Curriculum for Welding

(Certificate Level - 6 months)

1
 Contents

Overall objective of the course…………………………………………... 3

Competencies gained after completion of the course.……………….. 3
Job opportunities available immediately and in the future…………… . 4
Trainees Entry Level…………………………………………………….... 5
Minimum Qualification of Teacher …………………………….……….. 5
Curriculum Structure……………………………………………………… 5
Overview about the program…………………………………………….. 6
Curriculum Contents……………………………………………… 8
Module 1: Basic Metal work …………………………..………. 8
Module 2: Welding………………………………………………… 10
Module 3: Fabrication of Steel articles ……………….………… 14
Assessment………………………………………………………………… 15
Module 1: Basic Metal work ……………………………………. 15
Module 2: Welding …………………………………….………… 16
Module 3: Fabrication of Steel articles ………………………… 18
List of Tools, Equipment and Machines……………………………….. 19
Gas Welding Equipment and Accessories……………………. 20
Arc Welding Equipment and Accessories…………………….. 21
Consumables……………………………………………………. 22
Reference Books for Trainer…………………………………… 24
Supportive notes on Assessment……………………………………… 25
General Recommendations…………………………………………….. 26
Lesson Plan………………………………………………………………. 26
Workshop…………………………………………………………………. 26
Developers & members of NCRC……………………………………….

2
 Introduction
Name of course: Welding 06 month (800 hrs)

Overall objective of Course:

Improve the Level of skill of workers in industry and increase the economic potential of the country.
Provide industry with workers whose scope with job knowledge and skills are identified.
Assist in human resources development by providing precise and assessed country’s skilled manpower quantitatively as well as
qualitatively.
Create an incentive and desire for workers to attain a high level of knowledge and skills competency in their respective trade / profession.
Establish a co-ordination among employer’s, workers and government relating to human resources development programs.
Provide technical and vocational training basis which reflects the requirements of industry.
Facilitate the mobility skilled workers.

Competencies gained after completion of course:

Knowledge Competency:

After successful completion of this training, the trainee should be able to:

Describe Measuring, Marking, Cutting, Sawing, and Filing, Drilling/Counter sinking, Threading tools / instruments, their uses & Safety and
Personal safety.
Explain basic arithmetic & geometric terminologies, calculate, and solve the problems.
Explain the Gas Welding / Cutting tools and equipment, their use and safety.
Explain the Soldering & Brazing process and their use on common metals.
Determine Arc Welding processes, tools and equipment, their use and safety.
Express the suitable welding joints, welding positions, Electrodes, their use and selection.
Describe welding defects and their remedies.
Explain the inspection and testing of welded joints to ensure quality of weld.

3
Skill Competency:

After successful completion of this training, the trainee should be able to:

Measure, Mark, Cut, Saw, File, Grind, Drill / Counter sink, Tap / Thread the job observing work and personal safety.
Weld with Gas Welding process on different Joints and Positions.
Solder the sheet metals.
Braze the common metals i.e. Mild steel (MS), Cast iron (CI), Stainless steel (SS) and Copper (Cu).
Weld with Arc Welding process on different Joints and Positions.
Inspect and Test the welded joints.
Weld the simple structural shapes.

Job opportunities available immediately and in the future:

Steel manufacturing industry.

Construction industry.
Industrial projects.
Shipyards.
Railway.
Pakistan Ordinance Factory Wah.
Heavy Mechanical Complex Taxila.
Heavy Forge and Foundry Taxila.
Tractor and Agricultural Equipment Industry.
Automobile industry.
Local industry.
Local metal fabrication shops.
Self employment.
And many others.

4
Trainees Entry level:
Middle Pass

Minimum Qualification of Teacher:

DAE in Mechanical/Welding with two year relevant experience
Or
Two years (G-II) Proficiency Certificate of Welding Trade With six years experience.

Curriculum Structure
Duration of Course Six Months
Total Hours 800 hrs
Training Hours 765 hrs
Module Test 25 hrs
Final Test 10 hrs
Per Week Hours 30 hrs
Per Day Hours 05 hrs (6 days a week)

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 Overview about the program – Curriculum for Welding (06 months).
Module Title and Aim Learning Units Theory Workplace
hours hours
Module 1: Basic metal work.
1.1 BENCH WORK
Aim:
Provide knowledge and skill on I. Metal working tools, basic. 22 hrs. 98 hrs.
common bench work tools and
selected jobs. II. Practical Exercises.
Introduction to the kinds of
welding. III. Jobs, Tools and Personal Safety.
Reading of drawings
IV. Arithmetic’s/Geometrical terminologies and problems
solving.

V. Kinds of welding, their principles and use.

Module 2: Welding
2.1 GAS WELDING
Aim: I. Gas welding tools, equipment and accessories,
Provide knowledge and skill on their use, care and safety.
gas welding process. II. Welding joints and welding positions. 29 hrs 147 hrs
Identify gas welding defects III. Gas welding techniques.
and adopt remedies. IV. Gas cutting technique.
Provide knowledge and skill on V. Common gas welding / cutting and arc welding
soldering and brazing. defects and remedies.
Use of soldering and brazing VI. Gas welding practice.
Provide knowledge and skill on
arc welding joints and 2.2 SOLDERING AND BRAZING
positions.
Identify arc welding defects I. Soldering tools, equipment and accessories. 13 hrs 56 hrs
and adopt remedies. II. Soldering joints and practice.
III. Solder & Brazing filler metals and fluxes.
IV. Brazing on different metals and joints.

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 2.3 ARC WELDING
50 hrs 200 hrs
I. Basic Electricity and welding machines.

II. Welding polarities, classification of electrode, care

and storage.

III. Arc welding tools, equipment and accessories.

IV. Relationship among the size of electrode, current

setting and job thickness.

V. Arc welding practice on different joints and

positions.

Module 3 Fabrication of steel

articles 3.1 Design and weld the steel articles
30 hrs 120 hrs
Aim: I. Building construction
Provide knowledge and skill on II. Domestic use.
producing steel gates, doors,
windows, grills, railing etc.

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 Curriculum Contents for Welding
(Teacher and Learner Guide).
Module 1 title: Basic Metal work.
Objective of the Module: 1. Describe common metal working tools and prepare bench work exercises.
2. Explain the kinds of welding.
Duration: 120 hrs Theory: 22 hrs Practical: 98 hrs

Learning Unit Learning Outcomes Learning Elements Duration Material Learning

required place
1.1 Bench work. i. Is able to identify basic 1.1.1 Identify select and use the Measuring tools:
metal working tools. Steel foot rules, Steel tape, Vernier Caliper, Calipers 2 hrs -Original Tools, Class room
1.2 Job, tools and ii. Is able to select the (internal & external), Micrometer, Gauges, Solid steel -White/Chalk
personal safety. select the suitable tool squares, Protectors. board,
for the job. -OHP,
1.3 Practical iii. Observe safety for 1.1.2 Identify select and use the Marking tools: Steel 1 hrs -Information Class room
exercises. tools, work and scribers, Divider, Centre Punch, Surface gauge. sheets,
personal. -Materials,
1.4 Arithmetic’s / iv. Explain basic 1.1.3 Identify select and use the Cutting tools: 1 hrs -Exercise sheets Class room
Geometrical Arithmetic’s/Geometric Shears, Saws, Chisels, Punches. -work sheets
terminologies al Terminologies.
and problem v. Explain kinds of 1.1.4 Identify select and use the Files and Scrapers: 1 hrs Class room
solving. welding Single cut file, Cross cut, Rasp cut, Shapes of files, Flat
scraper, Triangle scrapers.
1.5 Kinds of Welding
their principles 1.1.5 Identify select and use the Grinding: Wheels, 1 hrs Class room
and use. Discs, and pencils.

1.1.6 Identify select and use the Drills / Counter 1 hrs Class room
Sinks: Twist drills, Counter sinks.

1.1.7 Identify select and use the Threading: Types of 1 hrs Class room
Threads, Tapes and Dies.

1.2.1 Explain and use the Safety Rules: Introduction to 1 hrs Class room
the safety rules and regulations for tools, work and
personal.

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1.3.1 Prepare the selected jobs according to the
drawing.
i. Filing Exercise (Channel) 27 hrs Workplace
ii. Squaring. 10 hrs Workplace
iii. Marking. 4 hrs Workplace
iv. Sawing. 8 hrs Workplace
v. Drilling. 10 hrs Workplace
vi. Counter Sinking. 4 hrs Workplace
vii. Threading. 10 hrs Workplace
viii. Stretching. 12 hrs Workplace
ix. Sheet Metal Box. 13 hrs Workplace

1.4.1 Solve the problems 0f Arithmetic’s / 11 hrs Class room

Geometrical using Terminologies: Addition &
Subtraction, Multiplication & Division, Metric system,
Diameter / Circumference finding., Percentage,
Conversion of Inches to Metric to Inches, Lines, Angles,
Drawing of Radius, Corner finding from Isometric views,
Views finding and matching of views.

1.5.1 Explain the different Kinds of Welding: Kinds of 2 hrs Class room
welding, their principles and use.

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 Module 2 Title: Welding
Objective of the Module: 2.1 Describe Gas welding process accessories, use them safely and weld the metals.
2.2 Differentiate between Soldering and Brazing processes, and solder / braze the different
ferrous and non-ferrous metals.
2.3 Describe Arc welding process, Tools, accessories, use them safely and weld the metals.
Duration: 495 hrs Theory: 92 hrs Practical: 403 hrs

Learning Unit Learning Outcomes Learning Elements Duration Material Learning

required place
2.1 GAS WELDING. i. Identify gas welding 2.1.1 Identify and select the Gas welding equipment
tools, equipment, care and accessories: -Original Tools,
Gas welding and use them Gas cylinders and Acetylene generator, Regulators, 20 hrs -White/Chalk Class room
equipment and observing safety rules Hoses with fittings, Goggles, Spark lighter, Gas welding board,
accessories, Welding and regulations. and Cutting Torches with nozzles / tips, Flashback -OHP,
joints and positions, ii. Explain welding joints arrestors, Filler rods, Burner pliers, their care and safety -Information
Welding and cutting and positions. rules. sheets,
techniques, Welding iii. Determine the gas -Materials,
defects and practical welding and cutting 2.1.2 Identify and Explain the types of welding joints: 2 hrs -Exercise sheets Class room
skill. techniques. Butt joint, Corner joint, Tee joint, Lap Joint, Edge Joint. -work sheets
iv. Identify gas and arc
welding defects and 2.1.3 Identify and Explain the types of welding 2 hrs Class room
adopt remedies. positions:
v. Weld the metals with Flat position, Horizontal position, Vertical position,
Oxy-Acetylene Overhead position.
process on different
joints and positions. 2.1.4 Explain and select the Welding techniques: 1 hrs Class room
Forehand welding, Backhand welding.

2.1.5 Select and use the Oxy-Acetylene Cutting 2 hrs Class room
techniques:
Flame cutting process, freehand cutting, Guide bar
cutting, Curve and Circular cutting.

2.1.6 Identify Welding defects (Arc & Gas), causes 2 hrs Class room
and select remedies:
Lack of Fusion, Under cut, Blowholes, Porosity, Slag
inclusion, Cracks, Their causes and remedies.

10
 2.1.7 Weld the job with Gas welding on practical
exercises:
I. Lightening of flame. 6 hrs Workplace
II. Adjusting of flames (Carburizing, Neutral and 6 hrs Workplace
Oxidizing).
III. Blind weld flat (Puddling procedure). 10 hrs Workplace
IV. Double flange edge weld. 10 hrs Workplace
V. Butt joint flat. 10 hrs Workplace
VI. Corner joint (out side) flat. 10 hrs Workplace
VII. V - Butt joint flat. 15 hrs Workplace
VIII. Corner joint outside horizontal. 10 hrs Workplace
IX. Butt joint horizontal. 10 hrs Workplace
X. T-joint horizontal. 10 hrs Workplace
XI. Square butt joint vertical. 10 hrs Workplace
XII. Square butt joint on pipe flat. 10 hrs. Workplace
XIII. Square butt joint on pipe horizontal. 15 hrs. Workplace
XIV. Square butt joint on pipe fix. 15 hrs. Workplace

2.2 Soldering and i. Select the proper tools 2.2.1 Explain, Identify and select the Soldering
Brazing. equipment and accessories. -Original Tools,
Soldering and brazing accessories for the I. Soldering Process, 2 hrs -White/Chalk Class room
tools, equipment, Filler soldering and brazing II. Types of soldering iron, 1 hr board, Class room
metals, Fluxes and job. III. Kinds of solders, 1 hrs -OHP, Class room
Practical exercises. ii. Select the solder or IV. Soldering fluxes. 1 hrs -Information Class room
brazing filler metals sheets,
and fluxes. 2.2.2 Solder the Joints on various metals. -Materials,
iii. Solder and braze the Lap joint soldering on MS, GI, Cu and brass 8 hrs -Exercise sheets Workplace
different metals. sheets. -work sheets
Butt joint soldering on MS, GI, Cu and brass 8 hrs Workplace
sheets.

2.2.3 Explain identify and select the Brazing

accessories.
I. Brazing process, 2 hrs Class room
II. Types of brazing filler metals, 2 hrs Class room
III. Brazing fluxes, 2 hrs Class room
IV. Melting Temperature of different metals, 1 hrs Class room
V. Melting temperature of brazing filler metals. 1 hr Class room

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 2.2.4 Braze the jobs on different metals.
Lap joint brazing on MS sheet. 8 hrs Workplace
Butt joint brazing on MS sheet. 8 hrs Workplace
Double lap joint brazing on MS sheet. 8 hrs Workplace
Brazing Non ferrous metals Cu, Brass, Stainless 8 hrs Workplace
Steel.
Pipe on sheet / plate brazing 8 hrs Workplace

2.3 Arc welding. i. Explain Basic electricity, 2.3.1 Explain the Basic Electricity terminologies and
.Provide knowledge welding current. Units: -Original Tools,
and skill on welding ii. Explain welding Conductor, Electrical Circuit, Current / Ampere, Voltage, 3 hrs -White/Chalk Class room
process, tools, machines, equipment, and Resistance and Watt. board,
equipment, terminology. -OHP,
accessories, iii. Select the electrode, 2.3.2 Explain the Arc welding Electrical -Information
electricity, welding care and storage. terminologies. sheets,
machines, welding iv. Strike an Arc and I. Alternating current (AC), Direct Current (DC). 2 hrs -Materials, Class room
different joints. maintain the desired arc II. Open Circuit Voltage, Close Circuit (Arc) 2 hrs -Exercise sheets Class room
length. Voltage. -work sheets
III. Polarity (Straight and Reverse). 2 hrs Class room

2.3.3 Distinguish the Welding Machines, their

construction and use:
I. Transformer, 3 hrs Class room
II. Generator, 3 hrs Class room
III. Rectifier, 3 hrs Class room

2.3.4 Identify and use the proper Tools and

Equipment:
Cables, Electrode holder, Earth clamp, Welding screen / 2 hrs Class room
helmet, Chipping hammer, Steel wire brush, Leather
apron, Leather gloves.

2.3.5 Identify, select, store the Arc welding

Electrode:
I. Types of Core wire. 2 hrs Class room
II. Types of coating. 3 hrs Class room
III. Function of coating. 2 hrs Class room
IV. Identifying electrode. 3 hrs Class room
V. Selecting the correct electrode. 2 hrs Class room
VI. Caring and storing electrode. 2 hrs Class room

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2.3.6 Explain the Welding Arc:
I. Method of striking an arc (Tapping / Scratching), 2 hr Class room
II. Maintaining the arc (Long, Standard, Short), 2 hr Class room
III. Running short beads. 2 hr Class room

2.3.7 Explain the factors for Running continuous

Bead: 5 hrs Class room
I. Correct electrode.
II. Arc length.
III. Current and amperage.
IV. Speed of travel.
V. Electrode angle.
VI. Crater formation.
VII. Maintaining crater.
VIII. Breaking the arc.
IX. Restarting the arc.
X. Running continuous bead.

2.3.8 Select the proper Bead forming Motions:

Straight, Crescent, Figure 8, Rotary, Triangle. 2 hrs Class room

2.3.9 Weld the jobs with Arc welding on Practical

exercises:
I. Striking the arc MS 200x100x6mm (1piece). 6 hrs Workplace
II. Running short beads. 6 hrs Workplace
III. Breaking and restarting the arc. 6 hrs Workplace
IV. Straight bead weld. 10 hrs Workplace
V. Depositing metal by weaving motion between 8 hrs Workplace
straight beads.
VI. Square butt joint flat. 10 hrs Workplace
VII. Lap joint single pass. 8 hrs Workplace
VIII. T-fillet joint single pass. 8 hrs Workplace
IX. T-fillet joints multiple pass. 8 hrs Workplace
X. Out side corner joint. 8 hrs Workplace
XI. V-butt joint flat. 12 hrs Workplace
XII. Straight bead in horizontal position. 10 hrs Workplace
XIII. Lap joint horizontal position single pass. 10 hrs Workplace
XIV. V-butt joint in horizontal position. 15 hrs Workplace
XV. Straight bead in vertical down position. 8 hrs Workplace
XVI. Straight bead in vertical up position. 10 hrs Workplace
XVII. Lap joint vertical up. 12 hrs Workplace
XVIII. Butt joint vertical up. 12 hrs Workplace
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 XIX. Pipe on plate 8 hrs Workplace
XX. Pipe weld fix. 15 hrs Workplace
XXI. Pipe weld horizontal 10 hrs Workplace

Module 3 Title: Fabrication of Steel articles.

Objective of the Module: Describe and Design Fabrication of different steel structure and weld skillfully for Domestic and Building
constructional use.
Duration: 150 hrs Theory: 30 hrs Practical: 120 hrs

Learning Unit Learning Outcomes Learning Elements Duration Material Learning

required place
3. Design and Weld i. Imitate and draw the 3.1.1 Explain the Actual size and Fabrication size
the steel articles. different designs seen Actual size of place, Tolerance / Margins of fitting, Actual 6 hrs -Original Tools, Class room
surroundings i.e. gate, making size, Type of design, Size of design. -White/Chalk
windows, grills, board,
railings and fences 3.1.2 Determine the steps of work process in making -OHP,
etc. the articles considering the design. -Information
ii. Make templates, dies I. Cutting of metals in size. 2 hrs sheets, Class room
and fixtures for equal II. Shaping or bending the pieces 3 hrs -Materials, Class room
size and uniform III. Placing the pieces in the fixture. 3 hrs -Exercise sheets Class room
shape / design. IV. Tacking of pieces. 2 hrs -work sheets Class room
iii. Assemble and weld V. Welding of pieces. 2 hrs Class room
the fabricated parts in VI. Hinge making 3 hrs Class room
correct shape, design VII. Hinge welding. 2 hrs Class room
and size. VIII. Making door bolt. 3 hrs Class room
IX. Welding door bolt. 2 hrs Class room
X. Grinding and Finishing. 2 hrs Class room

3.1.3 Practical exercises: (Should be prepared as

project in a group of 4-5 trainees).
i. Window with safety grill. (Hinges doors / Sliding 20 hrs Workplace
doors).
ii. Door with solid sheet fitted with Threshold. 20 hrs Workplace
iii. Door with safety grill and lattice fitted. 20 hrs Workplace
iv. Railing in different design. 20 hrs Workplace

14
 Assessment
Module 1: Basic Metal work.

Learning unit Theory Workplace Recommended formative assessment Recommended Scheduled

hours hours Methodology Dates
1.1 Bench work. Identify select and use the Measuring tools. Objective/short ans./oral

1.2 Job, tools and Identify select and use the Marking tools. Objective/short ans./oral
personal safety.
1.3 Practical exercises. Identify select and use the Cutting tools. Objective/short ans./oral

1.4 Arithmetic’s / 25 hrs 100 Identify select and use the Files and Scrapers. Objective/short ans./oral
Geometrical
terminologies and Identify select and use the Grinding. Objective/short ans./oral
problem solving.
1.5 Kinds of Welding their Identify select and use the Drills / Counter Sinks. Objective/short ans./oral
principles and use.
Identify select and use the Threading Objective/short ans./oral

Explain and use the Safety Rules. Objective/short ans./oral

Practical Test
Prepare the selected jobs according to the drawing.
Solve the problems 0f Arithmetic’s / Geometrical using Problem solving written
Terminologies. test

Explain the different Kinds of Welding. Objective/short ans./oral

15
Module 2: Welding.

Learning unit Theory Workplace Recommended formative assessment Recommended Scheduled

hours hours Methodology Dates
2.1 Gas Welding 40 hrs 160 hrs Identify and select the Gas welding equipment and Objective/short ans./oral
accessories.

Identify and Explain the types of welding joints. Objective/short ans./oral

Identify and Explain the types of welding positions. Objective/short ans./oral

Explain and select the Welding techniques. Objective/short ans./oral

Select and use the Oxy-Acetylene Cutting techniques. Objective/short ans./oral

Identify Welding defects (Arc & Gas), causes and Objective/short ans./oral
select remedies.

Weld the job with Gas welding on practical exercises Practical Test
2.2 Soldering and 15 hrs 60 hrs Explain, Identify and select the Soldering accessories. Objective/short ans./oral
Brazing
Solder the Joints on various metals. Practical Test

Explain identify and select the Brazing accessories. Objective/short ans./oral

Braze the jobs on different metals. Practical Test

2.3 Arc Welding 50 hrs 200 hrs Explain the Basic Electricity terminologies and Units. Objective/short ans./oral

Explain the Arc welding Electrical terminologies. Objective/short ans./oral

Distinguish the Welding Machines, their construction Objective/short ans./oral

and use.

Identify and use the proper Tools and Equipment. Objective/short ans./oral

Identify, select and store the Arc welding Electrode. Objective/short ans./oral

Explain the Welding Arc. Objective/short ans./oral

16
Explain the factors for Running continuous Bead. Objective/short ans./oral

Select the proper Bead forming Motions. Objective/short ans./oral

Weld the jobs with Arc welding on Designed Practical Practical Test
exercises.

17
 Module 3: Fabrication of Steel articles.

Learning unit Theory Workplace Recommended formative assessment Recommended Scheduled

hours hours Methodology Dates
3.1 Design and Weld 30 hrs 120 Explain the Actual size and Fabrication size. Objective/short
the steel articles. ans./oral
Determine the steps of work process in making
the articles considering the design. Objective/short
ans./oral
Practical exercises.
Practical Test

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 Mechanical Welding (06 Months)
List of Tools, Equipment and Machines (For 20-25 Trainees)
List of Tools and Machines
Sr. Name of Item Quantity Sr. Name of Item Quantity
No. No.
1. Steel rule 30 cm 25 Nos. 26. Allen key set 3mm to 12mm 01 No.
2. Steel Tape 3 meter 25 Nos. 27. Hand shear straight 12” 06 Nos.
3. Steel Tape 5 meter 06 Nos. 28. Blow lamp kerosene oil 02 Nos.
4. Sprit level 12 inch/30 Cm 06 Nos. 29. Soldering Iron 300 Watt. 06 Nos.
5. Work benches 13 Nos. 30. Chisel flat & crosscut 25 nos. each
6. Bench vice 5” 25 Nos. 31. Centre punch 25 Nos.
7. Hammer ball peen 500gm 25 Nos. 32. Twist Drill set 25 pieces (3-13 mm) 02 Nos.
8. Hammer cross peen 500 gm 25 Nos. 33. Counter sink set 25 pieces (3-13 mm) 02 Nos.
9. Hammer 1000 gm 06 Nos. 34. Hand vice 06 Nos.
10. Sledge hammer 8000 gm 06 Nos. 35. Tape and die set (6-12 mm) 02 Nos.
11. Hand Hacksaw frame (blade size 12”/30 cm) 25 Nos. 36. Line scriber 25 Nos.
12. Outside Caliper 6”/15 Cm 25 Nos. 37. Vernier Caliper 6” 06 Nos.
13. Inside Caliper 6”/15 Cm 25 Nos. 38. Vernier height gauge 01 No.
14. File flat 300 x 1 25 Nos. 39. Angle plate 01 No.
15. File half round 250 x 1 25 Nos. 40. Safety goggle 12 Nos.
16. File round 250 x 1 25 Nos. 41. Pedestal drill machine 01 No.
17. File triangular 200 x 1 25 Nos. 42. Pedestal grinder heavy duty wheel size 300 01 No.
x 50mm
18. Try square 8” 25 Nos. 43. Electric Hand drill machine 01 No.
19. Combination Pliers 8” 06 Nos. 44. Power saw 01 No.
20. Open end spanner set in Inch. (double end ¼ to 01 No. 45. Bench shear 01 No.
1”)
21. Open end spanner set in mm (double end 6mm 01 No. 46. Hand disc grinder 7” 03 Nos.
to 32mm)
22. Screw driver straight 8” & 12” 04 Nos. 47. Hand disc grinder 4” 03 Nos.
each
23. Screw driver Philips 8” & 12” 04 Nos. 48. Lever Shear Blade size 12” with profile 01 no
each cutting
24. Spanner adjustable 8”, 10” & 12” 03 Nos. 49. Cutoff machine dia. 14” with angle 01 no
each adjustment
25. Anvil 100 Kg with stand 01 No. 50

19
 Gas Welding Equipment and Accessories

Sr. No. Name of Item Quantity

26. Gas welding working stations 6 Nos.
27. Cylinder trolley or Manifold system (one) 5 Nos.
28. Cylinder for Oxygen gas with key 10 N0s.
29. Cylinder for Acetylene gas with key 10 Nos.
30. Regulator (oxygen) double stage 5 Nos.
31. Regulator (acetylene) double stage 5 Nos.
32. Flashback arrester acetylene 5Nos.
33. Flashback arrester oxygen 5 Nos.
34. Hose pipe (oxygen) 4 meter each 40 meter.
35. Hose pipe (acetylene) 4 meter each 40 meter.
36. Oxy-acetylene welding and cutting set (injector type) complete 5 Nos.
with tip Cleaner needles.
37. Steel table with fire bricks top 6 Nos.
38. Spark lighter 10 Nos.
39. Welding goggles 25 Nos.
40. Burner pliers or Tong 10 Nos.
41. Stool 10 Nos.
42. Table for gas cutting 01 N0.

20
 Arc Welding Equipment and Accessories

Sr. No. Name of Item Quantity

43. Welding Transformer 50-250 amp complete with leads, earth 06 Nos.
clamp and electrode holder
44. Welding Rectifier (AC / DC) 50-300 amp complete with leads, 03 Nos.
earth clamp and electrode holder
45. Welding Generator 50-350 amp complete with leads, earth clamp 01 Nos.
and electrode holder
46. Welding face shield complete 10 Nos.
47. Welding helmet complete 10 Nos.
48. Chipping hammer 10 Nos.
49. Steel wire brush 20 Nos.
50. Leather gloves (pair) 20 Nos.
51. Leather apron 10 Nos.
52. Welding Table 10 Nos.
53. Stool 10 Nos.
54. Electrode drier (electric) 01 No.
55. Welding Booth 10 Nos.

21
 Consumables (Minimum Required for Six Months)

Sr. No. Name of Item Quantity

1. MS Channel 100x75x38x6mm 25pcs.
2. MS Flat 100x62.5x15mm 25pcs.
3. MS Flat 173x25 2.5mm 25pcs.
4. Ms Sheet 132x162x1mm 25pcs.
5. MS Sheet 150x100x1.5mm 350pcs.
6. MS Sheet 150x50x1mm 50pcs.
7. MS Sheet 150x50x3.2mm 50pcs.
8. MS Pipe dia.50x3.2x50mm 200pcs.
9. MS Sheet 50x25x1mm 100pcs.
10. GI Sheet 50x25x22 SWG 100pcs.
11. Copper Sheet 50x25x1mm 100pcs.
12. Brass Sheet 50x25x1mm 100pcs.
13. MS Sheet 100x50x1.6mm 150pcs
14. Copper Sheet 100x50x1mm 50pcs.
15. Brass Sheet 100x50x1mm 50pcs.
16. Stainless Steel Sheet 100x50x1mm 50pcs.
17. MS Sheet 100x100x3.2mm 25pcs.
18. MS Sheet flat 200x100x6mm 250pcs.
19. MS flat 200x50x6mm 450pcs.
20. MS filler rod 1mm gas welding 10 kg.
21. MS filler rod 2mm gas welding 10 kg.
22. MS filler rod 3.2 mm gas welding 10 kg.
23. Brazing filler rod 1.5 mm 5 kg
24. Silver solder 50 / 50 1 kg
25. Solder Tin + Lead, 60 / 40 3 kg
26. Brazing flux for MS, Cu, Brass, Stainless steel 01 tin each
27. Soldering fluxes MS, GI, Cu, Brass 01 tin each
28. MS Electrode E-6013, Dia. 2.4 mm 250 kg
29. MS Electrode E-6013, Dia. 3.2 mm 300 kg
30. MS Electrode E-6013, Dia. 4mm 100 kg
31. MS Electrode E-7018, Dia. 2.4mm 50 kg
32. MS Electrode E-7018, Dia.3.2mm 50 kg
33. Filter glass green shade # 10 (for face shield / helmet ) 100 Nos.
34. Clear glass (for face shield / helmet ) 200 Nos.
22
35. Filter glass green shade # 5 (for gas welding goggle) 100 Nos.
36. Clear glass (for gas welding goggle) 100 Nos.
37. MS flat 100x100x6mm 20 pcs.
38. MS pipe dia. 100x50x6mm 100 pcs

23
 Reference Books for Trainer

1. Modern Welding
By Althhouse - Turnquist - Bowditch.

2. Welding Skills and Practices

By Giachino - Weeks.

3. Welding Skills
By Giachino - Weeks.

4. Welding Principles & Practices

By Sacks.

5. Practical Welding Technology

By Rudy Mohler.

6. Principles of Welding Technology

By L. M. Gourd.

7. Oxy-Acetylene Welding basic fundamentals

By Ronald J. Baird.

8. Brazing and soldering of Metals

N. Lashko - S. Lashko

9. Technology of the Metal Trade (GTZ)

Appold - Feiler - Reinhard - Schmith.

10. Oxy-Acetylene handbook,

By LINDE

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 Supportive notes on Assessment
Monthly Theory test (Objective / short answer type) should be conducted.
Each practical exercise should be marked on the provided marking criteria.
Final theory test should be Objective / Short answer type, not more than 30minutes.
Final practical test should be from the skill, the trainees have performed during training.

Passing Marks in Theory each Test 40 %

Passing Marks in Practical each exercise 60 %

RESULT:
Sessional marks obtained in Theory (A) 20%
Final Marks obtained in Theory (B) 80%

Total (A + B) = “C”

Sessional Marks obtained in Practical (D) 30%

Final Marks obtained in Practical (E) 70%

Total (D + E) = “F”

Certification Marks will be in percentage = 20 % of “C” + 80% of “F”

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 General Recommendations

Lesson plans

The teacher should prepare lesson plans for the classroom for each topic. This will provide guideline to the teacher regarding;
a. Topic.
b. Objectives.
c. Teaching aids required.
d. Motivation.
e. Sequence of knowledge transfer.
f. Chalkboard / Whiteboard layout to be developed during lesson delivery.
g. Revision of important points.
h. Test the Achievement of trainees.

Workshop

In order to facilitate the Trainees to develop the desired skills and competencies, it is recommended that:
a. Practical activities by the trainees should be carried out individually.
b. Workshop should be fully equipped as stipulated in the curriculum.
c. Budget provision should be made to replace/purchase the latest tools and equipments to up date the equipment.
d. Recommended consumables should be provided for practical in reasonable quantity.
e. The teacher should himself be able to make / demonstrate the practical exercises to the desired skill level.

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