Building & Construction · course plan
⚠ Pending professional review
This course plan, its lessons and its assessments has not yet been verified by a licensed professional engineer or master 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.
Welding
14 courses · 1,800 clock hours · 9–12 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.
14courses
109lessons
1,800hours
51assessments
Development progressPlanCourses, lessons and assessments written for this tradeLessons109 of 109 lesson pages writtenPractice872 practice questionsResources120 reference entries (study list)Review108 lesson pages reviewed by a licensed professional
Study now: 109 lesson pages are open (lesson titles below are links).
BLD-WELD01-01 Universal core
Universal Core: Safety, Math, Communication & Career for Welding
148 hr · $1,185 COMPLIMENTARY
This foundational course equips welding students with the safety knowledge, trade mathematics, technical literacy, and professional skills required before entering the shop. Students earn OSHA 10-Hour Construction and CPR/First Aid cards and build the numeracy and communication habits that underpin every subsequent welding course and credentialing exam.
Outcomes- Pass the OSHA 10-Hour Construction Industry outreach program and demonstrate hazard recognition specific to welding and cutting operations.
- Perform certified CPR and administer basic first aid for burns, eye injuries, and electrical shock using current American Heart Association protocols.
- Apply arithmetic, fractions, decimals, geometry, and unit conversion to solve welding trade problems involving material dimensions, weld sizes, and cut lengths with at least 80% accuracy.
- Read and interpret welding procedure documents, safety data sheets, work orders, and simple technical drawings using standard welding terminology.
- Use digital tools—including job-search platforms, email, basic spreadsheets, and employer-facing documentation—to manage career tasks appropriate to entry-level welding employment.
- Identify the AWS D1.1, NCCER, ASME Section IX, and AWS SENSE credentialing pathways and explain the role of each in career advancement within the Building and Construction sector.
Course text
This foundational course equips welding students with the safety knowledge, trade mathematics, technical literacy, and professional skills required before entering the shop. Students earn OSHA 10-Hour Construction and CPR/First Aid cards and build the numeracy and communication habits that underpin every subsequent welding course and credentialing exam.
How the course runs. 7 blocks: Welding Workplace Hazards and OSHA 10-Hour Construction; Personal Protective Equipment, Lockout/Tagout, and Emergency Response; Trade Math I — Whole Numbers, Fractions, and Decimals for Welding; Trade Math II — Geometry, Weld Area/Volume, and Unit Conversion; Technical Reading — Welding Documents, SDS, and Codes; Digital Tools, Technical Communication, and Documentation; Credentialing Pathways, Career Planning, and Industry Overview.
What competent looks like. Pass the OSHA 10-Hour Construction Industry outreach program and demonstrate hazard recognition specific to welding and cutting operations. Perform certified CPR and administer basic first aid for burns, eye injuries, and electrical shock using current American Heart Association protocols. Apply arithmetic, fractions, decimals, geometry, and unit conversion to solve welding trade problems involving material dimensions, weld sizes, and cut lengths with at least 80% accuracy. Read and interpret welding procedure documents, safety data sheets, work orders, and simple technical drawings using standard welding terminology. Use digital tools—including job-search platforms, email, basic spreadsheets, and employer-facing documentation—to manage career tasks appropriate to entry-level welding employment. Identify the AWS D1.1, NCCER, ASME Section IX, and AWS SENSE credentialing pathways and explain the role of each in career advancement within the Building and Construction sector.
| # | Lesson | Hr | Type | Objective | Activities | Materials | Check |
|---|---|---|---|---|---|---|---|
| 1 | Welding Workplace Hazards and OSHA 10-Hour Construction | 14 | theory | Students complete the OSHA 10-Hour Construction outreach program and correctly identify the leading hazards—fume/gas exposure, arc flash, fire, electrical, fall, and compressed-gas risks—present in welding and cutting environments. |
| OSHA 10-Hour Construction authorized trainer materials; OSHA Publication 3151 (Welding, Cutting, and Brazing); hazard-hunt photo packet; blank JHA form; pens; instructor OSHA 500/510 card on file | Students must score 70% or higher on the OSHA 10-Hour end-of-program quiz AND submit a JHA judged complete and accurate against the model rubric (all steps identified, no missing critical hazards) to receive OSHA 10 card processing. |
| 2 | Personal Protective Equipment, Lockout/Tagout, and Emergency Response | 18 | demo | Students select correct PPE for a given welding or cutting task, execute a lockout/tagout procedure on a demonstration machine, and perform CPR and basic first aid for the four injury types most common in welding shops. |
| Welding helmets (various shade lenses), leather gloves, flame-resistant jacket, safety glasses, hearing protection, respirators (N95 and half-face APF-10); LOTO demonstration panel and padlock set; AHA Heartsaver student workbooks; CPR manikins; AED trainer units; first-aid supplies; ANSI Z87.1 shade chart | Pass: correct PPE set assembled for at least 5 of 6 scenario cards; all six LOTO steps completed in correct order without prompting; AHA Heartsaver CPR/AED + First Aid card issued (requires passing AHA skills check and written test per AHA standards). |
| 3 | Trade Math I — Whole Numbers, Fractions, and Decimals for Welding | 20 | theory | Students solve welding-context problems involving whole numbers, proper and improper fractions, mixed numbers, and decimals with at least 80% accuracy, using both pencil-and-paper and a basic scientific calculator. |
| Steel rules (1/32 and metric); pre-cut steel coupons of varied lengths; scientific calculators; Welding: Principles and Applications 9th ed. (Jeffus) math appendix; pencils; graph paper | Scored worksheet: 80% correct (at least 16 of 20 problems) on a mixed fraction/decimal welding-context quiz administered without notes; all measurement readings within ±1/32 in or ±0.5 mm of instructor-verified values. |
| 4 | Trade Math II — Geometry, Weld Area/Volume, and Unit Conversion | 22 | theory | Students calculate perimeter, area, and basic volume of weld joints and structural shapes, apply the Pythagorean theorem to layout problems, and convert between US customary and SI units relevant to welding specifications. |
| Steel carpenter's square; tape measure; chalk line; layout table; AWS reference card; filler metal data sheets (e.g., AWS A5.1 electrode data); Welding: Principles and Applications 9th ed. (Jeffus) Chapters on weld math; calculators | Graded problem set: 80% correct (at least 20 of 25 items) covering area, volume, Pythagorean layout, and unit conversion; layout diagonal must be within ±1/16 in of calculated value. |
| 5 | Technical Reading — Welding Documents, SDS, and Codes | 24 | theory | Students accurately extract required information from a Welding Procedure Specification (WPS), a Safety Data Sheet (SDS), a basic work order, and a code reference table, demonstrating understanding of standard welding terminology. |
| Sample AWS D1.1 prequalified WPS (instructor-prepared or AWS-published example); GHS SDS for an E6010 or E7018 electrode (manufacturer-supplied); AWS D1.1 excerpt (reproduced under educational fair use); structured worksheets; Welding: Principles and Applications 9th ed. (Jeffus) glossary | WPS data-extraction form: 10 of 12 correct; SDS worksheet: 8 of 10 correct; vocabulary matching: 16 of 20 correct. Students who miss the threshold on any section receive targeted re-teaching and a parallel alternate form. |
| 6 | Digital Tools, Technical Communication, and Documentation | 26 | lab | Students produce a professional job-application package, complete a digital work order, and maintain a simple welding log using standard office software and trade-specific documentation formats. |
| Computers or tablets with word-processor and spreadsheet software; internet access for job-board review; printer; job-application rubric; spreadsheet template; welding log template; Welding: Principles and Applications 9th ed. (Jeffus); instructor email account for submission | Resume and cover letter score 14 of 20 on rubric (no critical omissions: name/contact, relevant skills, no spelling errors in key fields); spreadsheet formula output matches instructor key within rounding; welding log entry contains all six required fields. Missing items must be corrected and resubmitted within one class session. |
| 7 | Credentialing Pathways, Career Planning, and Industry Overview | 24 | theory | Students explain the purpose, scope, and employer relevance of the AWS D1.1 Certified Welder, AWS SENSE Level 1–2, NCCER Welding Levels 1–4, and ASME Section IX pipe credentials, and produce a personalized 12-month career plan aligned to at least two credentials in this program. |
| Printed AWS, NCCER, ASME credential overview pages (current as of curriculum publication); credential comparison table worksheet; career-plan template; local employer list or regional AGC/ABC chapter directory; Welding: Principles and Applications 9th ed. (Jeffus) Chapter 1 (Welding Careers and Opportunities); guest-speaker arrangement form | Credential comparison table: all four credentials addressed with at least three of four categories correct per credential (12 of 16 cells accurate); three guest-speaker takeaways submitted and specific (not generic); career plan contains all five required sections with at least two named local employers and a realistic credential sequence. Incomplete plans returned for revision before end of course. |
| Assessment | Type | Weight | Pass standard | Method & rubric |
|---|---|---|---|---|
| OSHA 10 and Safety Knowledge Exam | Written exam | 25% | 70% correct (per OSHA outreach program requirements) on OSHA 10 quiz; 80% correct on instructor-written welding-safety knowledge test covering PPE selection, LOTO, SDS interpretation, and emergency response | A two-part written exam: the required OSHA 10-Hour Construction quiz administered per authorized trainer protocol, followed immediately by a 25-question instructor-written multiple-choice test covering welding-specific hazards, PPE selection by task, LOTO steps, SDS section identification, and first-aid priorities for arc burns and electrical shock. Students who do not meet either threshold receive targeted remediation and one retake opportunity. Accuracy · Safety · Communication · Professionalism |
| Trade Math and Technical Reading Exam | Written exam | 25% | 80% correct overall (at least 32 of 40 items), with no sub-section below 70% | A 40-item written exam divided equally between trade math (fractions, decimals, geometry, unit conversion, weld area/volume estimation using supplied formulas) and technical reading (WPS data extraction, SDS section identification, welding terminology in context). Calculators are permitted for the math section only; all work must be shown for partial credit on calculation items. Accuracy · Safety · Communication · Professionalism |
| Career Readiness Portfolio | Project | 25% | Meets on all four required sections of the rubric (resume/cover letter, completed digital work order, welding log with minimum five entries across the course, and 12-month credential/career plan); any section marked 'Does Not Meet' requires revision and resubmission within five school days | Students submit a compiled portfolio containing: a finalized one-page resume and cover letter for a real entry-level welder posting, a correctly completed spreadsheet work order matching the instructor scenario, a welding log showing entries from each lesson, and their 12-month career plan with named employers and a credential sequence. The portfolio is evaluated against a published four-section rubric and serves as the foundation for the externship placement process. Accuracy · Safety · Communication · Professionalism |
| Safety and Career Readiness Oral Defense | Oral / panel | 25% | Satisfactory on all three evaluator prompts (no critical safety errors; credential pathway described accurately; career plan defended with specific rationale); any Unsatisfactory response requires a scheduled re-conference within five school days | In a 10-minute individual conference with the instructor (and a second evaluator when available), each student responds to three structured prompts: (1) walk through the LOTO procedure on the demonstration machine and explain why each step matters, (2) explain how at least two of the program's four credentials connect to jobs they listed in their career plan, and (3) describe one change they would make to their career plan based on the guest-speaker presentation and justify it. Responses are rated Satisfactory or Unsatisfactory per a defined anchor rubric. Accuracy · Safety · Communication · Professionalism |
BLD-WELD01-02 Trade course
Welding Safety
103 hr · $1,850 COMPLIMENTARY
This course builds the comprehensive safety foundation every welder must have before striking an arc or lighting a torch. Students earn OSHA 10-Hour General Industry/Construction recognition, gain First Aid and CPR certification, and master the hazard-control practices—PPE selection, ventilation, fire prevention, lockout/tagout, and confined-space awareness—required daily in structural and pipe welding shops and on building-construction worksites. All content maps directly to the safety and health knowledge areas tested in the AWS SENSE L1-2 and NCCER Welding Level 1 credentials.
Outcomes- Complete the OSHA 10-Hour Construction outreach training and correctly identify regulatory hierarchy (OSHA standards, employer programs, and worker rights) as demonstrated by passing the OSHA 10 card requirement.
- Select, inspect, don, and maintain personal protective equipment appropriate to SMAW, GMAW, FCAW, GTAW, oxy-fuel cutting, and plasma cutting operations, achieving 100% correct PPE selection on a practical scenario check.
- Perform a written lockout/tagout procedure and a physical energy-isolation demonstration on a welding machine to zero-energy state with no coaching errors.
- Identify electrical, fire, explosion, fume, UV/IR radiation, compressed-gas, and confined-space hazards in a welding environment and prescribe hierarchy-of-controls responses with at least 80% accuracy on a written exam.
- Respond appropriately to shop emergencies—including fire, arc flash, chemical spill, and medical emergency—and demonstrate adult CPR and use of an AED to the standard required for a recognized First Aid/CPR certification.
- Maintain a daily safety log documenting hazard observations, corrective actions, and PPE use throughout the course, meeting all entries required for the lab-log assessment.
Course text
This course builds the comprehensive safety foundation every welder must have before striking an arc or lighting a torch. Students earn OSHA 10-Hour General Industry/Construction recognition, gain First Aid and CPR certification, and master the hazard-control practices—PPE selection, ventilation, fire prevention, lockout/tagout, and confined-space awareness—required daily in structural and pipe welding shops and on building-construction worksites. All content maps directly to the safety and health knowledge areas tested in the AWS SENSE L1-2 and NCCER Welding Level 1 credentials.
How the course runs. 9 blocks: OSHA Framework, Worker Rights, and the Welding Regulatory Environment; Hazard Recognition and the Hierarchy of Controls in Welding; Personal Protective Equipment: Selection, Inspection, and Care; Electrical Safety and Arc Flash Prevention; Lockout/Tagout Procedures for Welding Equipment; Fume, Gas, and Ventilation Control; Fire Prevention, Hot-Work Permits, and Compressed-Gas Safety; Confined Space Entry Awareness and Fall Protection Basics; First Aid, CPR/AED, and Emergency Response in the Welding Shop.
What competent looks like. Complete the OSHA 10-Hour Construction outreach training and correctly identify regulatory hierarchy (OSHA standards, employer programs, and worker rights) as demonstrated by passing the OSHA 10 card requirement. Select, inspect, don, and maintain personal protective equipment appropriate to SMAW, GMAW, FCAW, GTAW, oxy-fuel cutting, and plasma cutting operations, achieving 100% correct PPE selection on a practical scenario check. Perform a written lockout/tagout procedure and a physical energy-isolation demonstration on a welding machine to zero-energy state with no coaching errors. Identify electrical, fire, explosion, fume, UV/IR radiation, compressed-gas, and confined-space hazards in a welding environment and prescribe hierarchy-of-controls responses with at least 80% accuracy on a written exam. Respond appropriately to shop emergencies—including fire, arc flash, chemical spill, and medical emergency—and demonstrate adult CPR and use of an AED to the standard required for a recognized First Aid/CPR certification. Maintain a daily safety log documenting hazard observations, corrective actions, and PPE use throughout the course, meeting all entries required for the lab-log assessment.
| # | Lesson | Hr | Type | Objective | Activities | Materials | Check |
|---|---|---|---|---|---|---|---|
| 1 | OSHA Framework, Worker Rights, and the Welding Regulatory Environment | 10 | theory | Students will explain the purpose and structure of OSHA, identify welding-specific standards under 29 CFR 1926 (construction) and 29 CFR 1910 (general industry), and describe employer obligations and worker rights including hazard reporting and the right to refuse unsafe work. |
| OSHA 10-Hour Construction outreach curriculum (OSHA-authorized trainer materials), 29 CFR 1926 Subpart J (Welding and Cutting) printout, 29 CFR 1910 Subpart Q (Welding) printout, student workbooks, whiteboard. | Exit quiz of 20 multiple-choice questions covering OSHA structure, employer/worker rights, and cited regulations; pass mark 80%. |
| 2 | Hazard Recognition and the Hierarchy of Controls in Welding | 12 | theory | Students will identify the six categories of welding hazards—electrical, thermal/fire, fume and gas, optical radiation, compressed gas, and ergonomic—and apply the NIOSH hierarchy of controls (elimination, substitution, engineering, administrative, PPE) to each category. |
| ANSI Z49.1 current edition (American Welding Society), NIOSH hierarchy-of-controls poster, hazard-identification checklist, shop diagram worksheet. | Completed hazard-identification worksheet scored against an answer key; all 15 scenarios must have correct control classification and written justification—pass mark 80%. |
| 3 | Personal Protective Equipment: Selection, Inspection, and Care | 12 | demo | Students will select the correct PPE—including welding helmet lens shade, flame-resistant clothing, gloves, respiratory protection, and foot protection—for five distinct welding and cutting processes and demonstrate proper donning, doffing, and pre-use inspection of each item. |
| Welding helmets (auto-darkening and passive, multiple shade lenses), FR shirts and jackets, leather welding gloves, TIG gloves, steel-toed boots, hearing protection (plugs and muffs), safety glasses, half-face respirators with appropriate cartridges, ANSI/ISEA Z87.1 reference card, PPE inspection checklist. | Practical PPE selection and inspection checklist: student must correctly select, inspect, and don PPE for three randomly assigned processes with zero critical errors (e.g., wrong shade lens, missing respiratory protection where required); 100% on critical items, 80% overall. |
| 4 | Electrical Safety and Arc Flash Prevention | 10 | theory | Students will explain the electrical hazards specific to arc welding—shock, electrocution, and arc flash—describe safe work practices for welding machine setup and grounding, and correctly interpret a welding machine data plate and cable-size requirements. |
| SMAW machine (de-energized, for inspection), ANSI Z49.1, OSHA 29 CFR 1926.406 reference sheet, electrical-hazard diagrams, welding machine data plate handout, inspection checklist. | Completed machine inspection checklist with all items answered and two written scenario-response paragraphs; instructor verifies all safety-critical items identified—pass mark 80% on checklist, no critical misses. |
| 5 | Lockout/Tagout Procedures for Welding Equipment | 10 | lab | Students will write a machine-specific lockout/tagout procedure and physically isolate a welding machine to a verified zero-energy state following OSHA 29 CFR 1910.147 steps without prompting. |
| SMAW welding machine, personal padlocks and hasp, lockout/tagout tags, OSHA 29 CFR 1910.147 printed standard, LOTO procedure template, step-by-step evaluation form. | Instructor-scored LOTO evaluation form: all OSHA-required steps must be performed in correct sequence with zero omissions on isolation and zero-energy verification steps; 100% on critical steps required to pass. |
| 6 | Fume, Gas, and Ventilation Control | 12 | demo | Students will identify the fumes and gases generated by common welding processes and base metals, read a Safety Data Sheet (SDS) for a welding consumable, and select appropriate ventilation and respiratory protection controls in compliance with ANSI Z49.1 and OSHA PELs. |
| Local exhaust ventilation unit, smoke tubes, ANSI Z49.1, SDS binders for common electrodes (E6010, E7018, ER70S-6, flux-core wire), OSHA PEL table for welding fumes, half-face respirators, supplied-air respirator (display unit), structured SDS worksheet. | Completed SDS worksheet (all sections answered correctly) and ventilation/respiratory plan for confined-space scenario reviewed by instructor; pass mark 80% on worksheet and plan must include correct respirator type for confined space. |
| 7 | Fire Prevention, Hot-Work Permits, and Compressed-Gas Safety | 12 | lab | Students will complete a hot-work permit for a simulated welding task, demonstrate correct fire-watch procedures, identify compressed-gas cylinder hazards, and safely transport, store, and connect an oxy-fuel cylinder set. |
| Hot-work permit form, fire extinguisher training prop, ABC fire extinguishers, fire-watch log, oxy-fuel cylinders (oxygen and acetylene, secured), cylinder hand truck, CGA-compliant regulators, leak-check solution, chain restraints, DOT hazmat label reference sheet. | Hot-work permit scored by instructor (all required fields completed, hazards correctly assessed—pass 80%); fire-watch log reviewed; cylinder handling evaluated on checklist—zero tolerance for cap-off cylinder left unrestrained or regulator installed without leak check. |
| 8 | Confined Space Entry Awareness and Fall Protection Basics | 10 | theory | Students will distinguish permit-required from non-permit confined spaces as defined by OSHA 29 CFR 1926.1202, identify atmospheric testing requirements for welding in confined spaces, and describe fall-protection options required at heights encountered in structural welding. |
| OSHA 29 CFR 1926 Subpart AA (confined spaces in construction) printout, confined-space permit form example, atmospheric monitor (for display), full-body harness, shock-absorbing lanyard, anchorage connector, manufacturer inspection guide, incident case-study handout. | Written corrective-action plan reviewed by instructor (must correctly identify all missing permit elements—pass 80%); harness inspection form completed with all defects identified—no missed critical defects allowed. |
| 9 | First Aid, CPR/AED, and Emergency Response in the Welding Shop | 15 | lab | Students will perform adult CPR and AED operation to the standard required for a recognized First Aid/CPR certification and demonstrate first-aid responses to welding-specific emergencies: electrical shock, thermal burn, eye injury from arc flash or spatter, and inhalation injury. |
| Adult CPR manikins (one per two students), training AED unit, First Aid/CPR certification curriculum (from an authorized provider), sterile burn dressings, eyewash station (plumbed), first-aid kit, shop emergency exit map, emergency-resource map worksheet. | Students must pass the certified First Aid/CPR skills evaluation administered by the authorized instructor (provider-standard pass mark); scenario-station performance evaluated by instructor—must correctly manage all four welding-specific emergencies with no step that would worsen the injury. |
| Assessment | Type | Weight | Pass standard | Method & rubric |
|---|---|---|---|---|
| Welding Safety Written Knowledge Exam | Written exam | 25% | 80% or higher (must score 100% on questions tagged as 'critical safety'—LOTO, confined space, and electrical isolation) | A 60-question closed-book exam covering OSHA regulatory framework, hazard recognition and hierarchy of controls, PPE selection for all five welding processes, electrical safety, fume and ventilation requirements, compressed-gas handling, hot-work permits, fire prevention, confined-space entry awareness, and emergency response. Questions are drawn from ANSI Z49.1, OSHA standards, and the AWS SENSE Level 1 and NCCER Welding Level 1 knowledge domains to ensure direct credential alignment. Standard met · Safety · Time · Quality/finish · Documentation |
| Lockout/Tagout and PPE Practical Skills Demonstration | Skills demonstration | 45% | 100% on all critical steps (zero-energy verification, correct PPE for assigned process); 80% overall on the full checklist | Each student individually performs a complete LOTO sequence on a designated welding machine and then selects, inspects, and dons the full PPE set for a randomly assigned welding process while an instructor scores a standardized checklist. Any critical error—such as failing to verify zero energy or selecting the wrong lens shade—requires an immediate re-demonstration after remediation before the student may continue in the program. Standard met · Safety · Time · Quality/finish · Documentation |
| Daily Safety Lab Log | Log | 15% | All required entries present and substantively completed; fewer than two entries returned for revision | Students maintain a bound lab log throughout the course with a dated entry for every lab session documenting: the process or task performed, hazards identified, PPE selected and reason, any near-miss or unsafe condition observed, and the corrective action taken or reported. The log is collected at the end of the course and scored for completeness, accuracy, and evidence of reflective hazard thinking; it also serves as part of the portfolio submitted for AWS SENSE L1 and NCCER Level 1 documentation requirements. Standard met · Safety · Time · Quality/finish · Documentation |
| End-of-Course Safety Walk Inspection | Safety audit | 15% | Identifies at least 90% of planted hazards with correct hazard category and control; zero critical hazards missed | The instructor plants a minimum of 15 realistic hazards throughout the welding shop—including an unrestrained cylinder, an electrode holder with damaged insulation, blocked emergency exit, missing machine guard, improper fume-extraction positioning, and a missing SDS—and each student independently walks the shop, completes a written hazard report identifying each hazard by category and prescribing a corrective action, and verbally briefs the instructor on their top three priority findings. This assessment mirrors the jobsite safety inspection competencies required in both NCCER Welding Level 1 and AWS SENSE Level 1 credential performance indicators. Standard met · Safety · Time · Quality/finish · Documentation |
BLD-WELD01-03 Trade course
Shielded Metal Arc Welding (SMAW)
103 hr · $1,850 COMPLIMENTARY
Students develop hands-on proficiency in shielded metal arc welding — the foundational stick-welding process used across structural steel, heavy equipment, and pipeline construction. The course covers electrode selection, machine setup, arc control, and weld-quality evaluation in flat, horizontal, vertical, and overhead positions on carbon steel plate. Lessons are sequenced from theory through supervised practice and are mapped to AWS D1.1 Certified Welder qualification requirements and NCCER Welding Level 1 core performance objectives.
Outcomes- Set up and safely operate a constant-current SMAW power source, selecting polarity, amperage range, and electrode type appropriate to the base metal and joint configuration.
- Run sound stringer and weave beads in the 1F, 2F, 3F, and 4F fillet-weld positions and the 1G, 2G, 3G, and 4G groove-weld positions on carbon steel plate to AWS D1.1 visual acceptance criteria.
- Select the correct SMAW electrode (E6010, E6011, E6013, E7018, E7024) for a given application, citing AWS A5.1 classification, storage requirements, and amperage range.
- Identify and correct common SMAW discontinuities — porosity, undercut, overlap, incomplete fusion, and excessive spatter — by adjusting travel speed, arc length, or amperage.
- Perform visual inspection and basic bend-test evaluation of SMAW welds against AWS D1.1 acceptance criteria, recording results in a weld log.
- Apply all SMAW-specific PPE requirements and safe work practices, including fume extraction, fire-watch protocol, and electrode stub disposal, without prompting.
Course text
Students develop hands-on proficiency in shielded metal arc welding — the foundational stick-welding process used across structural steel, heavy equipment, and pipeline construction. The course covers electrode selection, machine setup, arc control, and weld-quality evaluation in flat, horizontal, vertical, and overhead positions on carbon steel plate. Lessons are sequenced from theory through supervised practice and are mapped to AWS D1.1 Certified Welder qualification requirements and NCCER Welding Level 1 core performance objectives.
How the course runs. 9 blocks: SMAW Process Theory and Power-Source Fundamentals; Electrode Classification, Storage, and Selection; Safe Setup, PPE, and Workstation Preparation; Striking the Arc and Running Stringer Beads — Flat Position (1G/1F); Fillet Welds in Multiple Positions (2F, 3F, 4F) and Discontinuity Analysis; Groove Welds on Plate — 2G and 3G Positions; Overhead Groove Welds (4G) and Advanced Arc Control; Weld Inspection Methods: Visual, Guided-Bend, and Weld Symbols Introduction; SMAW Procedure Qualification Simulation and Course Review.
What competent looks like. Set up and safely operate a constant-current SMAW power source, selecting polarity, amperage range, and electrode type appropriate to the base metal and joint configuration. Run sound stringer and weave beads in the 1F, 2F, 3F, and 4F fillet-weld positions and the 1G, 2G, 3G, and 4G groove-weld positions on carbon steel plate to AWS D1.1 visual acceptance criteria. Select the correct SMAW electrode (E6010, E6011, E6013, E7018, E7024) for a given application, citing AWS A5.1 classification, storage requirements, and amperage range. Identify and correct common SMAW discontinuities — porosity, undercut, overlap, incomplete fusion, and excessive spatter — by adjusting travel speed, arc length, or amperage. Perform visual inspection and basic bend-test evaluation of SMAW welds against AWS D1.1 acceptance criteria, recording results in a weld log. Apply all SMAW-specific PPE requirements and safe work practices, including fume extraction, fire-watch protocol, and electrode stub disposal, without prompting.
| # | Lesson | Hr | Type | Objective | Activities | Materials | Check |
|---|---|---|---|---|---|---|---|
| 1 | SMAW Process Theory and Power-Source Fundamentals | 8 | theory | Students explain how the SMAW arc is established and sustained, identify AC and DC power-source controls, and match polarity (DCEP, DCEN, AC) to electrode type and application. |
| SMAW power source (CC transformer or inverter) for demonstration, AWS A5.1 Specification for Carbon Steel Electrodes for SMAW, NCCER Welding Level 1 Module 29101 textbook, volt-ampere curve poster, whiteboard. | Five-question multiple-choice quiz on arc physics, polarity, and OCV safety; students must score 80% or higher to proceed. |
| 2 | Electrode Classification, Storage, and Selection | 8 | theory | Students decode the AWS A5.1 electrode classification system and specify correct electrode type, amperage range, and storage procedure for at least five common SMAW electrodes. |
| Electrode sample set (E6010, E6011, E6013, E7018, E7024), rod oven with thermostat, AWS A5.1 specification, NCCER Welding Level 1 textbook, electrode reference cards (student-made). | Written electrode identification quiz: ten unknowns decoded from AWS classification string; 80% correct required. Instructor also checks that each student correctly records rod-oven temperature in the lab log. |
| 3 | Safe Setup, PPE, and Workstation Preparation | 10 | demo | Students safely assemble a complete SMAW workstation — power source, electrode holder, work clamp, ventilation, and fire-watch provisions — and don all required PPE before touching the machine. |
| SMAW power source, electrode holder and cable, work clamp and cable, welding helmet (auto-darkening, shade 10–12 minimum), leather gloves, leather jacket or FR sleeves, leather boots, face shield, ventilation fan or local exhaust, fire extinguisher, ANSI Z49.1 Safety in Welding and Cutting (current edition), station-setup checklist. | Instructor completes a go/no-go safety checklist for each student's station; all 12 checklist items must be correct (100%) before the student is permitted to strike an arc. This directly feeds the course Safety Check assessment. |
| 4 | Striking the Arc and Running Stringer Beads — Flat Position (1G/1F) | 14 | lab | Students strike and maintain a stable arc with E6013 on carbon steel plate and run uniform stringer beads in the flat position with consistent width (±1/8 in.), reinforcement height, and starts/stops free of crater cracks. |
| SMAW power source, E6013 electrodes (3/32 in. and 1/8 in.), 3/8 in. A36 carbon steel plate coupons, electrode holder, work clamp, chipping hammer, wire brush, weld gauge, steel rule, paint pen, lab log binder, AWS D1.1 visual acceptance criteria reference card. | Instructor visually inspects three consecutive stringer beads per student against AWS D1.1 visual criteria: acceptable width uniformity, no undercut exceeding 1/32 in., no visible porosity, complete fusion at toes. Students must pass on two of three beads to advance. |
| 5 | Fillet Welds in Multiple Positions (2F, 3F, 4F) and Discontinuity Analysis | 16 | lab | Students produce T-joint fillet welds meeting AWS D1.1 visual acceptance criteria in horizontal (2F), vertical-up (3F), and overhead (4F) positions using E6010 or E7018, and correctly identify at least four weld discontinuities by type and probable cause. |
| SMAW power source, E6010 (1/8 in.) and E7018 (1/8 in.) electrodes, rod oven, 3/8 in. A36 carbon steel T-joint coupons, abrasive chop saw, etchant kit (used by instructor only), magnifying glass, weld gauge, lab log, AWS D1.1 visual and dimensional acceptance criteria reference. | Each position (2F, 3F, 4F) is graded on a five-criteria rubric (fusion, undercut, overlap, convexity/concavity, crater fill); students must meet all five criteria in at least two of the three positions. Discontinuity ID worksheet must score 75% or higher. |
| 6 | Groove Welds on Plate — 2G and 3G Positions | 16 | lab | Students fit up, tack, and complete single-V groove welds on carbon steel plate in the horizontal (2G) and vertical-up (3G) positions using E7018, achieving root, fill, and cap passes that meet AWS D1.1 visual acceptance criteria. |
| SMAW power source, E6010 and E7018 electrodes (3/32 in. and 1/8 in.), rod oven, 3/8 in. A36 carbon steel plate pre-cut for single-V groove, angle grinder with grinding and flap-disc wheels, chipping hammer, wire brush, weld gauge, square, interpass thermometer, lab log, AWS D1.1 reference. | Instructor performs AWS D1.1 visual inspection on each coupon: crown reinforcement within specified limits, no cracks, undercut not exceeding limits, complete fusion visible at toes and root. Students must produce an acceptable coupon in both 2G and 3G positions to pass this lesson. |
| 7 | Overhead Groove Welds (4G) and Advanced Arc Control | 12 | practice | Students complete a single-V groove weld in the overhead (4G) position using E7018 with correct body positioning, electrode manipulation, and PPE, producing a weld that meets AWS D1.1 visual acceptance criteria. |
| SMAW power source, E7018 electrodes, rod oven, 3/8 in. A36 single-V groove coupons, overhead welding fixture or positioner, full leather PPE (jacket, sleeves, or cape), chipping hammer, wire brush, weld gauge, camera or phone for lab log photos, lab log. | Instructor inspects finished 4G coupon against AWS D1.1 visual acceptance criteria using the same five-criteria rubric used in lesson 5. A passing coupon plus a complete photo log entry are both required; incomplete documentation is a fail. |
| 8 | Weld Inspection Methods: Visual, Guided-Bend, and Weld Symbols Introduction | 10 | demo | Students perform a complete AWS D1.1 visual inspection procedure on a set of test coupons and demonstrate correct specimen preparation and interpretation of a guided-bend test, recording results in a standardized inspection report. |
| AWS D1.1 Structural Welding Code — Steel (current edition), guided-bend test jig, pre-cut groove-weld specimens, weld gauge set, magnifying glass, inspection report forms, sample drawing set with weld symbols, NCCER Welding Level 2 Blueprint Reading reference. | Students submit a completed visual inspection report for one assigned coupon; report must correctly identify all accept/reject conditions and cite the applicable AWS D1.1 clause (by table or paragraph number). Pass standard is instructor sign-off confirming all accept/reject calls match the answer key. |
| 9 | SMAW Procedure Qualification Simulation and Course Review | 9 | practice | Students independently complete a qualification-style SMAW test plate (3G or 4G per AWS D1.1 Table 4.9 essential variables) under exam-like conditions, demonstrating all skills and knowledge acquired in the course without instructor coaching. |
| SMAW power source, E7018 and E6010 electrodes, rod oven, 3/8 in. A36 single-V groove coupons, all standard PPE, chipping hammer, wire brush, weld gauge, inspection report forms, AWS D1.1, student lab logs and electrode reference cards, gap-analysis worksheet. | Instructor evaluates the mock qualification coupon against AWS D1.1 visual acceptance criteria; a pass on visual inspection is required to sit the Skills Demo assessment. The peer inspection report is collected as a lab-log entry and must be complete to receive credit. |
| Assessment | Type | Weight | Pass standard | Method & rubric |
|---|---|---|---|---|
| SMAW Written Knowledge Exam | Written exam | 25% | 75% correct (30 of 40 questions) | A 40-question closed-book exam covering SMAW process theory, AWS A5.1 electrode classification and storage, polarity and amperage selection, weld discontinuity identification and probable causes, and AWS D1.1 visual acceptance criteria. Questions are written at the knowledge and application levels and are mapped to AWS SENSE Level 1 performance objectives and NCCER Welding Level 1 core knowledge areas. Standard met · Safety · Time · Quality/finish · Documentation |
| SMAW Practical Skills Demonstration | Skills demonstration | 45% | All five visual-acceptance criteria met on both the 3G and 4G groove-weld coupons; no single criterion may be waived | Students independently produce two single-V groove-weld coupons — one in the vertical-up (3G) position and one in the overhead (4G) position — using E7018 under unassisted, timed conditions. Each coupon is evaluated by the instructor using the AWS D1.1 structural code visual acceptance criteria, directly replicating the AWS D1.1 Certified Welder qualification test format. Standard met · Safety · Time · Quality/finish · Documentation |
| SMAW Lab Log Portfolio | Log | 15% | All nine lesson entries present and complete; instructor signature on each; photographic evidence of coupons for lessons 4 through 9; overall portfolio rated Complete on the four-point rubric | Students maintain a running lab log throughout the course recording machine settings, electrode choices, weld-inspection results, and personal technique reflections for every practice session. The completed portfolio is submitted at the end of the course and evaluated for accuracy, completeness, and evidence of self-correction over time, supporting the NCCER Registry documentation habit and the AWS SENSE portfolio requirement. Standard met · Safety · Time · Quality/finish · Documentation |
| SMAW Workstation Safety Check | Safety audit | 15% | 100% on the 12-item go/no-go checklist; any single unsafe item is a failure requiring immediate correction and a full recheck before the student may weld | Conducted during Lesson 3 and re-administered unannounced once later in the course, the instructor uses a standardized 12-item checklist to verify that the student has correctly set up all machine, PPE, ventilation, fire-prevention, and housekeeping elements of a safe SMAW workstation before energizing the machine. This assessment is a prerequisite gate: students who fail may not continue welding until the deficiency is corrected and the full checklist is re-passed. Standard met · Safety · Time · Quality/finish · Documentation |
BLD-WELD01-04 Trade course
Gas Metal Arc Welding (GMAW)
102 hr · $1,830 COMPLIMENTARY
This course develops competency in Gas Metal Arc Welding (MIG welding) using short-circuit, globular, spray, and pulsed-spray transfer modes on carbon steel plate and structural members in flat, horizontal, vertical, and overhead positions. Students learn machine setup, shielding gas selection, wire feed systems, joint preparation, and weld quality inspection in accordance with AWS D1.1 structural welding standards. Successful completion prepares students for AWS SENSE Level 1 performance qualifications, NCCER Welding Level 2 GMAW modules, and entry-level structural welding employment.
Outcomes- Set up and calibrate a GMAW power source, wire feeder, gun, and shielding gas system to produce sound welds on carbon steel in all four standard positions per AWS D1.1 workmanship requirements.
- Identify and correct the five most common GMAW discontinuities—porosity, undercut, incomplete fusion, cold lap, and burn-through—by adjusting voltage, wire feed speed, travel speed, and gun angle.
- Select the correct shielding gas mixture, wire diameter, and transfer mode for a given base metal thickness and joint configuration using AWS filler metal classification charts.
- Perform visual inspection and basic destructive testing (nick-break and guided-bend) on GMAW test coupons and evaluate results against AWS D1.1 acceptance criteria.
- Demonstrate all required lockout/tagout, PPE, ventilation, and fire-watch procedures specific to GMAW operations before beginning any welding task.
- Interpret welding procedure specifications (WPS) and produce groove and fillet welds that meet dimensional tolerances and visual acceptance criteria required for AWS Certified Welder and NCCER Welding Level 2 performance tests.
Course text
This course develops competency in Gas Metal Arc Welding (MIG welding) using short-circuit, globular, spray, and pulsed-spray transfer modes on carbon steel plate and structural members in flat, horizontal, vertical, and overhead positions. Students learn machine setup, shielding gas selection, wire feed systems, joint preparation, and weld quality inspection in accordance with AWS D1.1 structural welding standards. Successful completion prepares students for AWS SENSE Level 1 performance qualifications, NCCER Welding Level 2 GMAW modules, and entry-level structural welding employment.
How the course runs. 9 blocks: GMAW Fundamentals, Hazards, and Machine Familiarization; Shielding Gases, Wire Electrodes, and Transfer Modes; Machine Setup, WPS Interpretation, and Bead-on-Plate (Flat); Fillet Welds in Flat and Horizontal Positions; Vertical and Overhead Fillet Welds; Groove Welds on Plate — Flat and Horizontal (1G, 2G); Weld Discontinuities, Troubleshooting, and Quality Control; GMAW Safety Audit, Ventilation, and Confined Space Awareness; Capstone Performance Welds and Portfolio Completion.
What competent looks like. Set up and calibrate a GMAW power source, wire feeder, gun, and shielding gas system to produce sound welds on carbon steel in all four standard positions per AWS D1.1 workmanship requirements. Identify and correct the five most common GMAW discontinuities—porosity, undercut, incomplete fusion, cold lap, and burn-through—by adjusting voltage, wire feed speed, travel speed, and gun angle. Select the correct shielding gas mixture, wire diameter, and transfer mode for a given base metal thickness and joint configuration using AWS filler metal classification charts. Perform visual inspection and basic destructive testing (nick-break and guided-bend) on GMAW test coupons and evaluate results against AWS D1.1 acceptance criteria. Demonstrate all required lockout/tagout, PPE, ventilation, and fire-watch procedures specific to GMAW operations before beginning any welding task. Interpret welding procedure specifications (WPS) and produce groove and fillet welds that meet dimensional tolerances and visual acceptance criteria required for AWS Certified Welder and NCCER Welding Level 2 performance tests.
| # | Lesson | Hr | Type | Objective | Activities | Materials | Check |
|---|---|---|---|---|---|---|---|
| 1 | GMAW Fundamentals, Hazards, and Machine Familiarization | 10 | theory | Students will explain the GMAW arc process, identify all major equipment components and their functions, and recite the specific electrical, fume, UV radiation, and shielding gas hazards before touching any equipment. |
| GMAW power source (CV/DC), wire feeder, welding gun, work leads; AWS A3.0 Standard Welding Terms and Definitions; Lincoln Electric GMAW welding guide; manufacturer operator manuals; OSHA 29 CFR 1910.252 ventilation reference sheet; lockout/tagout verification forms; labeled equipment diagram handout | Written 20-question identification quiz covering component names, hazard categories, and lockout/tagout steps; pass mark 75%. Instructor observes and signs off on each student's lockout/tagout demonstration before lab access is granted—no exceptions. |
| 2 | Shielding Gases, Wire Electrodes, and Transfer Modes | 10 | theory | Students will select the correct AWS ER-series wire classification and shielding gas mixture for a given base metal, thickness, and transfer mode by applying AWS A5.18 filler metal specifications and published gas selection charts. |
| CV/DC power source; ER70S-3 and ER70S-6 wire spools (0.030" and 0.035"); CO₂ and Ar/CO₂ mixed gas cylinders; flow meters; AWS A5.18 filler metal spec reference; manufacturer wire data sheets; WPS sample documents; leak-detection solution; student observation forms | Scenario-based worksheet: five written scenarios requiring students to specify wire classification, diameter, gas blend, flow rate, and transfer mode with written justification; scored with a rubric, pass mark 75%. Instructor signs off on cylinder/regulator setup for each student. |
| 3 | Machine Setup, WPS Interpretation, and Bead-on-Plate (Flat) | 12 | lab | Students will read a provided WPS, set voltage, wire feed speed, and polarity on the GMAW machine within the specified ranges, and run straight stringer beads on flat carbon steel plate that meet AWS D1.1 visual acceptance criteria for width consistency, straightness, and absence of porosity. |
| CV/DC GMAW machine; ER70S-6 0.035" wire; C25 shielding gas; ¼" A36 mild steel plate coupons (6"×6"); auto-darkening welding helmet (shade 10); leather gloves; chipping hammer; wire brush; fillet weld gauge; AWS D1.1 visual acceptance criteria reference card; sample WPS; process log forms; angle grinder with flap disc | Instructor evaluates three student-selected beads against AWS D1.1 visual acceptance criteria using a fillet weld gauge and checklist: consistent width (±1/16"), no porosity, no undercut exceeding code limits, complete fusion at toes; all three beads must pass for competency sign-off. Process logs reviewed for completeness. |
| 4 | Fillet Welds in Flat and Horizontal Positions | 12 | lab | Students will produce single-pass and multi-pass fillet welds in the flat (1F) and horizontal (2F) positions on T-joint coupons that meet the specified leg size, profile, and visual quality requirements of AWS D1.1. |
| CV/DC GMAW machine; ER70S-6 0.035" wire; C25 gas; ¼" and 3/8" A36 plate for T-joints; angle grinder; chipping hammer; wire brush; welding square; fit-up gauges; fillet weld gauge; bandsaw or hacksaw; nick-break test fixture or press; AWS D1.1 reference; camera or phone for documentation | Instructor measures fillet leg size with a gauge (must match WPS specified size ±1/16"), inspects all four coupons for undercut, overlap, porosity, and surface cracks per AWS D1.1 visual criteria; nick-break specimen must show complete fusion across the root with porosity pockets no larger than code allows. Students must pass all four coupons to proceed. |
| 5 | Vertical and Overhead Fillet Welds | 14 | lab | Students will produce fillet welds in the vertical-up (3F) and overhead (4F) positions on T-joint coupons that pass AWS D1.1 visual inspection criteria, demonstrating correct gun angle, travel technique, and heat management for out-of-position welding. |
| CV/DC GMAW machine; ER70S-6 0.035" wire; C25 gas; ¼" A36 T-joint coupons pre-tacked by students; positioner or fixture for 3F and 4F setups; full leather welding jacket or FR sleeves and apron; auto-darkening helmet; welding gloves; chipping hammer; fillet weld gauge; AWS D1.1 reference card; student self-assessment forms | Instructor inspects two 3F and two 4F coupons per student with fillet weld gauge against AWS D1.1 visual criteria: leg size within ±1/16" of WPS, no undercut exceeding code limits, no overlap or visible porosity; students must pass all four coupons. Safety spotter sign-off required before any 4F welding begins. |
| 6 | Groove Welds on Plate — Flat and Horizontal (1G, 2G) | 14 | lab | Students will prepare, fit up, and complete single-V groove welds in the flat (1G) and horizontal (2G) positions using root pass, fill passes, and cap pass technique, producing welds that pass AWS D1.1 visual inspection and guided-bend testing. |
| CV/DC GMAW machine; ER70S-6 0.035" and 0.045" wire; C25 gas; ¼" A36 plate beveled to 37.5°; grinding discs; angle grinder; fit-up gauge; root gap gauge; tack welding clamps; guided-bend test jig; face and root bend specimen templates; inspection report forms; AWS D1.1 tables for bend test acceptance; fillet weld gauge; ruler | Instructor performs visual inspection of cap pass (reinforcement not to exceed 1/8", complete fusion, no undercut exceeding limits) and evaluates two guided-bend specimens per student: no single crack or open defect exceeding 1/8" in any direction per AWS D1.1 acceptance criteria. Both visual and bend must pass to earn competency credit. |
| 7 | Weld Discontinuities, Troubleshooting, and Quality Control | 10 | demo | Students will diagnose the cause of at least five GMAW discontinuities presented in defective weld samples and specify the parameter or technique correction that would eliminate each one, referencing AWS D1.1 terminology. |
| Pre-welded defective coupon sample set (eight types); student defect log sheets; AWS D1.1 visual inspection acceptance criteria table; AWS A3.0 terminology reference; GMAW machine available for intentional defect exercise; ¼" A36 scrap plate; student-produced defective and corrected weld pairs; whiteboard for group presentations | Defect log sheets scored with an answer key: students must correctly identify discontinuity type, probable cause, and corrective action for at least six of eight stations (75%). The intentional defect exercise is reviewed by the instructor who confirms the corrected weld visually passes before sign-off. |
| 8 | GMAW Safety Audit, Ventilation, and Confined Space Awareness | 8 | field | Students will conduct a documented pre-shift safety audit of a GMAW workstation, verify ventilation adequacy, identify confined space indicators on a simulated site scenario, and complete a lockout/tagout procedure without error. |
| GMAW workstation safety checklist (30-item); smoke tube or airflow indicator; local exhaust ventilation hood; OSHA 29 CFR 1910.252 handout; confined space entry permit blank forms; OSHA 29 CFR 1910.146 permit-required confined spaces summary handout; lockout/tagout tags and locks; fire extinguisher (Class ABC) at station; camera for documentation | Safety audit checklist reviewed by instructor: student must correctly identify all five seeded deficiencies to pass (100% on planted deficiencies). Confined space permit form evaluated for completeness. Lockout/tagout sequence observed in real time—zero errors required for sign-off; any error requires immediate repeat. |
| 9 | Capstone Performance Welds and Portfolio Completion | 12 | practice | Students will independently produce a complete set of GMAW performance welds (1F, 2F, 3F, 1G) to AWS D1.1 visual acceptance criteria, assemble a process portfolio documenting their WPS interpretation, machine setup records, inspection logs, and bend test results, and present their best weld pair to the instructor in a structured review. |
| CV/DC GMAW machine; ER70S-6 0.035" wire; C25 gas; ¼" A36 plate for fillet and groove coupons; all lab log and inspection forms from prior lessons; portfolio binder or digital folder; fillet weld gauge; guided-bend jig; angle grinder; AWS D1.1 reference; student-completed WPS set; printer or digital submission tool | All four performance welds inspected by instructor against AWS D1.1 visual acceptance criteria using fillet weld gauge; 1G groove weld must also pass a face-bend test. Portfolio evaluated with a rubric: completeness (all required documents present), accuracy of self-inspection records, and quality of written reflection—must score 75% or higher. Verbal presentation must demonstrate correct use of AWS D1.1 terminology. |
| Assessment | Type | Weight | Pass standard | Method & rubric |
|---|---|---|---|---|
| GMAW Theory and Process Knowledge Exam | Written exam | 25% | 75% correct (30 of 40 questions) | A 40-question written exam covering GMAW arc physics, equipment components and functions, AWS ER-series wire classification, shielding gas selection, transfer mode characteristics, WPS interpretation, and AWS D1.1 visual acceptance criteria terminology. Questions include multiple choice, matching, and short-answer identification of discontinuities and their causes; mapped to AWS SENSE Level 1 knowledge areas and NCCER Welding Level 2 GMAW module objectives. Standard met · Safety · Time · Quality/finish · Documentation |
| GMAW Hands-On Performance Skills Demonstration | Skills demonstration | 45% | All four weld coupons pass AWS D1.1 visual inspection; 1G guided-bend specimens show no defect exceeding code limits | Students independently set up the GMAW machine from a provided WPS and produce four test coupons—1F fillet, 2F fillet, 3F fillet, and a single-V 1G groove weld on ¼" A36 plate—within a timed session. Each coupon is evaluated by the instructor using a fillet weld gauge and the AWS D1.1 visual acceptance criteria checklist; the 1G coupon also undergoes a guided face-bend test, directly mirroring the AWS Certified Welder and NCCER performance qualification test format. Standard met · Safety · Time · Quality/finish · Documentation |
| GMAW Process Portfolio and Lab Log | Log | 15% | 75% on rubric (minimum: all required documents present and bend test results accurately recorded and interpreted) | Students submit a complete GMAW process portfolio containing all machine setup records, WPS interpretation worksheets, defect identification logs, safety audit checklists, nick-break and bend test inspection reports, and a written reflection; the portfolio is scored on a rubric assessing completeness, accuracy of self-inspection documentation, correct application of AWS D1.1 acceptance criteria language, and coherence of the reflection. This log provides evidence for NCCER Registry documentation and supports AWS SENSE Level 1 program record requirements. Standard met · Safety · Time · Quality/finish · Documentation |
| GMAW Workstation Safety Compliance Check | Safety audit | 15% | 100% on all critical safety items (lockout/tagout, PPE donned, gas cylinder secured, ventilation active); zero tolerance for critical failures | Before the final performance weld session, each student is observed setting up their GMAW workstation from scratch; the instructor uses a 15-item critical safety checklist covering lockout/tagout sequence, correct PPE selection and donning, gas cylinder securing and regulator connection, shielding gas flow verification, fire extinguisher location confirmation, and ventilation activation. Any single critical item failure (electrical, fire, or asphyxiation hazard) results in an automatic retest after remediation; the student may not begin welding until a clean pass is recorded. Standard met · Safety · Time · Quality/finish · Documentation |
BLD-WELD01-05 Trade course
Flux-Cored Arc Welding (FCAW)
102 hr · $1,830 COMPLIMENTARY
This course develops competency in flux-cored arc welding using both self-shielded (FCAW-S) and gas-shielded (FCAW-G) processes on carbon steel plate in multiple positions. Students learn machine setup, wire and shielding gas selection, parameter optimization, and weld quality evaluation to structural fabrication standards. Lessons map directly to AWS D1.1 Certified Welder test positions and AWS SENSE Level 1 electrode/process knowledge areas.
Outcomes- Set up and operate FCAW-S and FCAW-G equipment, selecting correct wire diameter, shielding gas, polarity, voltage, and wire feed speed for a given joint and position.
- Produce groove and fillet welds on carbon steel plate in the 1F, 2F, 3F, 1G, 2G, and 3G positions that meet AWS D1.1 visual acceptance criteria.
- Identify, diagnose, and correct common FCAW discontinuities including porosity, lack of fusion, undercut, overlap, and excessive spatter by adjusting process variables.
- Perform pre-weld and in-process quality checks including preheat verification, interpass temperature monitoring, and visual inspection using AWS D1.1 criteria.
- Apply all required PPE, ventilation controls, and lockout/tagout procedures specific to the FCAW process and its fume, spatter, and electrical hazards.
- Interpret welding procedure specifications (WPS) and record essential variables to support qualification testing under AWS D1.1 and NCCER Welding Level 2 documentation requirements.
Course text
This course develops competency in flux-cored arc welding using both self-shielded (FCAW-S) and gas-shielded (FCAW-G) processes on carbon steel plate in multiple positions. Students learn machine setup, wire and shielding gas selection, parameter optimization, and weld quality evaluation to structural fabrication standards. Lessons map directly to AWS D1.1 Certified Welder test positions and AWS SENSE Level 1 electrode/process knowledge areas.
How the course runs. 9 blocks: FCAW Process Principles, Equipment, and Safety; Wire Selection, Shielding Gas, and Machine Setup; Flat and Horizontal Fillet Welds (1F and 2F); Flat and Horizontal Groove Welds (1G and 2G); Vertical Fillet and Groove Welds (3F and 3G); Weld Discontinuities, Causes, and Corrections; Welding Procedure Specifications and Quality Documentation; Destructive Testing Fundamentals and Coupon Evaluation; FCAW Certification Welding Test Preparation and Full-Position Practice.
What competent looks like. Set up and operate FCAW-S and FCAW-G equipment, selecting correct wire diameter, shielding gas, polarity, voltage, and wire feed speed for a given joint and position. Produce groove and fillet welds on carbon steel plate in the 1F, 2F, 3F, 1G, 2G, and 3G positions that meet AWS D1.1 visual acceptance criteria. Identify, diagnose, and correct common FCAW discontinuities including porosity, lack of fusion, undercut, overlap, and excessive spatter by adjusting process variables. Perform pre-weld and in-process quality checks including preheat verification, interpass temperature monitoring, and visual inspection using AWS D1.1 criteria. Apply all required PPE, ventilation controls, and lockout/tagout procedures specific to the FCAW process and its fume, spatter, and electrical hazards. Interpret welding procedure specifications (WPS) and record essential variables to support qualification testing under AWS D1.1 and NCCER Welding Level 2 documentation requirements.
| # | Lesson | Hr | Type | Objective | Activities | Materials | Check |
|---|---|---|---|---|---|---|---|
| 1 | FCAW Process Principles, Equipment, and Safety | 10 | theory | Students will explain how FCAW-S and FCAW-G differ in shielding mechanism, polarity requirements, and applicable positions, and will identify all PPE and ventilation controls required before striking an arc. |
| FCAW wire feeder and power source (CV), FCAW-G gun with diffuser and contact tip, FCAW-S gun, manufacturer's equipment manual, AWS SENSE Level 1 Reference Guide, OSHA 29 CFR 1910.252 handout, local exhaust ventilation unit, auto-darkening helmet (minimum shade 10), leather gloves and jacket, fire-resistant curtains | 10-question written quiz covering polarity (DCEP vs. DCEN), shielding mechanisms, and PPE requirements; pass mark 70%. |
| 2 | Wire Selection, Shielding Gas, and Machine Setup | 10 | demo | Students will select the correct AWS A5.20 or A5.36 wire classification and shielding gas mixture for a given base metal and position, then set voltage, wire feed speed, and inductance on a CV power source to within the WPS-specified range. |
| CV power source with digital meters, wire feeder, E71T-1C .045 in. and 0.035 in. wire spools, E71T-8 self-shielded wire, 75%Ar/25%CO2 and 100% CO2 cylinders with regulators and flowmeters, drive roll sets, contact tips and liners, scrap 3/8 in. A36 plate, WPS handout, AWS A5.20/A5.36 classification chart | Students successfully set up the machine to match all essential variables on an instructor-provided WPS (voltage ±2 V, WFS ±50 ipm, gas flow ±2 CFH) with no prompting; instructor signs setup checklist; pass requires all three parameters within tolerance. |
| 3 | Flat and Horizontal Fillet Welds (1F and 2F) | 12 | lab | Students will produce single-pass and multi-pass fillet welds on tee joints in the 1F and 2F positions that meet AWS D1.1 Table 6.1 visual acceptance criteria for size, uniformity, undercut, and overlap. |
| CV power source, wire feeder, E71T-1C .045 in. wire, 75%Ar/25%CO2, 3/8 in. x 3 in. x 6 in. A36 plate for tee joints, fillet weld gauges, AWS D1.1 Table 6.1 acceptance criteria reference card, chipping hammer, wire brush, angle grinder with flap disc, auto-darkening helmet shade 10, leather PPE | Three tee joint fillet welds (minimum one 1F, one 2F) visually inspected by instructor against AWS D1.1 Table 6.1; all four criteria (size within +1/4 in. -0, undercut ≤1/32 in., no overlap, uniform ripple) must pass; 100% pass required on submitted coupons. |
| 4 | Flat and Horizontal Groove Welds (1G and 2G) | 12 | lab | Students will produce a complete-joint-penetration V-groove weld on carbon steel plate in the 1G and 2G positions using a backing bar, meeting AWS D1.1 visual acceptance criteria for reinforcement, fusion, and profile. |
| CV power source, wire feeder, E71T-1C .045 in. wire, 75%Ar/25%CO2, 3/8 in. A36 plate pre-beveled to 30° per side, 3/8 in. x 1 in. backing bar stock, contact thermometer, groove weld gauge, AWS D1.1 visual acceptance criteria card, fit-up square, C-clamps, angle grinder | One 1G and one 2G groove coupon inspected by instructor; pass requires face reinforcement ≤3/16 in., no undercut exceeding D1.1 limits, complete fusion visible at toes, and no cracks; 100% pass required. |
| 5 | Vertical Fillet and Groove Welds (3F and 3G) | 14 | lab | Students will produce fillet and groove welds in the 3F and 3G positions using uphill travel technique with parameters adjusted for vertical welding, meeting AWS D1.1 visual acceptance criteria. |
| CV power source, wire feeder, E71T-1C .045 in. wire, 75%Ar/25%CO2, 3/8 in. A36 tee joint and beveled groove plate, backing bars, positioner or fixed weld table with vertical fixture, fillet gauge, groove gauge, AWS D1.1 criteria card, chipping hammer, wire brush | One 3F fillet coupon and one 3G groove coupon inspected against AWS D1.1 Table 6.1 and visual acceptance criteria; all discontinuity limits must be met; 100% pass on submitted coupons. |
| 6 | Weld Discontinuities, Causes, and Corrections | 12 | theory | Students will identify at least eight FCAW-specific discontinuities from photographs and actual weld samples, state the most likely cause for each, and specify the corrective parameter adjustment or technique change. |
| Labeled weld sample coupon set, AWS D1.1 structural code (selected sections on visual acceptance), AWS SENSE Level 1 Reference Guide chapter on discontinuities, projection screen and camera, cause-and-correction worksheet, pen and paper | 20-question written exam on discontinuity identification, causes, and corrections using photographs; pass mark 75%. |
| 7 | Welding Procedure Specifications and Quality Documentation | 10 | theory | Students will correctly read and apply a FCAW WPS, identify all essential variables listed on the document, and complete a weld traveler and visual inspection report to NCCER Welding Level 2 documentation standards. |
| Sample FCAW WPS documents, NCCER Welding Level 2 Module 29202 (or equivalent WPS/traveler section), blank weld traveler forms, visual inspection report forms, contact thermometer, pen, students' previously welded coupons | Completed weld traveler and inspection report reviewed by instructor; all required fields populated and consistent with the WPS; no essential variables missing; pass requires zero missing essential variable fields and correct WPS reference number. |
| 8 | Destructive Testing Fundamentals and Coupon Evaluation | 10 | demo | Students will perform guided bend testing and macro-etch examination on FCAW groove weld coupons and evaluate results against AWS D1.1 bend test acceptance criteria. |
| Guided bend test jig (wrapped-around or plunger type per AWS D1.1 dimensions), band saw or abrasive cutoff saw, angle grinder and polishing disc, mild acid etch solution (nital, pre-mixed by instructor), lighted magnifier or macro lens, steel rule, 1G groove weld coupons from Lesson 4, safety goggles and acid-resistant gloves, inspection forms | Students correctly classify each bend specimen as pass or fail, state the criterion applied (maximum open discontinuity ≤1/8 in.), and produce a labeled macro-etch sketch; instructor verifies classification accuracy; 100% correct classification required. |
| 9 | FCAW Certification Welding Test Preparation and Full-Position Practice | 12 | practice | Students will complete full AWS D1.1 Certified Welder test-position groove weld coupons (3G and 4G if applicable) under simulated test conditions, demonstrating compliance with all procedural and documentation requirements. |
| CV power source, wire feeder, E71T-1C .045 in. wire, 75%Ar/25%CO2, pre-beveled 3/8 in. A36 groove plate with backing bar pre-tacked, WPS document, contact thermometer, fillet and groove gauges, AWS D1.1 visual acceptance criteria card, timer, self-evaluation form | 3G groove coupon meets AWS D1.1 visual acceptance criteria (no cracks, complete fusion at toes, reinforcement within limits, undercut within limits) as assessed by instructor using the D1.1 criteria; 100% pass on all visual criteria required to complete the course at the mastery level; students who do not pass receive one remediation weld opportunity. |
| Assessment | Type | Weight | Pass standard | Method & rubric |
|---|---|---|---|---|
| FCAW Process and Theory Knowledge Exam | Written exam | 25% | 75% or higher | A 40-question written exam covering FCAW-S vs. FCAW-G process theory, AWS A5.20/A5.36 wire classification, machine parameters, shielding gas selection, discontinuity identification, and WPS interpretation. Questions are drawn from AWS SENSE Level 1 knowledge areas and NCCER Welding Level 2 content to align with credential exam domains. Standard met · Safety · Time · Quality/finish · Documentation |
| Multi-Position Skills Demonstration | Skills demonstration | 45% | All submitted coupons meet 100% of applicable AWS D1.1 visual acceptance criteria with no rejectable discontinuities | Students independently produce one 2F fillet weld coupon, one 2G groove weld coupon, and one 3G groove weld coupon under test-like conditions using a provided WPS; each coupon is inspected by a second instructor or qualified welding inspector using AWS D1.1 Table 6.1 and visual acceptance criteria as the pass standard. Standard met · Safety · Time · Quality/finish · Documentation |
| Lab Log Portfolio | Log | 15% | All nine lesson lab entries submitted; at least 80% of entries rated Complete by instructor | Students maintain a cumulative lab log throughout the course documenting machine setups (voltage, WFS, gas flow, wire type), interpass temperatures, self-inspection results, discontinuities observed, and corrective actions taken for every welding session; the log is reviewed at mid-course and at course end for completeness, accuracy, and reflective depth. Standard met · Safety · Time · Quality/finish · Documentation |
| FCAW Safety and Hazard Control Check | Safety audit | 15% | Zero critical safety errors; 100% of required PPE and LOTO steps performed correctly | An instructor observes each student performing a full station setup and pre-arc safety sequence: donning PPE (helmet shade verification, leather jacket, gloves, steel-toed boots), verifying ventilation is operating, checking the work clamp connection, and executing lockout/tagout on the power source before changing a contact tip; any step performed out of order or omitted results in an automatic remediation requirement before the student may continue welding independently. Standard met · Safety · Time · Quality/finish · Documentation |
BLD-WELD01-06 Trade course
Gas Tungsten Arc Welding (GTAW)
102 hr · $1,830 COMPLIMENTARY
Students develop hands-on proficiency in GTAW (TIG) welding on carbon steel, stainless steel, and aluminum using both DC and AC current, working from flat position through multiple positions on plate and pipe coupons. Lessons integrate arc physics, shielding gas selection, filler metal identification, and joint fit-up to meet AWS D1.1 and ASME Section IX quality standards. Safety practice, code-compliant documentation, and industry-standard visual and destructive testing prepare students for the AWS Certified Welder and NCCER Welding credential exams.
Outcomes- Set up and safely operate a GTAW power source, selecting correct polarity, amperage, and shielding gas for carbon steel, stainless steel, and aluminum base metals.
- Grind and prepare tungsten electrodes to the correct geometry for DC and AC welding and replace them using proper contamination-prevention procedures.
- Produce GTAW welds in flat, horizontal, vertical, and overhead positions on carbon steel plate that meet AWS D1.1 visual acceptance criteria.
- Weld stainless steel coupons using back-purging techniques and aluminum coupons using AC-GTAW, achieving full fusion with no porosity or tungsten inclusions visible on bend test.
- Perform guided-bend and fillet-weld break tests, interpret results against applicable code criteria, and record findings in a weld test log.
- Apply all required PPE, ventilation controls, and lockout/tagout procedures specific to GTAW operations and identify electrical shock hazards unique to high-frequency arc starting.
Course text
Students develop hands-on proficiency in GTAW (TIG) welding on carbon steel, stainless steel, and aluminum using both DC and AC current, working from flat position through multiple positions on plate and pipe coupons. Lessons integrate arc physics, shielding gas selection, filler metal identification, and joint fit-up to meet AWS D1.1 and ASME Section IX quality standards. Safety practice, code-compliant documentation, and industry-standard visual and destructive testing prepare students for the AWS Certified Welder and NCCER Welding credential exams.
How the course runs. 9 blocks: GTAW Fundamentals: Arc Physics, Equipment, and Safety; Tungsten Electrode Preparation and Torch Setup; Arc Starting, Puddle Control, and Stringer Bead on Carbon Steel (Flat); Multi-Position GTAW on Carbon Steel Plate (2G, 3G, 4G); GTAW on Stainless Steel: Filler Selection, Purging, and Sensitization Avoidance; AC-GTAW on Aluminum: Oxide Cleaning, Balance Control, and Technique; Shielding Gas, Filler Metal, and Code Documentation; Weld Discontinuities, Visual Inspection, and NDE Introduction; Certification Coupon Welding: Plate and Pipe Entry-Level Practice.
What competent looks like. Set up and safely operate a GTAW power source, selecting correct polarity, amperage, and shielding gas for carbon steel, stainless steel, and aluminum base metals. Grind and prepare tungsten electrodes to the correct geometry for DC and AC welding and replace them using proper contamination-prevention procedures. Produce GTAW welds in flat, horizontal, vertical, and overhead positions on carbon steel plate that meet AWS D1.1 visual acceptance criteria. Weld stainless steel coupons using back-purging techniques and aluminum coupons using AC-GTAW, achieving full fusion with no porosity or tungsten inclusions visible on bend test. Perform guided-bend and fillet-weld break tests, interpret results against applicable code criteria, and record findings in a weld test log. Apply all required PPE, ventilation controls, and lockout/tagout procedures specific to GTAW operations and identify electrical shock hazards unique to high-frequency arc starting.
| # | Lesson | Hr | Type | Objective | Activities | Materials | Check |
|---|---|---|---|---|---|---|---|
| 1 | GTAW Fundamentals: Arc Physics, Equipment, and Safety | 10 | theory | Students will identify the major components of a GTAW station, explain the roles of current type and polarity, and list the specific PPE and electrical-shock hazards associated with high-frequency arc starting. |
| GTAW power source (inverter type), air-cooled and water-cooled torches, foot pedal, argon regulator/flowmeter, AWS Welding Handbook Vol. 2, OSHA 1910.252 handout, shade 10–12 auto-darkening helmet, leather gloves, flame-resistant jacket | 10-question written quiz on current types, polarity, PPE requirements, and high-frequency shock controls; passing score 80%. |
| 2 | Tungsten Electrode Preparation and Torch Setup | 8 | demo | Students will select the correct tungsten electrode type and diameter for a given base metal and current, grind or ball the tip to the proper geometry, and assemble the torch cup, collet, and back cap without contaminating the electrode. |
| Dedicated bench grinder with aluminum-oxide wheel (GTAW use only), 2% ceriated and pure tungsten electrodes (1/16 in., 3/32 in., 1/8 in.), collets and cups, magnification loupe, nitrile gloves (for tungsten handling), AWS A5.12/A5.12M filler/electrode reference | Instructor inspects each finished tungsten under loupe: taper angle consistent, no longitudinal cracks, no contamination; torch assembled correctly on first unaided attempt — pass requires both criteria met. |
| 3 | Arc Starting, Puddle Control, and Stringer Bead on Carbon Steel (Flat) | 14 | lab | Students will strike a stable GTAW arc using high-frequency start, establish a molten puddle, and run straight stringer beads on carbon steel plate in the flat (1G) position with consistent width and no tungsten inclusions. |
| GTAW inverter power source, air-cooled torch, foot pedal, argon shielding gas (99.995% purity), ER70S-2 filler rod 1/16 in. and 3/32 in., 1/4-in. carbon steel plate coupons, weld gauge (Bridgeport or equivalent), stainless wire brush, chipping hammer, auto-darkening helmet shade 10 | Three consecutive 6-inch beads showing consistent width (±1/8 in.), no visible tungsten inclusions, no undercut exceeding AWS D1.1 limits, no surface porosity; instructor signs off on weld log entry — all three criteria required to pass. |
| 4 | Multi-Position GTAW on Carbon Steel Plate (2G, 3G, 4G) | 14 | practice | Students will complete groove and fillet welds on carbon steel plate coupons in horizontal, vertical, and overhead positions, meeting AWS D1.1 visual acceptance criteria and passing guided-bend tests. |
| GTAW inverter, foot pedal, argon gas, ER70S-2 filler rod, 3/8-in. and 1/2-in. carbon steel V-groove and T-joint coupons (pre-beveled), guided-bend test jig, weld gauge, angle grinder with flap disc, PPE full set | One passing guided-bend test (face or root) per position with no open defects larger than 1/8 in. in any direction per AWS D1.1; all coupons and results documented in weld log — minimum two of three positions passing required to advance. |
| 5 | GTAW on Stainless Steel: Filler Selection, Purging, and Sensitization Avoidance | 12 | lab | Students will set up a back-purge system, weld 304 stainless steel butt coupons using ER308L filler, and produce a root pass free of oxidation (sugaring) as confirmed by visual inspection of the back face. |
| GTAW inverter (DCEN), argon shielding gas, argon purge gas, ER308L filler rod 1/16 in., 304 stainless steel plate coupons (14 gauge and 1/4 in.), purge dams (heat-resistant tape), AWS A5.9 filler metal standard handout, stainless wire brushes (dedicated, not shared with carbon steel) | Back face of purged coupon shows no black oxidation (sugaring) over more than 10% of the root bead length; students correctly match filler to base metal on all three exercise scenarios — both criteria required to pass. |
| 6 | AC-GTAW on Aluminum: Oxide Cleaning, Balance Control, and Technique | 14 | lab | Students will configure an AC-capable GTAW machine for aluminum welding, adjust AC balance and frequency controls, and produce a lap or butt weld on 1/8-inch aluminum plate showing a visible bright oxide-cleaned zone and complete fusion. |
| AC/DC GTAW inverter with AC balance and frequency controls, pure or zirconiated tungsten 3/32 in., ER4043 filler rod, 1/8-in. 6061-T6 aluminum plate coupons, dedicated stainless wire brush (aluminum only), argon shielding gas, weld gauge, auto-darkening helmet shade 10 | Completed butt weld on aluminum shows a visible bright cleaning zone flanking the bead, complete fusion at both toes with no cold lap, and no porosity clusters larger than 1/16 in. diameter on surface; instructor visual acceptance required to pass. |
| 7 | Shielding Gas, Filler Metal, and Code Documentation | 10 | theory | Students will explain the effects of argon versus argon/helium shielding gas blends on arc characteristics and heat input, classify filler metals using AWS A5-series designations, and complete a sample Welding Procedure Specification (WPS) record for a GTAW application. |
| AWS A5.18, A5.9, A5.10 filler metal standard handouts, blank WPS template (AWS format), polished and etched cross-section samples of argon vs. argon-helium welds, flowmeters, AWS D1.1 structural code (relevant sections), projector/whiteboard | Written WPS completed with no more than two errors in critical variables (base metal, filler, shielding gas, position); filler metal classification drill score 80% or higher — both criteria required to pass. |
| 8 | Weld Discontinuities, Visual Inspection, and NDE Introduction | 10 | demo | Students will identify at least eight GTAW-related weld discontinuities from sample coupons and photographs, apply AWS D1.1 visual acceptance criteria to accept or reject each, and describe when liquid penetrant testing (PT) is used on GTAW welds. |
| Prepared defect coupon set (12 samples), weld gauge, magnifying glass (10×), AWS D1.1 structural code Table 6.1 handout, liquid penetrant test kit (visible dye), bright LED inspection light, inspection report forms | Discontinuity ID worksheet score 80% or higher (at least 10 of 12 correct); go/no-go decisions match instructor key on at least 5 of 6 coupons — both criteria required to pass. |
| 9 | Certification Coupon Welding: Plate and Pipe Entry-Level Practice | 10 | practice | Students will complete a full AWS Certified Welder-format GTAW test coupon in the 2G or 3G position, applying all learned technique, fit-up, and documentation practices under simulated test conditions. |
| Pre-beveled carbon steel coupons per AWS D1.1 test coupon dimensions, GTAW inverter, argon gas, ER70S-2 filler, clamps and fixturing, weld test record forms (AWS format), weld gauge, angle grinder, PPE full set | Test coupon meets all AWS D1.1 visual acceptance criteria (no cracks, porosity, undercut, or incomplete fusion visible); weld test record completed with no missing critical variable entries — both criteria required to pass lesson; coupon submitted for destructive testing in formal skills assessment. |
| Assessment | Type | Weight | Pass standard | Method & rubric |
|---|---|---|---|---|
| GTAW Written Knowledge Exam | Written exam | 25% | 75% minimum score (38 of 50 questions correct) | A 50-question multiple-choice and short-answer exam covering arc physics, polarity, tungsten electrode types and preparation, shielding gas selection, filler metal AWS classifications, GTAW discontinuities, and AWS D1.1 visual acceptance criteria. Questions are mapped to AWS SENSE L1 knowledge areas and NCCER Welding Level 2 module content. Standard met · Safety · Time · Quality/finish · Documentation |
| GTAW Skills Performance Demonstration | Skills demonstration | 45% | Coupon must pass AWS D1.1 visual inspection and guided-bend test (no open defect larger than 1/8 in. in any direction); WPS documentation complete and accurate | Student welds one V-groove butt joint in an assigned position (2G or 3G) on carbon steel plate using GTAW under test conditions, following a provided WPS; the completed coupon undergoes instructor visual inspection followed by face-and-root guided-bend testing. This assessment directly maps to the AWS D1.1 Certified Welder performance qualification and NCCER Welding Level 2 performance profile. Standard met · Safety · Time · Quality/finish · Documentation |
| GTAW Lab Welding Log | Log | 15% | All 9 lesson entries present; at least 6 entries include accept/reject decision with code reference; no missing test results | Students maintain a running weld log throughout the course recording coupon identity, base metal, filler, shielding gas, position, machine settings, visual inspection results with accept/reject decision citing the applicable AWS D1.1 criterion, and any destructive test results. The completed log is submitted at the end of the course and evaluated for completeness, accuracy, and professional documentation quality. Standard met · Safety · Time · Quality/finish · Documentation |
| GTAW Safety and Station Setup Check | Safety audit | 15% | Zero critical errors (any missed lockout/tagout step, missing PPE, or incorrect ventilation setup is an automatic fail regardless of other performance); all 12 checklist items correct | Before the final skills demonstration, each student performs a complete GTAW station setup from a de-energized state while the instructor evaluates using a 12-item checklist covering lockout/tagout of the power source, PPE donning sequence, ventilation confirmation, argon cylinder securing and regulator installation, high-frequency arc-start precautions, and tungsten contamination disposal per applicable SDS guidance. Standard met · Safety · Time · Quality/finish · Documentation |
BLD-WELD01-07 Trade course
Blueprint Reading & Welding Symbols
102 hr · $1,830 COMPLIMENTARY
Students develop the ability to read and interpret structural and fabrication drawings, applying AWS A2.4 standard welding symbols to plan and execute weld joints accurately. The course covers orthographic projection, section views, bill of materials, tolerancing, and the full set of welding symbol elements used on structural steel and pipe drawings. Lessons map directly to the drawing-interpretation competencies required for AWS D1.1 Certified Welder, NCCER Welding Levels 1–4, and AWS SENSE L1–2 written examinations.
Outcomes- Interpret orthographic, sectional, and auxiliary views on structural fabrication drawings to identify geometry, dimensions, and tolerances.
- Decode complete AWS A2.4 welding symbols — including weld type, size, length, pitch, groove angle, root opening, backing, and finish — and translate them into a joint setup plan.
- Read a bill of materials, title block, and revision block to verify material specifications and drawing revision status before beginning work.
- Apply geometric dimensioning and tolerancing (GD&T) fundamentals to confirm fit-up requirements are within acceptable limits.
- Sketch a freehand weld detail with a correct AWS A2.4 welding symbol from a verbal or written joint description.
- Identify discrepancies, missing information, and weld symbol errors on a drawing and document a formal request for information (RFI) in writing.
Course text
Students develop the ability to read and interpret structural and fabrication drawings, applying AWS A2.4 standard welding symbols to plan and execute weld joints accurately. The course covers orthographic projection, section views, bill of materials, tolerancing, and the full set of welding symbol elements used on structural steel and pipe drawings. Lessons map directly to the drawing-interpretation competencies required for AWS D1.1 Certified Welder, NCCER Welding Levels 1–4, and AWS SENSE L1–2 written examinations.
How the course runs. 9 blocks: Drawing Fundamentals: Orthographic Projection and Views; Title Blocks, Revision Blocks, and Bills of Materials; Dimensions, Tolerances, and GD&T Basics; Section Views and Detail Views; AWS A2.4 Welding Symbols — Core Elements; AWS A2.4 Welding Symbols — Groove and Pipe Details; Reading Structural Steel Drawings — Integrated Practice; Field Sketching, Redlines, and Requests for Information; Applied Blueprint Reading — Credential Exam Simulation.
What competent looks like. Interpret orthographic, sectional, and auxiliary views on structural fabrication drawings to identify geometry, dimensions, and tolerances. Decode complete AWS A2.4 welding symbols — including weld type, size, length, pitch, groove angle, root opening, backing, and finish — and translate them into a joint setup plan. Read a bill of materials, title block, and revision block to verify material specifications and drawing revision status before beginning work. Apply geometric dimensioning and tolerancing (GD&T) fundamentals to confirm fit-up requirements are within acceptable limits. Sketch a freehand weld detail with a correct AWS A2.4 welding symbol from a verbal or written joint description. Identify discrepancies, missing information, and weld symbol errors on a drawing and document a formal request for information (RFI) in writing.
| # | Lesson | Hr | Type | Objective | Activities | Materials | Check |
|---|---|---|---|---|---|---|---|
| 1 | Drawing Fundamentals: Orthographic Projection and Views | 10 | theory | Students will correctly identify and label the six standard orthographic views and read a three-view drawing to determine the shape of a structural steel component. |
| Drafting pencils, engineer's scale, graph paper, wooden block models, sample structural fabrication drawings (structural steel category), AWS Welding Handbook Vol. 1 (reference), NCCER Welding Level 2 Module 29201 (textbook) | Students correctly identify and label all views on a three-view drawing exercise; pass mark is 80% on the view-identification worksheet. |
| 2 | Title Blocks, Revision Blocks, and Bills of Materials | 8 | theory | Students will extract part numbers, material specifications, drawing scale, revision status, and required quantities from a title block and bill of materials on a structural fabrication drawing. |
| Printed full-size structural drawings (minimum five unique drawings), highlighters, NCCER Welding Level 2 Module 29201, AWS D1.1 Structural Welding Code — Steel (reference copy) | Students complete the scavenger-hunt exercise with 80% accuracy on all data fields extracted; instructor reviews each sheet. |
| 3 | Dimensions, Tolerances, and GD&T Basics | 10 | theory | Students will read linear, angular, and basic GD&T dimensions on a fabrication drawing and determine whether a measured part is within tolerance. |
| Steel rule (1/32 in. graduated), combination square, five pre-cut steel coupons with corresponding dimension drawing, GD&T symbol reference chart, NCCER Welding Level 2 Module 29201 | Accept/reject decision is correct for at least 4 of 5 coupons; GD&T matching exercise scored at 80% or better. |
| 4 | Section Views and Detail Views | 10 | demo | Students will interpret full-section, half-section, and removed-section views to determine internal joint geometry and groove dimensions on weld joint details. |
| Foam joint models, cutting-plane demonstration set, section-view drawing packet (five drawings), drafting pencils, answer key, NCCER Welding Level 2 Module 29201 | Students correctly identify the section type, joint type, and all labeled dimensions on at least 4 of 5 drawings; reviewed by instructor against answer key. |
| 5 | AWS A2.4 Welding Symbols — Core Elements | 14 | theory | Students will decode the reference line, arrow side vs. other side, tail, weld symbol, and basic supplementary symbols on any AWS A2.4 welding symbol and translate them into a written joint description. |
| AWS A2.4 Standard Symbols for Welding, Brazing, and Nondestructive Examination (current edition — student reference copies), laminated symbol poster, 30-card flash card set, structural detail drawings, NCCER Welding Level 2 Module 29201 | Students correctly decode at least 24 of 30 flash cards and correctly write symbols for at least 4 of 5 structural details; instructor verifies against AWS A2.4. |
| 6 | AWS A2.4 Welding Symbols — Groove and Pipe Details | 14 | theory | Students will read complete groove-weld symbols including groove angle, root opening, root face, weld size, effective throat, and contour/finish symbols as used on pipe and structural drawings. |
| AWS A2.4 (current edition), isometric pipe-spool drawings (five sheets), pipe joint symbol sketch sheets, whiteboard, ASME Section IX reference (for pipe joint qualification context), NCCER Welding Level 4 Module 29401 | Weld data tables are complete and accurate for at least 4 of 5 pipe drawings; symbol sketches pass instructor review against AWS A2.4 at 80% accuracy. |
| 7 | Reading Structural Steel Drawings — Integrated Practice | 14 | lab | Students will read a multi-sheet structural steel fabrication drawing package and produce a complete weld plan listing every joint, its welding symbol interpretation, required process, and fit-up dimensions. |
| Four-sheet structural steel fabrication drawing package, weld plan forms, AWS D1.1 (reference for joint design tables), AWS A2.4, engineer's scale, highlighters | Weld plan accounts for all joints on the drawing and decodes each welding symbol correctly; instructor scores at 80% accuracy minimum using a completed answer key. |
| 8 | Field Sketching, Redlines, and Requests for Information | 12 | practice | Students will produce a legible freehand field sketch with correct AWS A2.4 welding symbols and write a formal request for information (RFI) when drawing information is ambiguous or missing. |
| Printed structural drawings for markup, red pens, blank sketch paper, assembled steel T-joint specimens, AWS A2.4, RFI form template (contractor-standard format), NCCER Welding Level 2 Module 29201 | RFI clearly identifies the discrepancy and references the drawing sheet and detail number; field sketch includes all required AWS A2.4 elements; both graded at 80% or better. |
| 9 | Applied Blueprint Reading — Credential Exam Simulation | 10 | practice | Students will demonstrate full blueprint-reading and welding-symbol competency under timed, exam-like conditions aligned to NCCER Welding and AWS SENSE L1–2 written exam formats. |
| 40-question practice exam (instructor-developed, aligned to NCCER Welding Module 29201 objectives and AWS SENSE Level 1 blueprint-reading objectives), physical weld specimens (eight), welding symbol card set, AWS A2.4, answer keys | Students must score 70% or higher on the written exam and correctly match at least 6 of 8 specimens; students below 70% are flagged for targeted review in the Certification Exam Preparation course. |
| Assessment | Type | Weight | Pass standard | Method & rubric |
|---|---|---|---|---|
| Blueprint Reading Written Examination | Written exam | 25% | 70% or higher (28 of 40 questions correct) | A 40-question closed-book exam covering orthographic projection, title blocks and revision blocks, bill of materials, section and detail views, GD&T basics, and the full AWS A2.4 welding symbol system including groove, fillet, and pipe symbols. Questions are written to the difficulty level and topic distribution of the NCCER Welding written assessments and the AWS SENSE L1–2 knowledge exam to provide direct credential-prep value. Standard met · Safety · Time · Quality/finish · Documentation |
| Welding Symbol Decoding Skills Demonstration | Skills demonstration | 45% | Correct written interpretation and joint setup plan for at least 8 of 10 symbols; any life-safety or code-critical error (wrong joint type on a structural connection) requires a full retake | The instructor presents 10 complete AWS A2.4 welding symbols drawn from structural steel and pipe-spool drawings; the student writes a plain-English joint description and a fit-up parameter table (joint type, weld size, groove angle, root opening, finish, and any supplementary symbol meaning) for each symbol within a 45-minute period. Scoring follows the AWS A2.4 standard as the answer key. Standard met · Safety · Time · Quality/finish · Documentation |
| Blueprint Reading Lab Log | Log | 15% | All nine lesson entries present and complete; at least seven entries rated Satisfactory or above by instructor; no entry may be rated Unsatisfactory for safety or code compliance fields | Students maintain a lab log throughout the course recording the drawing package reviewed in each lesson, the specific views and symbols encountered, any ambiguities found and how they were resolved, and a self-assessment of their interpretation confidence. Entries are reviewed by the instructor at mid-course (after Lesson 5) and at course end, providing a portfolio of blueprint-reading practice that supports NCCER Registry documentation. Standard met · Safety · Time · Quality/finish · Documentation |
| Drawing Discrepancy and RFI Safety Check | Safety audit | 15% | Student must identify all three seeded safety-critical drawing discrepancies and correctly complete the RFI for each; any missed safety-critical discrepancy is an automatic fail requiring remediation and recheck | The instructor provides a drawing package containing three intentionally seeded errors: one structural weld symbol that under-sizes a fillet on a load-bearing joint, one conflicting dimension that would cause misfit in a pressure-boundary pipe joint, and one missing preheat note on a high-carbon-equivalent material. The student must identify, document, and formally communicate each discrepancy using RFI protocol before they would be permitted to weld — simulating the real-world gate check that protects worker and public safety. Standard met · Safety · Time · Quality/finish · Documentation |
BLD-WELD01-08 Trade course
Metallurgy for Structural and Pipe Welding
102 hr · $1,830 COMPLIMENTARY
This course develops the metallurgical knowledge welders need to select base metals, filler metals, and heat-input parameters that produce sound, code-compliant welds in structural steel and pipe applications. Students learn how steel composition, microstructure, heat treatment, and weld thermal cycles interact to cause or prevent common defects such as hydrogen cracking, porosity, and distortion. Content maps directly to the metallurgy and materials knowledge domains tested by AWS D1.1 Certified Welder, AWS SENSE L1-2, NCCER Welding Levels 1–4, and ASME Section IX qualification.
Outcomes- Identify the principal alloying elements in carbon and low-alloy steels and explain each element's effect on weldability and mechanical properties.
- Read and interpret a simplified iron-carbon phase diagram to predict microstructural changes during welding heat cycles in the heat-affected zone.
- Select a compatible filler metal and preheat temperature for a given base-metal chemistry and carbon equivalent, using AWS and ASME reference tables.
- Explain how heat input, cooling rate, and post-weld heat treatment affect grain structure, hardness, and susceptibility to hydrogen-induced cracking.
- Diagnose weld discontinuities—including porosity, cracking, undercut, and incomplete fusion—by linking each to its metallurgical or procedural root cause.
- Demonstrate safe handling of Mill Test Reports (MTRs), preheat equipment, and hydrogen-controlled electrodes in accordance with AWS D1.1 and OSHA requirements.
Course text
This course develops the metallurgical knowledge welders need to select base metals, filler metals, and heat-input parameters that produce sound, code-compliant welds in structural steel and pipe applications. Students learn how steel composition, microstructure, heat treatment, and weld thermal cycles interact to cause or prevent common defects such as hydrogen cracking, porosity, and distortion. Content maps directly to the metallurgy and materials knowledge domains tested by AWS D1.1 Certified Welder, AWS SENSE L1-2, NCCER Welding Levels 1–4, and ASME Section IX qualification.
How the course runs. 9 blocks: Metals in Construction: Classification, Mill Test Reports, and Safe Handling; Atomic Structure, Crystal Lattices, and the Iron-Carbon System; The Weld Thermal Cycle: HAZ Formation, Grain Growth, and Cooling Rate; Carbon Equivalent and Preheat: Preventing Hydrogen-Induced Cracking; Filler Metal Selection: Chemistry, Hydrogen Designators, and Storage; Weld Discontinuities: Metallurgical Root Causes and Code Acceptance Criteria; Stainless Steel, Chrome-Moly, and Non-Ferrous Metals in Construction; Heat Treatment: Preheat, Interpass Temperature Control, and PWHT; Integrated Metallurgy Case Study: Welding Procedure Review and Defect Prevention Plan.
What competent looks like. Identify the principal alloying elements in carbon and low-alloy steels and explain each element's effect on weldability and mechanical properties. Read and interpret a simplified iron-carbon phase diagram to predict microstructural changes during welding heat cycles in the heat-affected zone. Select a compatible filler metal and preheat temperature for a given base-metal chemistry and carbon equivalent, using AWS and ASME reference tables. Explain how heat input, cooling rate, and post-weld heat treatment affect grain structure, hardness, and susceptibility to hydrogen-induced cracking. Diagnose weld discontinuities—including porosity, cracking, undercut, and incomplete fusion—by linking each to its metallurgical or procedural root cause. Demonstrate safe handling of Mill Test Reports (MTRs), preheat equipment, and hydrogen-controlled electrodes in accordance with AWS D1.1 and OSHA requirements.
| # | Lesson | Hr | Type | Objective | Activities | Materials | Check |
|---|---|---|---|---|---|---|---|
| 1 | Metals in Construction: Classification, Mill Test Reports, and Safe Handling | 10 | theory | Given a sample Mill Test Report and ASTM/AISI designation list, the student correctly identifies base-metal type, chemical composition limits, and minimum mechanical properties for at least four structural steel grades. |
| Sample MTRs (A36, A572-50, A514, A53-B pipe), ASTM A6 and A370 standard excerpts, AWS B2.1 base-metal grouping table, AISI steel designation chart, SDS binders, instructor-prepared classification card sets | Exit quiz of 15 questions on designation systems, MTR reading, and SDS interpretation; 12 of 15 correct (80%) required to advance. |
| 2 | Atomic Structure, Crystal Lattices, and the Iron-Carbon System | 12 | theory | Using a labeled iron-carbon phase diagram, the student correctly identifies phase regions, critical transformation temperatures, and the microstructures that form during slow cooling for steels ranging from 0.10% to 0.80% carbon. |
| Iron-carbon phase diagram poster and reproducible blank worksheet, Lincoln Electric Welding Metallurgy reference guide (or equivalent), digital photomicrographs of steel microstructures, scientific calculator | Labeled diagram reproduced from memory with all required regions and temperatures correct; quiz on microstructure-property relationships; 80% minimum on combined 20-question assessment. |
| 3 | The Weld Thermal Cycle: HAZ Formation, Grain Growth, and Cooling Rate | 12 | demo | The student explains how peak temperature and cooling rate in each HAZ sub-zone produce specific microstructures, and calculates heat input for a given amperage, voltage, and travel speed using the standard AWS heat-input formula. |
| Welding power source with calibrated meters, A36 plate coupons, thermocouple or contact thermometer, weld cross-section macrograph set, AWS D1.1 Structural Welding Code excerpt, calculator, lab notebooks | Student correctly calculates heat input for three given parameter sets (all three within ±5% of instructor answer) and correctly labels all four HAZ sub-zones on a macrograph with no more than one error. |
| 4 | Carbon Equivalent and Preheat: Preventing Hydrogen-Induced Cracking | 12 | lab | Given base-metal chemistry from an MTR, the student calculates carbon equivalent using the IIW formula and selects a minimum preheat temperature consistent with AWS D1.1 guidance for the applicable thickness range. |
| MTRs for four steel grades, IIW CE formula reference card, AWS D1.1 preheat table excerpt, propane rosebud torch or induction preheat blanket, calibrated contact thermometer, temperature-indicating sticks (Tempilstik), 1-in. A572-50 plate coupons, PPE (leather gloves, face shield, welding jacket), lab notebooks | All four CE calculations correct within ±0.01; correct preheat temperature selected for each thickness; preheat verification documented in lab notebook with temperature confirmed by instructor sign-off before welding begins. No pass without instructor preheat sign-off (safety gate). |
| 5 | Filler Metal Selection: Chemistry, Hydrogen Designators, and Storage | 11 | theory | Using AWS filler metal classification charts, the student selects a compatible electrode or wire for a given base metal and service condition, and explains the handling and storage requirements for low-hydrogen electrodes. |
| AWS A5.1, A5.18, A5.20, A5.9, and A5.5 filler metal specification excerpts, electrode holding oven, E7018-H4R and E6010 electrodes, filler metal selection matrix worksheet, rod-log form, digital thermometer | All five electrode classifications fully and correctly decoded; filler metal selection matrix completed with correct specification cited for each scenario; rod-log entry verified by instructor. Score 80% or better on a 20-question written check. |
| 6 | Weld Discontinuities: Metallurgical Root Causes and Code Acceptance Criteria | 12 | lab | The student identifies at least six types of weld discontinuities in sectioned or macro-etched coupons, states the metallurgical or procedural cause of each, and applies a simplified AWS D1.1 visual acceptance criterion to determine accept or reject. |
| Set of 8 macro-etched weld cross-section samples, visual inspection kit (fillet and undercut gauges, steel scale, 10× loupe), AWS D1.1 simplified visual acceptance criteria handout, root-cause analysis worksheet, lab notebooks | Correct identification of discontinuity type and cause on at least 6 of 8 samples; accept/reject decisions on physical coupons match instructor key with no more than one error; root-cause analysis demonstrates correct metallurgical reasoning on all three samples. 80% overall. |
| 7 | Stainless Steel, Chrome-Moly, and Non-Ferrous Metals in Construction | 11 | theory | The student compares the weldability challenges of austenitic stainless steel (sensitization), chrome-moly (PWHT requirements), and aluminum (oxide layer, hot cracking) and selects correct PPE and ventilation controls for each. |
| OSHA Hexavalent Chromium standard fact sheet, AWS D1.6 and D1.2 summary excerpts, comparison table worksheet, scenario problem set, half-face respirator and P100/OV cartridge for demonstration | Comparison table complete and accurate for all three material families; OSHA Cr-VI controls correctly listed; all three scenario problems answered correctly with metallurgical reasoning. 80% minimum. |
| 8 | Heat Treatment: Preheat, Interpass Temperature Control, and PWHT | 11 | demo | The student demonstrates verification and control of preheat, interpass temperature, and simulated post-weld heat treatment (PWHT) parameters on a structural steel weld, and documents the thermal record on a standard heat-treatment log. |
| Resistance heating blanket or propane rosebud torch, calibrated contact thermometer, temperature-indicating sticks, 1.5-in. A572-50 plate coupons, SMAW power source, E7018-H4R electrodes, heat-treatment log form, ASME Section IX PWHT requirements excerpt, PPE (welding jacket, gloves, face shield) | Preheat verified and documented before welding begins (safety gate—instructor signature required); interpass temperature recorded for each pass; PWHT log completed correctly with all fields filled. Instructor signs thermal record. Any missed temperature check = automatic redo of station. |
| 9 | Integrated Metallurgy Case Study: Welding Procedure Review and Defect Prevention Plan | 11 | lab | Working from a provided Welding Procedure Specification (WPS) and MTR, the student produces a written defect-prevention plan that specifies filler metal, preheat, heat input range, interpass limits, inspection hold points, and PWHT decision, and defends it orally to the instructor. |
| Instructor-prepared WPS package, MTR, AWS D1.1 simplified acceptance criteria handout, IIW CE formula card, filler metal selection chart, defect-prevention plan template, lab notebook | CE calculation correct; preheat adequately justified; all five risk items identified with correct controls; oral defense answers technically sound; final plan revised per feedback. Instructor scores on a rubric with 80% minimum. Unsatisfactory oral defense requires one resubmission within one week. |
| Assessment | Type | Weight | Pass standard | Method & rubric |
|---|---|---|---|---|
| Metallurgy Knowledge Exam | Written exam | 25% | 75% (30 of 40 questions correct) | A 40-question written exam covering steel designation systems, the iron-carbon phase diagram, HAZ sub-zones, CE calculation, filler metal classification, discontinuity identification, and PWHT principles; mapped to the metallurgy and materials knowledge domains of AWS SENSE L1-2, NCCER Welding, and ASME Section IX welder qualification content areas. Students have 90 minutes; two retake attempts are permitted with a minimum 24-hour interval between attempts. Standard met · Safety · Time · Quality/finish · Documentation |
| Preheat and Interpass Temperature Skills Demonstration | Skills demonstration | 45% | All four competency gates achieved; any single gate failure requires full redo of the station | Each student individually sets up preheat for a provided steel coupon, calculates and verifies the correct minimum preheat temperature from the MTR and IIW CE, measures and records interpass temperature between two weld passes using a calibrated contact thermometer, and completes the heat-treatment log; the instructor evaluates using a four-gate checklist (correct CE calculation, correct preheat temperature achieved and verified before welding, interpass temperature within specified limits on every pass, log fully completed) and must sign the log before the student may proceed to the capstone. Standard met · Safety · Time · Quality/finish · Documentation |
| Lab Notebook and Defect-Prevention Plan Portfolio | Log | 15% | 80% on instructor rubric covering completeness, technical accuracy, and professional presentation | The student submits all nine lesson lab notebook entries plus the final integrated defect-prevention plan from Lesson 9; the rubric evaluates accuracy of calculations and sketches, completeness of data records, correct use of trade terminology, and evidence that findings were used to make or support a welding procedure decision, reflecting the documentation practices expected under AWS D1.1 and ASME Section IX. Standard met · Safety · Time · Quality/finish · Documentation |
| Metallurgy Safety Check | Safety audit | 15% | 100% on all safety behaviors; any failure is immediate and requires remediation before returning to the lab | Instructor uses a binary (present/absent) safety observation checklist during Lessons 4 and 8 to verify that the student: confirms SDS location before handling new base or filler metals; inspects and dons correct PPE (welding jacket, gloves, face shield) before any heat source is activated; obtains instructor preheat sign-off before striking an arc; uses local exhaust ventilation or supplied-air respirator when welding stainless steel; and stores low-hydrogen electrodes in the holding oven with a completed rod-log entry. All items must be observed as satisfactory—this assessment is a program-level safety gate aligned with OSHA general industry and construction standards. Standard met · Safety · Time · Quality/finish · Documentation |
BLD-WELD01-09 Trade course
Oxy-fuel & Plasma Cutting
102 hr · $1,830 COMPLIMENTARY
Students develop safe, accurate cutting skills using oxy-fuel and plasma arc equipment on structural steel, pipe, and plate in positions and joint configurations required by AWS D1.1 and NCCER Welding curricula. Instruction covers equipment setup, gas chemistry, kerf control, heat management, and post-cut finishing to industry-accepted tolerances. Emphasis on compressed-gas and electrical hazards, lockout/tagout, and fire prevention establishes safety habits transferable to every subsequent course.
Outcomes- Set up, light, adjust, and safely shut down oxy-fuel cutting equipment following CGA and manufacturer procedures with zero observed safety violations.
- Produce straight, bevel, and pierced oxy-fuel cuts on carbon steel plate within ±1/8 in. dimensional tolerance and AWS D1.1 surface quality expectations.
- Set up and operate a plasma arc cutting system on carbon steel, stainless steel, and aluminum, achieving clean kerf edges within ±1/8 in. tolerance.
- Select correct tip size, gas pressures, travel speed, and amperage for material type and thickness using published cutting charts.
- Identify and correct common cutting defects—excessive slag, gouging, wandering kerf, and incomplete separation—by adjusting process variables.
- Comply with OSHA general industry standards for compressed gases, ventilation, PPE, and fire watch when performing all cutting operations.
Course text
Students develop safe, accurate cutting skills using oxy-fuel and plasma arc equipment on structural steel, pipe, and plate in positions and joint configurations required by AWS D1.1 and NCCER Welding curricula. Instruction covers equipment setup, gas chemistry, kerf control, heat management, and post-cut finishing to industry-accepted tolerances. Emphasis on compressed-gas and electrical hazards, lockout/tagout, and fire prevention establishes safety habits transferable to every subsequent course.
How the course runs. 9 blocks: Compressed-Gas Safety, Equipment Identification, and Hazard Controls; Oxy-fuel Equipment Setup, Gas Pressures, and Leak Testing; Lighting, Flame Adjustment, and Safe Shutdown; Straight-Line and Shape Cutting on Carbon Steel Plate; Piercing, Beveling, and Structural Layout Cuts; Plasma Arc Cutting: Equipment, Setup, and Process Principles; Plasma Cutting Practice on Carbon Steel, Stainless, and Aluminum; Cutting Defects: Identification, Causes, and Corrective Action; Fire Prevention, Ventilation, Post-Cut Cleanup, and Lab Proficiency Review.
What competent looks like. Set up, light, adjust, and safely shut down oxy-fuel cutting equipment following CGA and manufacturer procedures with zero observed safety violations. Produce straight, bevel, and pierced oxy-fuel cuts on carbon steel plate within ±1/8 in. dimensional tolerance and AWS D1.1 surface quality expectations. Set up and operate a plasma arc cutting system on carbon steel, stainless steel, and aluminum, achieving clean kerf edges within ±1/8 in. tolerance. Select correct tip size, gas pressures, travel speed, and amperage for material type and thickness using published cutting charts. Identify and correct common cutting defects—excessive slag, gouging, wandering kerf, and incomplete separation—by adjusting process variables. Comply with OSHA general industry standards for compressed gases, ventilation, PPE, and fire watch when performing all cutting operations.
| # | Lesson | Hr | Type | Objective | Activities | Materials | Check |
|---|---|---|---|---|---|---|---|
| 1 | Compressed-Gas Safety, Equipment Identification, and Hazard Controls | 10 | theory | Students identify every major component of oxy-fuel and plasma cutting systems and state the applicable OSHA compressed-gas, fire, and electrical safety requirements before touching any equipment. |
| Oxygen and acetylene cylinders (secured, not in use), plasma cutting unit, AWS Safety & Health Fact Sheets, OSHA 29 CFR 1910.253 summary handout, component-labeling worksheet, whiteboard. | Scored component-identification quiz: students correctly label ≥90% of diagram items and answer all six safety scenario questions correctly; any missed fire or electrical hazard question requires immediate re-teach before lab access. |
| 2 | Oxy-fuel Equipment Setup, Gas Pressures, and Leak Testing | 12 | demo | Students assemble an oxy-fuel cutting outfit, set working pressures from a manufacturer cutting chart, and verify a leak-free system using approved soapy-water method before ignition. |
| Oxy-acetylene outfit (cylinders, dual regulators, hoses, torch, cutting tips sizes 0–3), manufacturer cutting-tip chart, leak-test solution, open-end wrenches, setup checklist, PPE (shade 5 goggles, leather gloves, leather jacket). | Instructor checklist: all eight setup steps completed in correct order, pressures within ±2 psi of chart value, zero leaks confirmed before sign-off; any safety step skipped restarts the entire sequence—pass requires 100% checklist completion. |
| 3 | Lighting, Flame Adjustment, and Safe Shutdown | 10 | demo | Students light an oxy-fuel torch, adjust it to a neutral cutting flame, and execute a safe shutdown sequence without supervision errors. |
| Oxy-acetylene outfit, striker (flint type), flame-type reference photograph cards, shutdown checklist, PPE as above, fire extinguisher within reach, fire watch bucket. | Instructor direct observation: neutral flame achieved within 60 seconds of lighting on three consecutive attempts; shutdown sequence completed in correct order with zero steps missed on three consecutive attempts—any missed step requires additional practice before proceeding. |
| 4 | Straight-Line and Shape Cutting on Carbon Steel Plate | 14 | lab | Students produce straight oxy-fuel cuts and template-guided shape cuts on 1/4 in. and 3/8 in. carbon steel plate within ±1/8 in. dimensional tolerance with slag removed. |
| Oxy-acetylene cutting outfit, 1/4 in. and 3/8 in. A36 plate stock, soapstone markers, steel rule, magnetic circle guide, 45-degree bevel guide, angle grinder with grinding and flap discs, protractor, steel square, measuring tape, lab log booklet, PPE (shade 5 goggles, leather jacket, leather gloves, steel-toed boots). | Each completed cut is measured by instructor: dimensional deviation ≤1/8 in. at all check points, cut face free of gross gouging, all slag removed before measurement; students must pass 4 of 5 cuts to advance—failing students repeat the activity before Lesson 5. |
| 5 | Piercing, Beveling, and Structural Layout Cuts | 12 | lab | Students execute preheat-and-pierce entries and cut compound shapes and bevels representative of structural fabrication prep work to D1.1 fit-up quality. |
| Oxy-acetylene outfit, 3/8 in. and 1/2 in. A36 plate, soapstone, steel rule, cardboard template, angle grinder, weld gauge (Gage-It or equivalent), PPE as above. | Instructor inspection with weld gauge: bevel angle within ±2.5 degrees, root face within ±1/16 in., no undercut gouging deeper than 1/16 in. on any cut face; all three cut types must pass to move to plasma lessons. |
| 6 | Plasma Arc Cutting: Equipment, Setup, and Process Principles | 10 | theory | Students explain the plasma arc cutting process, identify power-supply, torch, consumable, and gas-supply components, and set machine parameters from a manufacturer cutting chart for three material types. |
| Plasma cutting unit (air-plasma, 40–60 A class), manufacturer operator manual and parameter chart, fill-in diagram worksheet, parameter-selection worksheet, whiteboard, projector. | Parameter-selection worksheet scored by instructor: all nine parameter cells (three materials × three parameters) correct within the chart's listed range—score ≥8/9 required; students who score below re-read the manual section and retest on an alternate worksheet. |
| 7 | Plasma Cutting Practice on Carbon Steel, Stainless, and Aluminum | 14 | lab | Students produce plasma arc cuts on carbon steel, stainless steel, and aluminum to within ±1/8 in. dimensional tolerance with minimal dross, demonstrating correct travel speed and standoff distance. |
| Air-plasma cutting unit, 1/4 in. A36 plate, 1/8 in. 304 stainless plate, 1/8 in. 6061 aluminum plate, steel rule, angle grinder, dross chisel, PPE (auto-darkening helmet shade 7–9 for plasma, leather gloves, hearing protection, respiratory protection—local exhaust ventilation required for stainless), lab log. | Instructor measures all cut samples: dimensional deviation ≤1/8 in., dross removable without grinding on carbon steel and aluminum samples, cut face not re-welded on stainless sample; students must pass cuts on all three materials to complete the lesson. |
| 8 | Cutting Defects: Identification, Causes, and Corrective Action | 10 | practice | Students diagnose cutting defects on provided samples and intentionally produced specimens, state the process-variable cause, and apply a corrective adjustment that eliminates the defect within two attempts. |
| Pre-cut defect sample set (oxy-fuel and plasma), blank defect-identification chart, oxy-acetylene outfit, plasma cutting unit, A36 plate coupons, cutting charts, PPE as above, lab log. | Defect-identification chart scored: ≥8/10 defects correctly identified with plausible cause and corrective action; before/after cut pair shows measurable improvement confirmed by instructor measurement—both elements must pass. |
| 9 | Fire Prevention, Ventilation, Post-Cut Cleanup, and Lab Proficiency Review | 10 | field | Students conduct a pre-work fire watch setup, complete a timed combined oxy-fuel and plasma cutting proficiency exercise, and perform a compliant post-shift equipment shutdown and area inspection. |
| Oxy-acetylene outfit, plasma cutting unit, A36 plate stock, stainless coupon, fire extinguisher (CO₂ or dry chemical, appropriate class), fire watch checklist, proficiency scorecard, area-clearance checklist, PPE as above, AWS Safety & Health Fact Sheets. | Proficiency scorecard: all three cuts within ±1/8 in. tolerance; fire watch checklist and area-clearance checklist 100% complete with instructor signature—any missed safety item on either checklist fails the lesson and triggers immediate re-instruction before the skills demonstration assessment. |
| Assessment | Type | Weight | Pass standard | Method & rubric |
|---|---|---|---|---|
| Written Knowledge Exam | Written exam | 25% | 75% or higher; students scoring below 75% receive targeted re-instruction and may retake one alternate-form exam | A 50-question multiple-choice and short-answer exam covering oxy-fuel and plasma process theory, gas identification and hazard controls, equipment components, flame types, parameter selection from cutting charts, defect identification, and applicable OSHA compressed-gas and fire-prevention requirements. Questions are mapped to NCCER Welding Module knowledge checks and AWS SENSE L1 academic standards. Standard met · Safety · Time · Quality/finish · Documentation |
| Cutting Skills Demonstration | Skills demonstration | 45% | All four cuts must meet dimensional tolerance (±1/8 in.) and surface quality criteria; one re-test of a failed cut is permitted after additional practice | Each student independently completes four timed cuts without instructor assistance: (1) a straight oxy-fuel cut on 3/8 in. carbon steel plate, (2) a 45-degree bevel on 1/2 in. carbon steel plate, (3) a plasma straight cut on 1/4 in. carbon steel, and (4) a plasma cut on 1/8 in. aluminum. An instructor uses a weld gauge and steel rule to measure each cut against AWS D1.1 workmanship and NCCER performance profile criteria. Standard met · Safety · Time · Quality/finish · Documentation |
| Lab Log Portfolio | Log | 15% | Minimum score of 80% on the scoring rubric; incomplete entries must be corrected before the portfolio is accepted | Students submit their completed lab log covering all practice lessons: each entry must include date, material type and thickness, process used, machine parameters or gas pressures, a sketch or photograph of the cut, a dimensional measurement, a defect description (or 'none observed'), and a corrective action note where applicable. Entries are scored on completeness, accuracy of recorded parameters, and quality of self-assessment commentary using a four-criterion rubric. Standard met · Safety · Time · Quality/finish · Documentation |
| Safety Compliance Check | Safety audit | 15% | 100% on all critical safety behaviors; any critical item failure (PPE not worn, fire watch not established, leak test skipped) results in immediate removal from the lab and a mandatory safety conference before re-entry | An instructor observes each student during an unannounced 15-minute cutting session and scores 20 observable safety behaviors using a binary (yes/no) checklist: PPE selection and donning, cylinder securing, hose and regulator condition check, purge procedure, leak test, fire watch setup, appropriate ventilation confirmed, correct shutdown sequence, and post-cut area inspection. All 20 items must be marked 'yes' to pass. Standard met · Safety · Time · Quality/finish · Documentation |
BLD-WELD01-10 Trade course
Pipe Welding
102 hr · $1,830 COMPLIMENTARY
Students apply SMAW, GTAW, and FCAW processes to carbon-steel pipe in the 1G, 2G, 5G, and 6G positions, progressing from open-root groove preparation through cap passes on schedule-80 pipe. Instruction is grounded in AWS D1.1 structural welding requirements and ASME Section IX welder-qualification variables so that students are prepared to sit both the AWS D1.1 Certified Welder test and an ASME Section IX pipe-qualification test. Safety practice throughout follows OSHA 29 CFR 1910 confined-space and hot-work requirements and AWS Z49.1 fume-control standards.
Outcomes- Prepare pipe ends by grinding, beveling, and fitting up joints to dimensional tolerances required by ASME Section IX and AWS D1.1 weld procedure specifications.
- Deposit sound open-root and fill/cap passes on 2-inch through 6-inch schedule-80 carbon-steel pipe in the 1G, 2G, 5G, and 6G positions using SMAW and GTAW root/SMAW fill-and-cap procedures.
- Interpret weld procedure specifications (WPS) and select correct amperage, polarity, travel speed, and filler metal for each pipe position and process.
- Visually inspect completed pipe welds against AWS D1.1 visual acceptance criteria and identify common discontinuities including lack of fusion, incomplete penetration, porosity, and undercut.
- Apply OSHA hot-work permits, confined-space entry procedures, lockout/tagout, and respiratory protection requirements to pipe welding environments.
- Document heat-input calculations, WPS compliance records, and welder qualification test records in formats consistent with ASME Section IX PQR and WQR paperwork.
Course text
Students apply SMAW, GTAW, and FCAW processes to carbon-steel pipe in the 1G, 2G, 5G, and 6G positions, progressing from open-root groove preparation through cap passes on schedule-80 pipe. Instruction is grounded in AWS D1.1 structural welding requirements and ASME Section IX welder-qualification variables so that students are prepared to sit both the AWS D1.1 Certified Welder test and an ASME Section IX pipe-qualification test. Safety practice throughout follows OSHA 29 CFR 1910 confined-space and hot-work requirements and AWS Z49.1 fume-control standards.
How the course runs. 9 blocks: Pipe Welding Safety, Codes, and WPS Interpretation; Pipe Fitting, Joint Preparation, and Tack Welding; SMAW Open-Root Pass on Pipe – 1G Position; SMAW Fill and Cap Passes – 1G and 2G Positions; GTAW Root Pass on Pipe – Introduction to TIG Pipe; GTAW Root / SMAW Fill – 5G Fixed Position; 6G Position Pipe Welding – GTAW Root / SMAW Fill and Cap; Weld Inspection, NDE Concepts, and Quality Documentation; ASME Section IX and AWS D1.1 Pipe Test Simulation.
What competent looks like. Prepare pipe ends by grinding, beveling, and fitting up joints to dimensional tolerances required by ASME Section IX and AWS D1.1 weld procedure specifications. Deposit sound open-root and fill/cap passes on 2-inch through 6-inch schedule-80 carbon-steel pipe in the 1G, 2G, 5G, and 6G positions using SMAW and GTAW root/SMAW fill-and-cap procedures. Interpret weld procedure specifications (WPS) and select correct amperage, polarity, travel speed, and filler metal for each pipe position and process. Visually inspect completed pipe welds against AWS D1.1 visual acceptance criteria and identify common discontinuities including lack of fusion, incomplete penetration, porosity, and undercut. Apply OSHA hot-work permits, confined-space entry procedures, lockout/tagout, and respiratory protection requirements to pipe welding environments. Document heat-input calculations, WPS compliance records, and welder qualification test records in formats consistent with ASME Section IX PQR and WQR paperwork.
| # | Lesson | Hr | Type | Objective | Activities | Materials | Check |
|---|---|---|---|---|---|---|---|
| 1 | Pipe Welding Safety, Codes, and WPS Interpretation | 10 | theory | Students will correctly identify OSHA confined-space, hot-work-permit, and respiratory-protection requirements applicable to pipe welding and interpret a written WPS for a given pipe joint, selecting correct process variables. |
| AWS D1.1 Structural Welding Code – Steel (current edition), ASME BPVC Section IX (current edition), sample WPS/PQR forms, OSHA 29 CFR 1910 subparts relevant to welding, AWS Z49.1 Safety in Welding Cutting and Allied Processes, whiteboard, projector | Instructor-graded WPS interpretation quiz: 10 questions; students must score 80% or higher to proceed; any OSHA safety question answered incorrectly requires immediate re-teach and retest regardless of total score. |
| 2 | Pipe Fitting, Joint Preparation, and Tack Welding | 12 | lab | Students will prepare a pipe joint by cutting, beveling, deburring, and fitting up two sections of schedule-80 carbon-steel pipe to the root opening and bevel angle specified in the WPS, then apply tack welds that meet dimensional and visual acceptance criteria. |
| Schedule-80 carbon-steel pipe (2-inch and 6-inch), angle grinders, pipe beveling machine, pipe stands and chain clamps, gap gauges, calipers, protractors, SMAW power source, E6010 electrodes, chipping hammer, wire brush, personal protective equipment (welding helmet shade 10–11, leather gloves, flame-resistant jacket, safety glasses, steel-toed boots), fit-up log forms | Instructor measures bevel angle (37.5° ± 2.5°), root face (1/16 in ± 1/32 in), and root opening per WPS; tack welds visually inspected to AWS D1.1 Table 8.1 criteria; any out-of-tolerance joint must be redone before the student advances to root-pass practice. |
| 3 | SMAW Open-Root Pass on Pipe – 1G Position | 12 | practice | Students will weld a consistent open-root pass on 6-inch schedule-80 carbon-steel pipe in the 1G (rolled) position using SMAW E6010, achieving full fusion, complete penetration, and a root bead profile within AWS D1.1 visual acceptance limits. |
| SMAW power source (DC), E6010 electrodes (3/32 in and 1/8 in), schedule-80 carbon-steel pipe sections (6-inch), pipe stands and positioners, welding helmet (shade 10–11), leather PPE, chipping hammer, wire brush, inside-diameter inspection mirror, flashlight, personal weld log binder, AWS D1.1 visual inspection checklist | Instructor visually examines inside-diameter bead: complete penetration with root bead height 1/16–3/16 in above ID flush, no cracks, no burn-through greater than WPS allowance; student must produce two acceptable root passes consecutively before advancing. |
| 4 | SMAW Fill and Cap Passes – 1G and 2G Positions | 12 | practice | Students will deposit fill and cap passes on pipe coupons in both the 1G and 2G positions using SMAW E7018, producing a finished weld that meets AWS D1.1 visual acceptance criteria for reinforcement height, undercut, overlap, and surface porosity. |
| SMAW power source (DC), E7018 electrodes (1/8 in and 5/32 in, low-hydrogen, stored in rod oven at manufacturer-specified temperature), schedule-80 carbon-steel pipe coupons, pipe stands, welding helmet, full leather PPE, chipping hammer, wire brush, fillet weld gauges, AWS D1.1 visual inspection checklist, weld log binders | Instructor visual inspection per AWS D1.1 Table 8.1: cap reinforcement no more than 3/16 in above base metal, undercut no deeper than 1/32 in, no cracks, no visible porosity; student must complete one acceptable 1G and one acceptable 2G coupon before advancing. |
| 5 | GTAW Root Pass on Pipe – Introduction to TIG Pipe | 12 | demo | Students will set up a GTAW workstation for pipe welding and deposit a full-penetration root pass on 2-inch schedule-80 carbon-steel pipe in the 1G position using ER70S-2 filler, demonstrating control of arc length, puddle visibility, and argon purge technique. |
| GTAW power source (AC/DC), 2-percent thoriated or 2-percent ceriated tungsten electrodes (3/32 in), ER70S-2 filler rod (1/16 in and 3/32 in), argon shielding gas cylinders with regulators, back-purge dams and tubing, schedule-80 carbon-steel 2-inch pipe, pipe stands, GTAW torch and collets, welding helmet (shade 10–11 minimum), full leather PPE, GTAW setup checklist, weld log binders | Instructor visually inspects inside-diameter bead for complete penetration and absence of oxidation (sugaring); student must produce one clean, oxide-free root bead with complete penetration before advancing; GTAW setup checklist signed off by instructor. |
| 6 | GTAW Root / SMAW Fill – 5G Fixed Position | 14 | lab | Students will weld a complete pipe joint in the 5G (horizontal fixed, pipe axis horizontal) position using a GTAW open-root pass followed by SMAW fill and cap passes, completing the joint without repositioning the pipe and achieving results that meet AWS D1.1 visual acceptance criteria. |
| GTAW and SMAW power sources, ER70S-2 filler (3/32 in), E6010 (3/32 in) for hot pass, E7018 (1/8 in) for fill and cap, schedule-80 carbon-steel 6-inch pipe, fixed pipe stands and fixtures, argon back-purge setup, welding helmets, full leather PPE, fillet and groove weld gauges, travel-log cards, AWS D1.1 visual checklist, intentionally defective sample coupons | Instructor visual inspection of completed 5G joint per AWS D1.1 Table 8.1 criteria; student must complete a joint where all clock positions show full fusion, cap reinforcement within limits, and no cracks; any failure requires the student to re-weld a new coupon and pass before advancing. |
| 7 | 6G Position Pipe Welding – GTAW Root / SMAW Fill and Cap | 16 | lab | Students will complete a full pipe weld joint in the 6G (inclined fixed, 45-degree angle) position using GTAW root and SMAW fill/cap, demonstrating all positional technique variations needed to qualify on the most demanding AWS D1.1 and ASME Section IX test position. |
| GTAW and SMAW power sources, ER70S-2 filler, E6010 and E7018 electrodes, schedule-80 carbon-steel 6-inch pipe, 45-degree inclined pipe fixture, argon back-purge setup, welding helmets (shade 10–11), full leather PPE, weld gauges, weld log binders, shop camera or tablet for video review, ASME Section IX welder qualification record forms (blank), calculator | Instructor visual inspection per AWS D1.1 Table 8.1 and ASME Section IX QW-191 criteria; student must produce one fully acceptable 6G joint visually before scheduling the formal skills-demo assessment; pass standard mirrors the ASME Section IX visual acceptance criteria used in the certification exam. |
| 8 | Weld Inspection, NDE Concepts, and Quality Documentation | 8 | theory | Students will classify pipe weld discontinuities by type and cause, explain the principles of radiographic testing and ultrasonic testing as used in pipe weld quality assurance, and correctly complete an ASME Section IX welder-qualification record for a sample test weld. |
| Rejected pipe weld coupons (labeled for instructional use), radiographic film viewing box and sample RT films, ASME BPVC Section V overview excerpts, ASME Section IX WQR blank forms, answer-key WQR, AWS D1.1 visual acceptance criteria table, projector, guided notes worksheet | Instructor grades WQR documentation form: all essential variable fields completed correctly and discontinuity classification worksheet scored at 80% or higher; documentation errors relating to essential variables require correction and re-submission before the student is eligible for the final skills demonstration. |
| 9 | ASME Section IX and AWS D1.1 Pipe Test Simulation | 6 | lab | Students will complete a full simulated ASME Section IX or AWS D1.1 Certified Welder pipe test under exam-like conditions, producing a 6G test coupon that meets specified visual acceptance criteria and completing all required welder qualification documentation without assistance. |
| Pre-beveled schedule-80 carbon-steel 6-inch pipe coupons (matched sets), GTAW and SMAW power sources, ER70S-2 filler, E6010 and E7018 electrodes, 45-degree inclined pipe fixture, argon back-purge setup, welding helmets, full leather PPE, weld gauges, stopwatch, blank ASME Section IX WQR forms, AWS D1.1 Certified Welder test documentation forms (sample), exam-readiness checklist | Instructor visual inspection per AWS D1.1 Table 8.1 and ASME Section IX QW-191 visual criteria; coupon passes if it meets all visual acceptance requirements without coaching; student also submits completed WQR form — both weld and paperwork must pass to receive a passing record for this simulation; results inform Certification Exam Preparation (Course 14) priority areas. |
| Assessment | Type | Weight | Pass standard | Method & rubric |
|---|---|---|---|---|
| Pipe Welding Codes and WPS Knowledge Exam | Written exam | 25% | 80% or higher on all sections; any question in the OSHA safety or code-compliance section answered incorrectly requires mandatory re-teach and retest of that section before final grade is recorded | A 50-question written exam covering ASME Section IX essential variables, AWS D1.1 structural pipe provisions, WPS/PQR interpretation, pipe joint preparation tolerances, weld discontinuity classification, NDE principles, and OSHA hot-work and confined-space requirements. Questions are written at the comprehension and application level, mirroring the style of AWS SENSE Level 1-2 and NCCER Welding written assessments. Standard met · Safety · Time · Quality/finish · Documentation |
| 6G Pipe Weld Skills Demonstration | Skills demonstration | 45% | All AWS D1.1 Table 8.1 visual acceptance criteria met on the completed coupon with no coaching; welder qualification documentation form completed accurately; a single crack or incomplete-root-fusion indication is an automatic fail requiring a re-test on a new coupon | Each student independently fits up, tacks, and completes a full GTAW root / SMAW fill-and-cap weld on a 6-inch schedule-80 carbon-steel pipe coupon in the 6G position, following an assigned WPS without instructor assistance. The finished coupon is evaluated by visual inspection per AWS D1.1 and ASME Section IX criteria, and the student simultaneously submits a completed welder qualification record, directly mirroring the AWS D1.1 Certified Welder and ASME Section IX pipe-qualification testing conditions. Standard met · Safety · Time · Quality/finish · Documentation |
| Pipe Welding Lab Log | Log | 15% | All nine lesson lab logs submitted; each log rated Satisfactory by instructor, meaning it contains correct measurements, heat-input calculations, accurate discontinuity descriptions, and completed WPS compliance notations; any log rated Unsatisfactory must be corrected and resubmitted within five instructional days | Students maintain a running lab log throughout the course, recording joint measurements, process parameters, heat-input calculations, pass-by-pass travel logs, and self-inspection results for every practice coupon. The log serves as the primary documentation habit builder for ASME Section IX record-keeping requirements and is reviewed by the instructor after each lab lesson. Standard met · Safety · Time · Quality/finish · Documentation |
| Pipe Welding Safety Compliance Check | Safety audit | 15% | 100% compliance on all critical safety behaviors (PPE worn, LOTO applied where required, hot-work permit conditions met, back-purge gas confirmed before welding, fire watch stationed); a single critical safety violation stops the session and requires a documented safety conference and remediation before the student returns to welding | The instructor conducts two unannounced observation checks during lab sessions — one during a fitting and tacking phase and one during active welding — using a standardized behavioral checklist that covers lockout/tagout, PPE selection and wear, fume-control ventilation, hot-work and confined-space procedures, electrode storage (E7018 rod oven), and fire-watch practices per OSHA 29 CFR 1910.252 and AWS Z49.1. Results are recorded in the student's safety file and feed directly into the Capstone and Externship safety evaluations. Standard met · Safety · Time · Quality/finish · Documentation |
BLD-WELD01-11 Trade course
Fabrication: Layout, Fitting, and Structural Assembly
102 hr · $1,830 COMPLIMENTARY
Students apply layout, fitting, and tack-welding skills to fabricate multi-piece structural steel assemblies from blueprints, incorporating weld symbols, dimensional tolerance control, and distortion management. Emphasis is placed on accurate material preparation, proper fit-up, and documentation practices that meet AWS D1.1 structural code requirements. This course integrates knowledge from blueprinting, metallurgy, and all four welding processes to prepare students for capstone and industry work.
Outcomes- Lay out and mark structural steel members to blueprint dimensions within ±1/16-inch tolerance using scribers, squares, and layout tools.
- Prepare, fit, and tack-weld a multi-joint structural assembly that meets AWS D1.1 fit-up requirements for root opening, alignment, and joint geometry.
- Select and apply distortion-control techniques—including pre-setting, sequenced welding, and back-step methods—to hold finished assemblies within specified tolerances.
- Interpret weld symbols and fabrication notes on structural drawings to determine joint type, weld size, position, and finish requirements.
- Inspect completed fabrications using visual inspection criteria, a weld gauge set, and square/level to document conformance or identify nonconformance.
- Complete a fabrication traveler and weld log that records material heat numbers, welder ID, joint inspections, and corrective actions per standard shop practice.
Course text
Students apply layout, fitting, and tack-welding skills to fabricate multi-piece structural steel assemblies from blueprints, incorporating weld symbols, dimensional tolerance control, and distortion management. Emphasis is placed on accurate material preparation, proper fit-up, and documentation practices that meet AWS D1.1 structural code requirements. This course integrates knowledge from blueprinting, metallurgy, and all four welding processes to prepare students for capstone and industry work.
How the course runs. 9 blocks: Layout Fundamentals: Tools, Measurement, and Marking; Material Preparation: Cutting, Grinding, and Edge Prep; Weld Symbol and Blueprint Application in Fabrication; Fixturing, Clamping, and Tack Welding for Fit-Up; Distortion Control: Prediction, Pre-Setting, and Sequencing; Multi-Joint Structural Assembly: Fitting and Full Welding; Visual and Dimensional Inspection Using Weld Gauges; Fabrication Documentation: Travelers, Weld Logs, and Non-conformance Reports; Fabrication Capstone Mini-Project: Layout Through Inspection.
What competent looks like. Lay out and mark structural steel members to blueprint dimensions within ±1/16-inch tolerance using scribers, squares, and layout tools. Prepare, fit, and tack-weld a multi-joint structural assembly that meets AWS D1.1 fit-up requirements for root opening, alignment, and joint geometry. Select and apply distortion-control techniques—including pre-setting, sequenced welding, and back-step methods—to hold finished assemblies within specified tolerances. Interpret weld symbols and fabrication notes on structural drawings to determine joint type, weld size, position, and finish requirements. Inspect completed fabrications using visual inspection criteria, a weld gauge set, and square/level to document conformance or identify nonconformance. Complete a fabrication traveler and weld log that records material heat numbers, welder ID, joint inspections, and corrective actions per standard shop practice.
| # | Lesson | Hr | Type | Objective | Activities | Materials | Check |
|---|---|---|---|---|---|---|---|
| 1 | Layout Fundamentals: Tools, Measurement, and Marking | 10 | lab | Students will lay out and mark structural steel shapes to blueprint dimensions within ±1/16-inch tolerance using scribers, combination squares, dividers, and chalk lines. |
| A36 flat bar and angle iron stock, combination squares, steel tapes, scribers, dividers, center punches, chalk line reels, layout dye (Dykem), hammers, safety glasses, leather gloves; AWS D1.1 Structural Welding Code – Steel (current edition), shop drawing set | Student-marked layout is checked against blueprint with instructor steel tape; all critical dimensions within ±1/16 inch and all hole centers within ±1/32 inch; pass = 100% of dimensions in tolerance on final marked piece |
| 2 | Material Preparation: Cutting, Grinding, and Edge Prep | 12 | lab | Students will cut structural steel members to length using band saw, angle grinder, and plasma cutter, then prepare groove and fillet weld joint edges that meet AWS D1.1 edge prep requirements. |
| A36 plate (3/8-inch and 1/2-inch), horizontal band saw, angle grinders, grinding wheels, flap discs, cutting wheels, bevel protractor, machinist squares, acetone, rags, wire brushes, face shields, hearing protection, leather gloves, leather apron; AWS D1.1 current edition | Cut length within ±1/16 inch of blueprint; bevel angle within ±2.5° of specified angle; all edges free of burrs, scale, and contamination confirmed by instructor tactile and visual check; pass = all three criteria met on final prep set |
| 3 | Weld Symbol and Blueprint Application in Fabrication | 8 | theory | Students will interpret AWS weld symbols and fabrication notes on a multi-joint structural drawing to produce a complete joint-by-joint weld plan listing joint type, weld size, position, and any testing or finish requirements. |
| AWS A2.4 Standard Symbols for Welding (current edition), AWS D1.1 current edition, multi-joint structural drawing set, weld symbol flash cards, engineering paper, pencils; no shop equipment required | Written weld plan graded by instructor against answer key; pass = correct interpretation of at least 90% of symbol elements across all joints and all three drawing discrepancies correctly identified |
| 4 | Fixturing, Clamping, and Tack Welding for Fit-Up | 12 | demo | Students will fixture and tack-weld a two-piece T-joint and a three-piece corner assembly to achieve root opening, alignment, and squareness within AWS D1.1 fit-up tolerances before full welding begins. |
| A36 flat bar, angle iron, C-clamps, locking pliers (Vise-Grips), strongback bars, combination and speed squares, SMAW power source with E7018 electrodes or GMAW power source with ER70S-6 wire, fillet weld gauge set, feeler gauges, fabrication traveler form; AWS D1.1 current edition | Instructor measures root opening (≤1/16 inch for fillet, within symbol tolerance for groove), hi-lo mismatch (≤1/16 inch per AWS D1.1), and corner squareness (within 1/8 inch over 12 inches); pass = all joints within tolerance before full welding; tack quality visually acceptable |
| 5 | Distortion Control: Prediction, Pre-Setting, and Sequencing | 10 | theory | Students will predict the direction and approximate magnitude of weld-induced distortion on common joint configurations and select the correct control technique—pre-setting, back-step, intermittent welding, or balanced welding—for a given assembly. |
| A36 plate coupons (3/8-inch), SMAW or GMAW welding station, bevel protractor, steel rules, tape measure, guided-notes worksheet, fabrication log; Lincoln Electric Welding Handbook or AWS Welding Handbook Vol. 1 (Welding Science and Technology) as reference | Worksheet scored by instructor: pass = correctly identifies distortion direction and control method for at least 8 of 10 scenarios; pre-set T-joint final angle within ±1° of target; written sequencing comparison entry demonstrates correct cause-and-effect reasoning |
| 6 | Multi-Joint Structural Assembly: Fitting and Full Welding | 20 | practice | Students will fit up, tack, and fully weld a multi-joint structural steel assembly (gusset-plate bracket or equivalent) using an assigned welding process, completing all welds to the size and profile specified on the shop drawing. |
| A36 plate and flat bar per drawing BOM, SMAW station (E7018 electrodes) or GMAW station (ER70S-6, 75/25 Ar/CO2 shielding gas), chipping hammer, wire brush, steel tape, combination square, fillet weld gauge, weld table with strongbacks, full PPE (welding helmet shade 10–12, leather gloves, leather jacket, leather boots, hearing protection); shop drawing, fabrication traveler | Instructor visual inspection: all welds meet minimum specified size per AWS D1.1 visual acceptance criteria (no cracks, undercut ≤1/32 inch, overlap absent, craters filled); final assembly dimensions within ±1/8 inch of blueprint; pass = all visual criteria met and all dimensions in tolerance |
| 7 | Visual and Dimensional Inspection Using Weld Gauges | 12 | lab | Students will perform a complete visual and dimensional inspection of a welded structural assembly, using a bridge cam gauge, fillet weld gauge, and steel rule, and document all findings on a standard inspection report against AWS D1.1 visual acceptance criteria. |
| Bridge cam weld gauge (Gage Products or equivalent), fillet weld gauge set, steel rule, magnifying glass (10×), AWS D1.1 current edition (Table for visual acceptance criteria), inspection report forms, adequate lighting (minimum 1-foot candle per AWS D1.1 or shop lighting); completed bracket assemblies from Lesson 6 | Instructor spot-checks five measurements per student against reference measurements; pass = all five within ±1/32 inch of reference; inspection report correctly classifies all seeded defects in the sample as accept or reject per AWS D1.1 visual criteria (100% correct classification required) |
| 8 | Fabrication Documentation: Travelers, Weld Logs, and Non-conformance Reports | 10 | theory | Students will complete a fabrication traveler, a welder qualification log entry, and a non-conformance report (NCR) for a given scenario, demonstrating understanding of traceability, quality records, and corrective-action documentation. |
| Blank fabrication traveler forms, blank weld log forms, blank NCR forms, simulated material certifications, completed bracket assembly and inspection report from Lessons 6–7, AWS D1.1 current edition; no welding equipment required | Instructor reviews completed traveler and NCRs; pass = traveler contains all required fields correctly filled with no missing sign-off blocks; each NCR correctly identifies the nonconformance, cites the applicable AWS D1.1 criterion, and proposes a technically valid corrective action (100% of three NCRs must be acceptable) |
| 9 | Fabrication Capstone Mini-Project: Layout Through Inspection | 8 | lab | Students will independently complete a short fabrication task—from blueprint reading and layout through fit-up, welding, inspection, and documentation—demonstrating integrated mastery of all course skills under time and quality constraints. |
| A36 steel per drawing BOM, full welding station (SMAW or GMAW per drawing), layout tools, cutting tools, angle grinder, fillet weld gauge set, bridge cam gauge, steel tape, combination square, fabrication traveler, weld log, inspection report form, full PPE; unseen shop drawing issued at lesson start | Pass requires: all layout dimensions within ±1/16 inch; all welds meet AWS D1.1 visual acceptance criteria confirmed by instructor re-inspection; final assembly dimensions within ±1/8 inch of blueprint; traveler and inspection report fully completed with correct accept/reject determination; all four criteria must be met to pass |
| Assessment | Type | Weight | Pass standard | Method & rubric |
|---|---|---|---|---|
| Fabrication Theory Knowledge Exam | Written exam | 25% | 70% or higher | A 50-question written exam covering weld symbol interpretation (AWS A2.4), AWS D1.1 fit-up and visual acceptance criteria, distortion prediction and control methods, edge preparation specifications, and fabrication documentation requirements. Questions are multiple-choice and short-answer drawn from lesson content and code references. Standard met · Safety · Time · Quality/finish · Documentation |
| Multi-Joint Structural Assembly Skills Demonstration | Skills demonstration | 45% | All AWS D1.1 visual acceptance criteria met; assembly dimensions within ±1/8 inch of blueprint on 100% of checked dimensions | Students independently lay out, fit, and weld the gusset-plate bracket from Lesson 6 (or an equivalent multi-joint assembly) while an instructor evaluates setup, fixturing, tack quality, welding technique, distortion control, and final dimensional and visual conformance against AWS D1.1 criteria. Standard met · Safety · Time · Quality/finish · Documentation |
| Fabrication Lab Log and Documentation Portfolio | Log | 15% | All required entries present and technically accurate; NCRs receive a 'satisfactory' rating from instructor on a three-point rubric | Students submit their complete fabrication traveler, weld log, and inspection reports maintained throughout the course, plus the three NCRs written in Lesson 8; the portfolio is reviewed for completeness, accuracy of code citations, correct use of terminology, and professional presentation. Standard met · Safety · Time · Quality/finish · Documentation |
| Fabrication Area Safety Compliance Check | Safety audit | 15% | Zero critical safety violations; all items on the safety checklist rated 'compliant' before student may continue or retest immediately | Prior to the final skills demonstration, an instructor conducts a point-of-work safety audit: PPE selection and condition, grinder guard in place, ventilation system on, fire watch established, hot-work area clear of combustibles, electrical equipment visually inspected, and lockout/tagout procedures verified for any non-welding power equipment used during layout and cutting; any critical violation stops the assessment until corrected. Standard met · Safety · Time · Quality/finish · Documentation |
BLD-WELD01-12 Capstone
Capstone Project: Structural and Pipe Weldment Fabrication
216 hr · $2,160 COMPLIMENTARY
Students design, fabricate, inspect, and document a multi-joint structural and pipe weldment that integrates skills from every prior course in the program. The project culminates in a formal oral defense before a panel that evaluates both the finished weld assembly and the supporting technical documentation. Successful completion demonstrates job-entry readiness and directly maps to AWS D1.1 Certified Welder, AWS SENSE L1-2, NCCER Welding L1-4, and ASME Section IX performance qualification standards.
Outcomes- Produce a multi-process weldment (SMAW, GMAW or FCAW, and GTAW) that meets AWS D1.1 visual acceptance criteria and ASME Section IX groove-weld dimensional requirements as confirmed by instructor dimensional inspection and visual weld inspection (VT).
- Develop a complete Weld Procedure Specification (WPS) document and Bill of Materials for the capstone assembly using standard industry formats, with no missing essential variable fields.
- Apply and document all required pre-weld, in-process, and post-weld quality checks, including fit-up dimensions, interpass temperature limits, and final visual inspection findings, using a written inspection log.
- Demonstrate safe shop practices throughout fabrication, including verified lockout/tagout compliance on all equipment startups and shutdowns, correct PPE selection for each process, and a clean, hazard-free workstation maintained for all 216 hours.
- Interpret and work to a multi-view orthographic drawing with welding symbols conforming to AWS A2.4, translating joint geometry, weld size, and process requirements directly into the fabricated assembly.
- Defend design decisions, process selections, and quality outcomes orally before a panel, correctly answering questions tied to AWS D1.1 structural requirements, ASME Section IX qualification logic, and NCCER craft knowledge.
Course text
Students design, fabricate, inspect, and document a multi-joint structural and pipe weldment that integrates skills from every prior course in the program. The project culminates in a formal oral defense before a panel that evaluates both the finished weld assembly and the supporting technical documentation. Successful completion demonstrates job-entry readiness and directly maps to AWS D1.1 Certified Welder, AWS SENSE L1-2, NCCER Welding L1-4, and ASME Section IX performance qualification standards.
How the course runs. 4 blocks: Project Planning, Drawing Interpretation, and WPS Development; Material Preparation, Fit-Up, and Tack Welding; Multi-Process Welding, In-Process Inspection, and Distortion Control; Documentation, Portfolio Assembly, and Oral Defense Preparation.
What competent looks like. Produce a multi-process weldment (SMAW, GMAW or FCAW, and GTAW) that meets AWS D1.1 visual acceptance criteria and ASME Section IX groove-weld dimensional requirements as confirmed by instructor dimensional inspection and visual weld inspection (VT). Develop a complete Weld Procedure Specification (WPS) document and Bill of Materials for the capstone assembly using standard industry formats, with no missing essential variable fields. Apply and document all required pre-weld, in-process, and post-weld quality checks, including fit-up dimensions, interpass temperature limits, and final visual inspection findings, using a written inspection log. Demonstrate safe shop practices throughout fabrication, including verified lockout/tagout compliance on all equipment startups and shutdowns, correct PPE selection for each process, and a clean, hazard-free workstation maintained for all 216 hours. Interpret and work to a multi-view orthographic drawing with welding symbols conforming to AWS A2.4, translating joint geometry, weld size, and process requirements directly into the fabricated assembly. Defend design decisions, process selections, and quality outcomes orally before a panel, correctly answering questions tied to AWS D1.1 structural requirements, ASME Section IX qualification logic, and NCCER craft knowledge.
| # | Lesson | Hr | Type | Objective | Activities | Materials | Check |
|---|---|---|---|---|---|---|---|
| 1 | Project Planning, Drawing Interpretation, and WPS Development | 36 | theory | Given an instructor-issued orthographic drawing of the capstone assembly, students produce a complete written project plan that includes a Bill of Materials, joint-by-joint welding sequence, and a draft WPS for each welding process to be used, with all essential variables correctly identified per ASME Section IX and AWS D1.1 requirements. |
| Instructor-issued orthographic drawing (multi-view, to scale); AWS D1.1 Structural Welding Code — Steel (current edition); ASME Boiler and Pressure Vessel Code Section IX (current edition); AWS A2.4 Standard Symbols for Welding; blank WPS forms; Bill of Materials worksheet; engineering scale ruler; calculator; program reference WPS library binder | Instructor reviews completed WPS drafts, Bill of Materials, and annotated drawing against a 20-point checklist covering all essential variables and symbol interpretations; students must score 80% or higher and receive sign-off on all three documents before material is requisitioned — any missing essential variable is an automatic re-do. |
| 2 | Material Preparation, Fit-Up, and Tack Welding | 48 | lab | Students cut, clean, fit, and tack-weld all structural and pipe joints of the capstone assembly to dimensional tolerances specified on the drawing, documenting each fit-up measurement in an inspection log before any full weld pass is deposited. |
| Structural steel plate and pipe stock per Bill of Materials (typically A36 plate and A53/A106 pipe, grades per drawing); oxy-fuel cutting outfit or plasma cutting system; angle grinder with grinding and flap disc wheels; C-clamps, pipe clamps, and strongbacks; combination square, framing square, torpedo level, weld-fit-up gauge (Bridgeport or equivalent), tape measure; pre-weld inspection log forms; SMAW machine for tacking; PPE: welding helmet (minimum shade 10 for SMAW tacking), leather gloves, leather jacket, safety glasses, hearing protection, steel-toed boots; fire watch equipment | Instructor performs a dimensional hold-point inspection at fit-up completion using the student's recorded inspection log and independent measurements; all critical dimensions (root opening ±1/16 in., groove angle within ±2.5°, hi-lo within 1/8 in. for pipe) must be within tolerance — any out-of-tolerance joint must be corrected and re-inspected; 100% of joints must pass before full welding begins. |
| 3 | Multi-Process Welding, In-Process Inspection, and Distortion Control | 96 | practice | Students complete all full-penetration groove welds and fillet welds on the capstone assembly using at least three welding processes (SMAW, GMAW or FCAW, and GTAW for pipe root or thin-section joints) in accordance with the approved WPS, maintaining a written in-process inspection log that records interpass temperature, interpass cleaning, and visual findings after each pass. |
| SMAW power source and electrode holder; GMAW or FCAW wire-feed machine with appropriate shielding gas (ER70S-6 wire/C25 blend for GMAW, or E71T-1 flux-core wire for FCAW); GTAW power source with high-frequency start, TIG torch, filler rod, and argon shielding gas; electrodes/filler metals per approved WPS (e.g., E7018, ER70S-2 for pipe root); chipping hammer, wire brush, angle grinder; contact or infrared thermometer; weld gauge; in-process inspection log forms; AWS D1.1 current edition (visual acceptance criteria table); ASME Section IX (acceptance criteria reference); full PPE for each process (auto-darkening helmet set to appropriate shade, leather PPE, respiratory protection as needed per SDS for filler metals in use) | Instructor performs a mid-project hold-point inspection at the completion of all root passes (before fill passes begin), reviewing the inspection log for completeness and verifying root pass appearance against AWS D1.1 visual criteria; at project completion, instructor conducts a formal visual weld inspection (VT) of all welds using a weld gauge and measuring tape, scoring against a 25-point rubric covering weld size, profile, undercut, overlap, surface porosity, cracks, and arc strikes — a score of 80% or higher with zero cracks and zero unrepaired undercut exceeding D1.1 limits is required to proceed to documentation and defense. |
| 4 | Documentation, Portfolio Assembly, and Oral Defense Preparation | 36 | field | Students compile all project documents into a complete technical portfolio and deliver a structured oral defense to a panel, demonstrating the ability to explain and justify every fabrication and quality decision in terms of applicable code requirements and industry standards. |
| Completed weldment assembly; full project documentation binder; camera or smartphone for weld photography; AWS D1.1 current edition; ASME Section IX current edition; NCCER Welding Level 1-4 reference modules; portfolio assembly checklist; oral defense scoring rubric; presentation area with table for displaying assembly; peer-review checklist forms | Panel scores the oral defense on a rubric with four domains — technical accuracy of code references, clarity of process justification, quality of inspection documentation, and professional communication — each scored 1-4; a minimum total score of 80% across all domains is required to pass; any factually incorrect code statement must be corrected on the spot or the student receives a re-defense opportunity within five business days; portfolio completeness (all six sections present and legible) is a prerequisite gate — an incomplete portfolio prevents the defense from proceeding. |
| Assessment | Type | Weight | Pass standard | Method & rubric |
|---|---|---|---|---|
| Capstone Weldment Project | Project | 60% | Visual weld inspection score of 80% or higher on the 25-point rubric with zero unrepaired cracks and all weld sizes meeting the drawing requirements; dimensional hold-point inspections at fit-up and root pass must have been passed with instructor sign-off prior to advancing. | Students produce a finished multi-process structural and pipe weldment built to the instructor-issued drawing and approved WPS; the completed assembly is inspected by the instructor using AWS D1.1 visual acceptance criteria and ASME Section IX dimensional requirements, mirroring the performance test format of both the AWS Certified Welder and ASME Section IX welder qualification tests. The weldment is retained for display alongside the portfolio. Meets specification · Within estimate · Workmanship · Safety · Documentation |
| Technical Project Portfolio | Portfolio | 20% | All six required sections present and complete; WPS documents contain no missing essential variables; inspection logs show a continuous record with no undocumented hold points; written reflection is a minimum of one full page and references at least one specific AWS D1.1 acceptance criterion by table or clause description — overall portfolio completeness score of 80% or higher on the instructor checklist. | The portfolio compiles every planning, inspection, and reflection document produced during the capstone into a single organized binder that mirrors the job-site paperwork a welder is responsible for on a code-governed project; it is evaluated against a completeness and accuracy checklist aligned to AWS SENSE L1-2 portfolio requirements and NCCER Welding Level 3-4 documentation competencies. Completeness · Organization · Evidence quality |
| Oral Defense | Oral / panel | 20% | Minimum score of 80% on the four-domain panel rubric (technical accuracy, process justification, documentation quality, professional communication); any domain scored below 50% triggers a focused re-defense on that domain within five business days. | Students present their assembly and portfolio to a two-person panel and respond without notes to technical questions drawn from AWS D1.1 structural code requirements, ASME Section IX qualification logic, NCCER craft knowledge, and shop safety decisions made during the project; the format develops the verbal technical communication skills tested in AWS SENSE oral evaluation components and expected by employers during trade interviews. Explains decisions · Answers technical questions · Professional communication |
BLD-WELD01-13 Externship / clinical
Externship / Worksite Placement
324 hr · $1,295 COMPLIMENTARY
Students complete 324 supervised hours at a vetted construction or fabrication employer, applying structural, pipe, and production welding skills under journeyman or foreman oversight in real job-site conditions. The externship bridges classroom training and full employment by exposing learners to industry scheduling, quality-control documentation, and multi-trade coordination. Employer and instructor evaluations, combined with a reflective field log, verify professional readiness against AWS, NCCER, and ASME industry standards.
Outcomes- Perform SMAW, GMAW, FCAW, or GTAW welds on assigned worksite tasks that meet the quality and dimensional tolerances specified by the employer's applicable welding code or procedure specification.
- Follow all worksite safety protocols including lockout/tagout, PPE selection, hot-work permits, and confined-space entry procedures without prompting from a supervisor.
- Read and interpret employer-issued blueprints, weld symbols, and procedure qualification records (PQRs/WPSs) to set up and execute assigned welds correctly.
- Maintain a daily field log documenting processes used, parameters observed, non-conformances encountered, and corrective actions taken, meeting a minimum completeness standard reviewed by the instructor.
- Receive a passing midpoint and final employer evaluation rating in categories of technical skill, safety behavior, professionalism, and teamwork.
- Identify at least two areas of personal skill growth observed during the externship and articulate a continuing-education or career pathway plan in a written reflection.
Course text
Students complete 324 supervised hours at a vetted construction or fabrication employer, applying structural, pipe, and production welding skills under journeyman or foreman oversight in real job-site conditions. The externship bridges classroom training and full employment by exposing learners to industry scheduling, quality-control documentation, and multi-trade coordination. Employer and instructor evaluations, combined with a reflective field log, verify professional readiness against AWS, NCCER, and ASME industry standards.
How the course runs. 4 blocks: Pre-Placement Orientation and Site Safety Integration; Supervised Production Welding — Structural and Fabrication Tasks; Pipe, Pressure, and Specialty Welding Tasks; Professional Practice, Field Log Completion, and Exit Reflection.
What competent looks like. Perform SMAW, GMAW, FCAW, or GTAW welds on assigned worksite tasks that meet the quality and dimensional tolerances specified by the employer's applicable welding code or procedure specification. Follow all worksite safety protocols including lockout/tagout, PPE selection, hot-work permits, and confined-space entry procedures without prompting from a supervisor. Read and interpret employer-issued blueprints, weld symbols, and procedure qualification records (PQRs/WPSs) to set up and execute assigned welds correctly. Maintain a daily field log documenting processes used, parameters observed, non-conformances encountered, and corrective actions taken, meeting a minimum completeness standard reviewed by the instructor. Receive a passing midpoint and final employer evaluation rating in categories of technical skill, safety behavior, professionalism, and teamwork. Identify at least two areas of personal skill growth observed during the externship and articulate a continuing-education or career pathway plan in a written reflection.
| # | Lesson | Hr | Type | Objective | Activities | Materials | Check |
|---|---|---|---|---|---|---|---|
| 1 | Pre-Placement Orientation and Site Safety Integration | 24 | field | Students will complete all employer site-specific safety and onboarding requirements and demonstrate understanding of the host company's welding procedures, PPE matrix, and emergency response plan before performing any production welding. |
| Host employer site-specific safety orientation materials, PPE issued by employer (welding helmet auto-darkening or fixed shade as required, FR clothing, steel-toed boots, gloves, hearing protection), OSHA 10 wallet card, student field-log notebook or digital log, WPS/PQR documents provided by host employer, AWS D1.1 or applicable code reference used on site. | Supervisor confirms student has completed all onboarding paperwork and site safety training; instructor reviews field-log entries for days 1–3 for completeness. Pass standard: all site paperwork signed and accepted by employer; field-log entries rated 'complete' (all required fields filled, safety observations noted) by instructor. |
| 2 | Supervised Production Welding — Structural and Fabrication Tasks | 150 | lab | Students will execute assigned structural or fabrication welding tasks using the process specified by the employer (SMAW, GMAW, FCAW, or GTAW) at a quality level that passes the employer's in-process visual inspection on at least 80 percent of welds without rework. |
| Employer-provided welding equipment and consumables (electrodes, wire, shielding gas), work-holding fixtures and positioners as available on site, weld inspection gauge (bridge cam or equivalent), personal PPE, daily field-log forms, applicable code or standard in use on site (AWS D1.1, ASME Section IX, or employer quality plan), NCCER Welding Levels 1–4 skills reference for student self-check. | Supervising journeyman or foreman completes a midpoint employer evaluation form at the end of Lesson 2 (approximately week 12 of externship), rating technical skill, safety behavior, professionalism, and teamwork on a 1–4 scale. Pass standard: minimum average rating of 2.5 out of 4.0 on all four categories, with no category rated 1; field log reviewed by instructor for the production phase and rated complete. |
| 3 | Pipe, Pressure, and Specialty Welding Tasks | 100 | lab | Where the host employer's scope includes pipe or pressure-vessel work, students will perform or assist with pipe joint fit-up, root pass, fill, and cap sequences in accordance with the applicable ASME Section IX or process-piping procedure, demonstrating awareness of essential variables and quality hold-points. |
| Employer-provided pipe or specialty base metal and filler materials per WPS, purge gas equipment for GTAW root passes if applicable, pipe beveling tools or supplied pre-beveled pipe, visual inspection tools (mirror, weld gauge, flashlight), liquid-penetrant inspection kit if used on site, ASME Section IX reference or employer's procedure documentation, field-log forms. | Supervising journeyman documents each pipe or specialty weld completed by the student in the field log with a pass/fail notation against the employer's acceptance criteria. Pass standard: at least 70 percent of student-performed welds accepted at first inspection without major repair; instructor reviews technical summary for accuracy and rates it satisfactory if it correctly identifies at least three parameter differences or code-requirement references. |
| 4 | Professional Practice, Field Log Completion, and Exit Reflection | 50 | field | Students will compile a complete externship field log, solicit and review their final employer evaluation, and produce a written reflection identifying specific skill gains and a personal career pathway plan. |
| Complete field-log notebook or digital log, final employer evaluation form (program standard form), word-processing software or paper for reflection essay, AWS SENSE L1-2 performance objectives checklist for self-assessment, NCCER Registry credential tracking information for student reference. | Instructor reviews the completed field-log portfolio against a 10-point checklist (process entries, hours totals, safety observations, defect documentation, supervisor signatures, etc.). Pass standard: score of 8 out of 10 or higher on the log checklist; final employer evaluation average of 2.5 out of 4.0 or higher across all categories; reflection rated satisfactory if it includes at least two specific skill examples and a credentialing plan with named credential and timeline. |
| Assessment | Type | Weight | Pass standard | Method & rubric |
|---|---|---|---|---|
| Final Employer Skills Evaluation | Skills demonstration | 70% | Average rating of 2.5 out of 4.0 or higher across all four categories (technical skill, safety behavior, professionalism, teamwork), with no single category scored 1.0; any category rated 1.0 requires a remediation plan and a repeat evaluation. | The host employer's journeyman or foreman completes the program's standardized final evaluation form at the conclusion of the externship hours, rating the student in technical welding skill, consistent safety behavior, professionalism and attendance, and teamwork and communication. The signed form is submitted to the program instructor and becomes part of the student's permanent externship record, supporting AWS SENSE L1-2 and NCCER workplace-performance documentation requirements. Competency · Safety · Attendance · Conduct · Initiative |
| Externship Field Log Portfolio | Log | 30% | Score of 8 out of 10 on the instructor's completeness checklist and a satisfactory rating on the written reflection; portfolios scoring 7 or below are returned for revision and must be resubmitted within five business days. | The student submits a bound or digital portfolio containing all daily field-log entries covering the full 324 externship hours, organized chronologically, with supervisor initials or signatures, plus the signed final employer evaluation form and the two-to-three-page career reflection. The instructor evaluates completeness, accuracy of technical entries, and the quality of the self-assessment using a 10-point checklist aligned to AWS SENSE L1-2 workplace documentation standards and NCCER Registry submission requirements. Complete · Verified |
BLD-WELD01-14 Exam prep
Certification Exam Preparation: AWS D1.1 CW, AWS SENSE L1-2, NCCER Welding L1-4, and ASME Sec. IX
90 hr · $900 COMPLIMENTARY
Students systematically review every knowledge and performance domain tested on the AWS D1.1 Certified Welder, AWS SENSE L1-2, NCCER Welding Levels 1-4, and ASME Section IX pipe welder qualification exams, closing individual skill and theory gaps identified through diagnostic testing. The course culminates in full-length, timed mock examinations that replicate the format, time limits, and performance standards of each credential examination so students enter testing day with demonstrated readiness.
Outcomes- Correctly answer written questions covering weld joint design, process variables, inspection criteria, metallurgy, and safety at or above the passing threshold for each targeted credential exam.
- Produce groove and fillet weld test coupons in required positions that meet the visual and destructive-test acceptance criteria specified in AWS D1.1 and ASME Section IX.
- Demonstrate safe setup, LOTO application, and PPE selection for SMAW, GMAW, FCAW, GTAW, and oxy-fuel/plasma cutting tasks as evaluated during mock practical stations.
- Read and interpret welding procedure specifications (WPS), symbols, and shop drawings to the level required on NCCER Welding Level 3-4 and AWS SENSE L1-2 written assessments.
- Self-diagnose deficient performance areas using scored practice tests and implement targeted remediation before sitting the credentialing examinations.
- Complete timed mock examinations for each credential under simulated test conditions and achieve the program's minimum readiness benchmark prior to scheduling official exams.
Course text
Students systematically review every knowledge and performance domain tested on the AWS D1.1 Certified Welder, AWS SENSE L1-2, NCCER Welding Levels 1-4, and ASME Section IX pipe welder qualification exams, closing individual skill and theory gaps identified through diagnostic testing. The course culminates in full-length, timed mock examinations that replicate the format, time limits, and performance standards of each credential examination so students enter testing day with demonstrated readiness.
How the course runs. 4 blocks: Diagnostic Assessment and Exam-Domain Mapping; Knowledge Domain Review: Theory, Code, and Symbols; Performance Skill Stations: Welding and Inspection to Code; Full Mock Certification Examinations.
What competent looks like. Correctly answer written questions covering weld joint design, process variables, inspection criteria, metallurgy, and safety at or above the passing threshold for each targeted credential exam. Produce groove and fillet weld test coupons in required positions that meet the visual and destructive-test acceptance criteria specified in AWS D1.1 and ASME Section IX. Demonstrate safe setup, LOTO application, and PPE selection for SMAW, GMAW, FCAW, GTAW, and oxy-fuel/plasma cutting tasks as evaluated during mock practical stations. Read and interpret welding procedure specifications (WPS), symbols, and shop drawings to the level required on NCCER Welding Level 3-4 and AWS SENSE L1-2 written assessments. Self-diagnose deficient performance areas using scored practice tests and implement targeted remediation before sitting the credentialing examinations. Complete timed mock examinations for each credential under simulated test conditions and achieve the program's minimum readiness benchmark prior to scheduling official exams.
| # | Lesson | Hr | Type | Objective | Activities | Materials | Check |
|---|---|---|---|---|---|---|---|
| 1 | Diagnostic Assessment and Exam-Domain Mapping | 10 | theory | Each student identifies their individual weak domains across all four credential exams by scoring a written diagnostic and a timed visual-inspection practical, then builds a personal remediation plan. |
| 100-question diagnostic test packet (instructor-developed from AWS D1.1, AWS SENSE content outline, NCCER module objectives, ASME Sec. IX), six prepared coupon sets with known defects, AWS D1.1 current edition, ASME BPVC Section IX current edition, NCCER Welding Trainee Guides Levels 1-4, inspection report forms, Personal Remediation Plan template | Written diagnostic scored by instructor; student must correctly identify at least 80 percent of defects on the visual inspection practical; Personal Remediation Plan approved by instructor before Lesson 2 begins — no pass/fail gate here, results drive differentiated instruction in subsequent lessons. |
| 2 | Knowledge Domain Review: Theory, Code, and Symbols | 30 | theory | Students correctly answer practice questions at or above 80 percent in every written knowledge domain tested across the four credential exams, including welding processes, metallurgy, joint and groove design, WPS interpretation, welding symbols, inspection methods, and safety regulations. |
| AWS D1.1 current edition, AWS A2.4 current edition, ASME BPVC Section IX current edition, NCCER Welding Trainee Guides Levels 1-4, AWS SENSE Level 1 and Level 2 content outlines, domain-organized practice question bank (instructor-developed), welding symbol exercise packets, structural and pipe fabrication drawings, personal study notebooks, whiteboard and projector | Each 20-question domain quiz scored immediately; student must reach 80 percent or above on each domain quiz before moving on — students who score below 80 percent on any quiz receive a targeted reading assignment and a second 20-question alternate quiz on the same domain before Lesson 3; all three timed practice tests must average 75 percent or above across sections. |
| 3 | Performance Skill Stations: Welding and Inspection to Code | 36 | lab | Students produce groove and fillet weld test coupons in the positions required by their chosen credential qualifications — using SMAW, GMAW/FCAW, and GTAW on plate and SMAW or GTAW on pipe — that meet the visual, bend, and break acceptance criteria specified in AWS D1.1 and ASME Section IX. |
| SMAW power sources (constant-current), GMAW and FCAW power sources (constant-voltage) with wire feeders, GTAW power source with high-frequency start, oxy-fuel and plasma cutting stations for coupon preparation, pipe positioners and rotation fixtures, guided-bend test jig, carbon steel plate (various thicknesses per WPS), carbon steel pipe (2-inch and larger schedule fittings), E6010, E6011, E7018, ER70S-6, E71T-1, ER70S-2 filler metals, prequalified WPS documents, AWS D1.1 current edition, ASME BPVC Section IX current edition, personal PPE for each student (helmet, FR clothing, leather gloves, steel-toed boots, hearing protection, safety glasses), LOTO equipment, self-inspection checklists, Performance Test Logs | Each coupon evaluated by instructor using D1.1 Table 6.1 visual criteria and guided-bend or nick-break results per D1.1 or ASME Sec. IX acceptance criteria; visual acceptance is required before mechanical testing; students must pass at least one coupon at each required position and process combination for their intended credential before sitting the mock exam in Lesson 4 — any coupon failing three consecutive attempts triggers a mandatory conference with the instructor and a remediation plan addendum. |
| 4 | Full Mock Certification Examinations | 14 | practice | Students complete timed full-length mock examinations for each targeted credential — written and performance components — under simulated test-day conditions and achieve the program's minimum readiness benchmark of 80 percent on written sections and passing coupons on all performance sections. |
| Timed mock written exam packets (instructor-developed, domain-weighted to match official content outlines), Scantron or bubble-sheet answer forms, stopwatch/timer visible to students, welding equipment and consumables as listed in Lesson 3, fresh plate and pipe coupons cut to test dimensions, prequalified WPS documents, AWS D1.1 current edition (for examiner reference only, not student use during written), ASME BPVC Section IX current edition (examiner reference), guided-bend jig, CWI inspection kit (fillet weld gauge, undercut gauge, ruler, flashlight), official AWS D1.1 CW and NCCER performance evaluation checklists, individual debrief score report forms | Written mock: 80 percent or above on each credential's written section constitutes GO recommendation; scores of 75-79 percent on any section receive NOT-YET with targeted remediation; scores below 75 percent require documented remediation and retake. Performance mock: coupons must meet all visual and mechanical acceptance criteria per D1.1 and ASME Sec. IX without any coaching during the test; a single failing coupon in a required position receives NOT-YET for that credential's performance component — students receive a written GO/NOT-YET recommendation for each credential separately. |
| Assessment | Type | Weight | Pass standard | Method & rubric |
|---|---|---|---|---|
| Full-Program Mock Certification Examination Suite | Mock certification exam | 100% | Written components: 80 percent or above on each credential's written mock exam. Performance components: all required welding coupons meet AWS D1.1 Table 6.1 visual acceptance criteria and pass guided-bend or nick-break mechanical tests per D1.1 or ASME Section IX acceptance criteria without examiner coaching; a GO recommendation is issued for each credential separately. | Administered in Lesson 4 under controlled, timed, test-day conditions by the instructor and, where available, an AWS Certified Welding Inspector serving as proctor, this suite includes separate timed written mock exams for AWS SENSE L1-2, NCCER Welding Levels 1-4, and ASME Section IX knowledge, plus performance welding stations replicating the AWS D1.1 Certified Welder and ASME Section IX pipe qualification coupon requirements in the positions and processes each student intends to certify in. Results are documented on official-style score reports and used to issue a written GO or NOT-YET recommendation for each credential, advising students and program staff on readiness to schedule the official third-party examinations. Score · Time management |
Program completion
External credential: ASME Sec. IX pipe; AWS D1.1 Certified Welder; AWS SENSE L1-2; NCCER Welding L1-4
Students sit credentialing exams administered by the American Welding Society (AWS) for the Certified Welder and SENSE Level 1-2 credentials, by the National Center for Construction Education and Research (NCCER) for the Welding Levels 1-4 credential, and by an authorized testing facility for the ASME Section IX pipe welder qualification; each exam is conducted independently of the school under that issuing organization's proctoring and quality requirements. Pass standard: Credential issued by the body.
Back to Welding · How the school gets authority to award these credentials
