete a structured daily work log that documents task descriptions, safety observations, tools and processes used, and self-assessed NCCER/AWS skill areas, with entries rated satisfactory by the program coordinator. Receive a final employer evaluation score of at least 75 out of 100 across competency categories including workmanship, safety behavior, communication, and attendance. Identify at least three specific technical or professional skills developed during the externship and articulate their connection to credentialed exam areas in the exit interview.

Lessons · 4 blocks

#	Lesson	Hr	Type	Objective	Activities	Materials	Check
1	Site Orientation, Safety Integration, and Work-Log Launch	40	field	Students complete the host employer's site-specific safety orientation, establish daily logging habits, and map the facility's operations to the NCCER and AWS credential areas they will practice.	Attend and document the employer's full new-worker orientation including emergency action plan, PPE zones, LOTO station locations, and hazard communication (SDS binder locations); student signs the employer's acknowledgment form and submits a copy to the program coordinator. Complete the first week of daily work logs using the program's standardized template: columns include date, supervisor name, task performed, tools and processes used, safety protocols observed, and self-rated NCCER/AWS skill area (e.g., NCCER Shipfitting Module: layout and fitting; AWS D1.1: SMAW structural); coordinator reviews and returns logs with written feedback by end of Week 2. Conduct a structured walkthrough of the facility with the assigned journeyman mentor, sketching a simple floor plan that labels welding bays, plate-prep areas, fit-up stations, coating areas, and outfitting zones, then annotate the sketch with at least five OSHA General Industry or Maritime standards (29 CFR 1910 or 1915 series) that apply to observed operations.	Employer orientation packet, program daily-log template (printed and digital), NCCER Shipfitting and Maritime Welding module task lists, AWS D1.1 and D1.2 scope summaries, OSHA 1915 Maritime Industry standards reference card, hard hat, safety glasses, steel-toed boots, hearing protection, hi-vis vest.	Employer orientation acknowledgment form on file; first-week logs submitted with all columns complete and at least one NCCER or AWS skill area identified per entry; annotated facility sketch reviewed by coordinator — pass requires all three deliverables submitted and coordinator rates log quality as satisfactory (meets template requirements with no blank required fields).
2	Production Fitting and Welding: Supervised Task Rotations	160	field	Students perform assigned production tasks in at least three of the five trade areas — hull fitting, structural welding, outfitting, plate preparation, or marine coatings — to employer quality standards while maintaining uninterrupted daily logs.	Under direct journeyman supervision, execute assigned fitting tasks such as tacking frames to keel assemblies, scribing and cutting bracket blanks, or aligning bulkhead stiffeners using plumb bobs, levels, and combination squares; supervisor initials the daily log after each observed task to confirm the work met production quality — NCCER Shipfitting credential areas: structural assembly, layout, and fitting. Perform SMAW, FCAW, GMAW, or GTAW welds as assigned by the employer (process determined by production needs and student qualification level); student photographs representative weld samples weekly, attaches photos to the log, and self-assesses against AWS D1.1 visual acceptance criteria (weld profile, undercut, porosity) or AWS D1.2 for aluminum joints; supervisor confirms or corrects the self-assessment in writing. Rotate through at least one non-welding production area (marine coatings surface prep, pipe or electrical outfitting rough-in, or template-making for structural components) for a minimum of 24 hours; student writes a one-page reflection per rotation describing the process, safety controls used, tools handled, and how the work connects to NCCER Outfitting or Shipfitting module content.	Employer-issued production tools and PPE (welding helmet rated for process in use, leather gloves, face shield, respirator appropriate to coating or grinding task), combination square, chalk line, plumb bob, grinder, chipping hammer, wire brush, measuring tape, digital camera or smartphone for weld photos, daily log binder, AWS D1.1 and D1.2 visual inspection criteria reference card, NCCER task-area checklist.	Supervisor initials present on daily log for each observed production task; minimum of three trade-area rotations documented with photos or reflections; mid-term employer evaluation (completed at approximately 160 cumulative hours) scores student at 70 or above out of 100 across workmanship, safety, communication, and attendance — students scoring below 70 receive a written improvement plan with specific measurable benchmarks and a coordinator check-in within five business days.
3	Independent Task Performance and Professional Skill Development	84	field	Students progressively perform assigned tasks with reduced direct supervision, demonstrate professional workplace behaviors, and accumulate documented evidence of competency across NCCER and AWS credential areas.	With supervisor approval, take the lead on a bounded production sub-task (e.g., laying out and tacking a floor-timber assembly from a cut list, or completing a weld joint from fit-up through final inspection) without step-by-step prompting; student documents the full workflow in the log including any problems encountered and how they were resolved, referencing applicable code or standard (AWS D1.1 visual criteria, NCCER module procedure, or OSHA 1915 safety rule). Participate in at least one workplace quality-control activity observed at the host site — such as a weld visual inspection, dimensional check on a structural assembly, or pre-coating surface cleanliness check — and record the criteria used, the result, and who had authority to accept or reject the work; this directly mirrors ABS/USCG weld-test inspection logic and NCCER quality-documentation requirements. Complete a mid-to-late externship professional skills self-assessment using the program's rubric (categories: punctuality, communication with supervisor, response to feedback, initiative, and knowledge application); compare scores to the supervisor's concurrent rating of the same categories, identify gaps, set one written goal for the final weeks, and share the goal with the supervisor for acknowledgment.	Production tools as assigned by employer, program professional-skills self-assessment rubric, quality-control checklist (employer-issued or program-supplied), daily log binder, AWS D1.1 visual weld inspection reference, ABS survey inspection overview handout, NCCER task-competency checklist.	At least one documented lead task in the log with problem-solving narrative; one quality-control participation entry with criteria and outcome recorded; professional self-assessment and supervisor parallel rating both on file and gap goal documented — pass requires all three components submitted and supervisor confirms the student's lead-task performance was acceptable for production at that stage (verbal confirmation recorded by coordinator).
4	Final Hours, Employer Evaluation, and Exit Interview	40	field	Students complete their final production hours, receive and discuss the formal employer evaluation, compile a complete externship portfolio, and articulate skill growth and credential readiness in a structured exit interview with the program coordinator.	Complete remaining production hours with full log entries; on the final day at the site, review the completed log binder for missing supervisor initials, photo attachments, or incomplete columns, and resolve any gaps; submit the final daily log to the coordinator within three business days of the last site day. Meet with the host supervisor (and employer HR contact if available) to receive the formal final employer evaluation form; review each category score together, ask at least two clarifying questions about areas rated below 85, and record the supervisor's specific feedback verbatim in the log; student and supervisor both sign the evaluation form. Attend a 30-minute exit interview with the program coordinator: present the log binder and employer evaluation, identify three technical skills strengthened during the externship and map each to a specific NCCER Shipfitting, NCCER Maritime Welding, AWS D1.1/D1.2, or ABS/USCG credential exam area, and state one professional behavior goal for the Exam Prep course and entry-level employment.	Complete daily log binder (all weeks), employer final evaluation form, program externship portfolio checklist, NCCER credential task maps, AWS D1.1 and D1.2 scope summaries, exit interview guide (coordinator-held).	Final log binder complete with no missing required fields across all weeks; employer final evaluation form signed by both parties and on file; exit interview completed with three credential-area skill mappings documented in writing — pass requires employer evaluation overall score of 75 or above out of 100 and coordinator rates exit interview as satisfactory (student can name and correctly map all three skills without prompting).

Assessments

Assessment	Type	Weight	Pass standard	Method & rubric
Employer Worksite Skills Demonstration Evaluation	Skills demonstration	70%	Composite score of 75 or above out of 100 on the final employer evaluation form, with no individual category (workmanship, safety behavior, communication, attendance) scored below 60.	The host employer's journeyman or foreman supervisor rates the student on four competency categories — workmanship quality, safety behavior, professional communication, and attendance/reliability — using the program's standardized 100-point evaluation form completed at mid-term and again at the conclusion of the externship. A student whose mid-term score falls below 70 receives a written improvement plan; failure to reach 75 on the final evaluation requires the coordinator and employer to determine whether additional hours or a remediation plan is feasible before the student advances to Exam Prep. Competency · Safety · Attendance · Conduct · Initiative
Externship Daily Work Log Portfolio	Log	30%	All log entries complete with no required fields left blank, supervisor initials present for every observed production task, weld photos or rotation reflections attached as specified, and coordinator rates overall log quality as satisfactory on the program rubric (meets requirements in at least 80 percent of evaluated entries).	Students maintain a structured daily work log for all 324 hours using the program's standardized template, documenting tasks performed, processes and tools used, safety observations, and self-assessed NCCER and AWS credential-area connections; the complete binder — including the professional self-assessment, quality-control participation record, and signed employer evaluations — is submitted as a portfolio within three business days of the final site day and reviewed by the program coordinator against a completeness checklist. Complete · Verified

MFG-SHIP13-09 Exam prep

Certification Exam Preparation: Shipfitting, Maritime Welding, AWS & ABS/USCG Credentials

90 hr · ~~$900~~ COMPLIMENTARY

This 90-hour course systematically reviews every knowledge and performance domain covered by the NCCER Shipfitting, NCCER Maritime Welding, AWS D1.1 Structural Steel Certified Welder, AWS D1.2 Aluminum Certified Welder, and ABS/USCG Weld Test credentials. Learners identify personal knowledge gaps through diagnostic quizzes, then drill targeted content through timed practice tests, hands-on weld performance rehearsals, and shipfitting layout simulations that mirror actual exam conditions. The course closes with full-length mock exams under proctored, timed conditions for all five credentials.

Outcomes

Score at or above the passing threshold on full-length NCCER Shipfitting and NCCER Maritime Welding practice knowledge tests administered under timed, closed-book conditions.
Produce groove and fillet weld test coupons in steel and aluminum that meet AWS D1.1 and D1.2 visual and destructive-test acceptance criteria as rehearsal for the Certified Welder performance qualification.
Complete a timed shipfitting layout exercise—including template development, layout lines, and fit-up to tolerance—replicating NCCER Shipfitting performance task conditions.
Demonstrate correct weld procedure, position, and documentation practices required for the ABS/USCG Weld Test, including pre-weld cleaning, interpass temperature control, and visual inspection of the finished coupon.
Explain the purpose, format, sponsoring body, and scheduling process for each of the five target credentials, and correctly complete sample credential application paperwork.
Develop a personalized study plan based on diagnostic gap analysis that allocates remaining independent study time to lowest-scoring exam domains before test day.

Course text

How the course runs. 4 blocks: Credential Landscape, Diagnostic Assessment & Gap Analysis; NCCER Knowledge Domain Review: Shipfitting & Maritime Welding; AWS D1.1 / D1.2 & ABS/USCG Performance Qualification Rehearsal; Full Mock Certification Exams Under Proctored Conditions.

What competent looks like. Score at or above the passing threshold on full-length NCCER Shipfitting and NCCER Maritime Welding practice knowledge tests administered under timed, closed-book conditions. Produce groove and fillet weld test coupons in steel and aluminum that meet AWS D1.1 and D1.2 visual and destructive-test acceptance criteria as rehearsal for the Certified Welder performance qualification. Complete a timed shipfitting layout exercise—including template development, layout lines, and fit-up to tolerance—replicating NCCER Shipfitting performance task conditions. Demonstrate correct weld procedure, position, and documentation practices required for the ABS/USCG Weld Test, including pre-weld cleaning, interpass temperature control, and visual inspection of the finished coupon. Explain the purpose, format, sponsoring body, and scheduling process for each of the five target credentials, and correctly complete sample credential application paperwork. Develop a personalized study plan based on diagnostic gap analysis that allocates remaining independent study time to lowest-scoring exam domains before test day.

Lessons · 4 blocks

#	Lesson	Hr	Type	Objective	Activities	Materials	Check
1	Credential Landscape, Diagnostic Assessment & Gap Analysis	12	theory	Learners will correctly identify the format, sponsoring body, exam domains, and passing standards of all five target credentials and will score each diagnostic practice test to produce a written gap-analysis plan.	Instructor-led credential comparison: learners fill in a five-column matrix (credential name, issuing body, exam type—knowledge vs. performance, major content domains, passing standard) using official NCCER, AWS, and ABS/USCG candidate handbooks and then discuss how each credential maps to the program's eight preceding courses. Learners individually complete a 50-question diagnostic knowledge quiz drawn from NCCER Shipfitting and Maritime Welding content areas (blueprint reading, hull geometry, marine terminology, welding symbols, code requirements, safety) under timed conditions, then score and color-code results by domain to identify weak areas. Each learner drafts a one-page written gap-analysis study plan listing their three lowest-scoring domains per credential, specific lesson resources to revisit, and a daily study schedule for the remainder of the course; instructor reviews and approves each plan before the next lesson begins.	NCCER Shipfitting Trainee Guide (current edition), NCCER Maritime Welding Trainee Guide (current edition), AWS D1.1 Structural Welding Code—Steel (current edition), AWS D1.2 Structural Welding Code—Aluminum (current edition), ABS Rules for Materials and Welding (current edition), printed diagnostic quiz packets, gap-analysis worksheet template, highlighters, pencils.	Learner submits a complete, instructor-approved gap-analysis plan; scores ≥60% on the diagnostic quiz are noted as baseline (no pass/fail gate here—data drives differentiation); instructor confirms all five credential matrix rows are accurate before the lesson closes.
2	NCCER Knowledge Domain Review: Shipfitting & Maritime Welding	28	theory	Learners will answer practice questions drawn from every NCCER Shipfitting and Maritime Welding knowledge domain at or above the NCCER passing standard on two timed module-level practice tests.	Rotating small-group stations (90 minutes each over multiple sessions) covering the core NCCER knowledge domains: ship structural nomenclature and hull geometry; reading marine construction drawings, weld maps, and bill of materials; template and pattern development; fastener and fitting identification; welding process selection (SMAW, FCAW, GMAW, GTAW) and procedure variables for marine applications; distortion control and heat input management; marine safety regulations including confined-space entry, hot-work permits, and shipyard-specific OSHA 1915 subpart requirements. Each station uses flashcard drills, short whiteboard problems, and annotated drawing exercises. Learners complete two timed, 60-question practice knowledge tests—one mapped to NCCER Shipfitting domains and one to NCCER Maritime Welding domains—under closed-book, exam-simulating conditions; after scoring, learners compare results to their gap-analysis plan and update study priorities. Peer-teaching exercise: each learner selects one domain where they scored highest and teaches a 10-minute mini-lesson to a small group using a whiteboard and one sample practice question, reinforcing retention and exposing remaining misconceptions for instructor correction.	NCCER Shipfitting Trainee Guide, NCCER Maritime Welding Trainee Guide, printed NCCER-style practice test packets (school-developed from module review questions), marine construction drawing sets from the capstone project, welding symbol reference charts per AWS A2.4, whiteboard and markers, OSHA 29 CFR 1915 Subparts B and Q reference cards.	Learner scores ≥70% on both the Shipfitting and Maritime Welding timed practice tests before advancing; learners below 70% on any domain receive a targeted re-teach from the instructor and must re-attempt that domain's 20-question mini-quiz to ≥70% before the course proceeds.
3	AWS D1.1 / D1.2 & ABS/USCG Performance Qualification Rehearsal	38	lab	Learners will produce steel and aluminum weld test coupons in the positions required by their target AWS D1.1, AWS D1.2, and ABS/USCG qualifications, and each coupon will pass visual inspection and guided bend-test rehearsal to the applicable code acceptance criteria.	Instructor demonstrates a complete AWS D1.1 3G and 4G groove weld test sequence on carbon steel plate—covering pre-weld checks (mill scale removal, joint fitup, root opening measurement), travel speed and arc voltage discipline, interpass cleaning and temperature monitoring, and post-weld visual inspection using the D1.1 visual acceptance criteria checklist; learners then each complete at least two full groove weld coupons per position, with instructor observing and coaching in real time. Learners set up and complete AWS D1.2 aluminum GMAW (spray or pulse transfer) groove weld coupons on 6061-T6 plate in the 3G position, applying pre-weld oxide removal with a stainless steel brush dedicated to aluminum, correct shielding gas (argon), and D1.2 visual acceptance criteria; each coupon is visually inspected by the learner using the code checklist, then reviewed by the instructor, and one coupon per learner is guided through a strap-guided face and root bend rehearsal to demonstrate expected ductility and identify any fusion defects before the actual exam. ABS/USCG Weld Test simulation: learners complete a timed, procedure-document-driven test weld on steel plate or pipe (per the weld procedure specification the instructor assigns to simulate ABS qualification conditions), fill out a simulated WPS compliance log, perform visual inspection against ABS acceptance criteria, and participate in a structured debrief where the instructor identifies any would-be failures and the corrective technique required.	SMAW, GMAW, and FCAW welding machines with appropriate consumables (E7018 low-hydrogen electrodes, ER70S-6 wire, E71T-1 flux-core wire for steel; ER4043 or ER5356 wire for aluminum), carbon steel plate and 6061-T6 aluminum plate cut to AWS test coupon dimensions, dedicated stainless steel brushes for aluminum, angle grinders with grinding and flap-disc wheels, welding PPE (auto-darkening helmet ≥ANSI Z87.1, FR sleeves, leather gloves, steel-toed boots), weld gauges (fillet gauge, undercut gauge), AWS D1.1 and D1.2 current editions open at visual acceptance criteria tables, ABS Rules for Materials and Welding, bend-test jig (guided-bend fixture per applicable code dimensions), oxy-fuel or propane torch for interpass temperature check with temp-sticks, LOTO equipment for machine setup.	Each steel coupon passes AWS D1.1 visual acceptance criteria (no cracks, complete fusion, undercut ≤1/32 in where permitted, reinforcement within limits) and survives guided bend without open discontinuities >1/8 in; each aluminum coupon passes D1.2 visual criteria and bend rehearsal; ABS simulation coupon passes instructor visual inspection against ABS criteria; learners who fail a coupon must identify the defect cause, adjust technique, and re-weld a replacement coupon to passing standard before the mock exam session.
4	Full Mock Certification Exams Under Proctored Conditions	12	practice	Learners will complete full-length mock versions of the NCCER Shipfitting and Maritime Welding knowledge tests and a timed ABS/USCG weld performance simulation under proctored, exam-equivalent conditions, scoring at or above each credential's passing standard.	Two-session written mock exam block: Session 1 administers a full-length NCCER Shipfitting knowledge mock exam (timed, closed-book, multiple-choice format mirroring NCCER module test structure) immediately followed by a short break and Session 2 administering the NCCER Maritime Welding knowledge mock exam under identical conditions; learners use only a non-programmable calculator and a blank scratch sheet as permitted; an instructor serves as proctor enforcing no-phone, no-notes rules throughout. AWS written review segment: learners complete a 30-question timed practice quiz covering AWS D1.1 code provisions (joint design, prequalified joints, inspection requirements, welder qualification variables) and AWS D1.2 aluminum-specific provisions (base metal grouping, shielding gas, pre-weld cleaning requirements), scored immediately and reviewed question-by-question with the instructor to clarify any remaining misunderstandings. Structured individual debrief and credential readiness sign-off: each learner meets one-on-one with the instructor to review all mock exam scores against passing thresholds, review the ABS/USCG coupon produced in Lesson 3, confirm or update application paperwork for each credential they are ready to sit, and receive a written readiness statement listing which exams they are cleared to schedule immediately versus which need additional independent study with a specific remediation plan.	Printed mock exam packets (NCCER Shipfitting and Maritime Welding full-length, school-developed from published module review banks), AWS D1.1 and D1.2 written practice quiz packets, non-programmable calculators, blank scratch paper, analog wall clock or proctor timer, individual learner credential application checklists (NCCER Registry, AWS QC7, ABS), instructor readiness sign-off form.	Learner scores ≥70% on the NCCER Shipfitting mock exam AND ≥70% on the NCCER Maritime Welding mock exam AND ≥70% on the combined AWS D1.1/D1.2 written quiz to receive a full readiness sign-off; learners who score 65–69% on any section receive a conditional sign-off with a written remediation task (minimum 4 hours self-study on specified domains) before scheduling that exam; learners below 65% on any section meet with the instructor for an extended remediation plan and may not schedule that specific credential exam until the next available retake window.

Assessments

Assessment	Type	Weight	Pass standard	Method & rubric
Full-Program Mock Certification Examination Suite	Mock certification exam	100%	≥70% on each of the two NCCER knowledge mock exams (Shipfitting and Maritime Welding) and ≥70% on the combined AWS D1.1/D1.2 written practice quiz; ABS/USCG weld coupon passes visual inspection to ABS acceptance criteria as evaluated by the instructor; all four components must be passed to receive the course completion credential-readiness sign-off.	Administered in Lesson 4 under proctored, timed, closed-book conditions that replicate actual exam environments, this suite includes a full-length NCCER Shipfitting knowledge mock exam, a full-length NCCER Maritime Welding knowledge mock exam, an AWS D1.1/D1.2 written practice quiz, and instructor evaluation of the ABS/USCG weld coupon produced in Lesson 3; results from all four components are reviewed in a one-on-one debrief that produces either a full credential-readiness sign-off or a written remediation plan identifying specific domains and retake conditions before the learner schedules any live credential exam. Score · Time management

Program completion

External credential: ABS/USCG Weld Test; AWS D1.1 Certified Welder; AWS D1.2 Aluminum; NCCER Maritime Welding; NCCER Shipfitting

Students sit the NCCER Shipfitting and NCCER Maritime Welding knowledge and performance assessments administered through an NCCER-accredited training sponsor, the AWS Certified Welder performance qualification tests under D1.1 (structural steel) and D1.2 (aluminum) administered at an AWS-Accredited Test Facility, and the ABS/USCG welder qualification test administered by an authorized ABS surveyor or approved test facility. Pass standard: Credential issued by the body.

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