PROGRAM OUTLINE

Welder Foundation
 The latest version of this document is available in PDF format on the ITA website
www.itabc.ca

To order printed copies of Program Outlines

or learning resources (where available)
for BC trades contact:

Crown Publications, Queen’s Printer

Web: www.crownpub.bc.ca
Email: [email protected]
Toll Free 1 800 663-6105

Copyright © 2016 Industry Training Authority

This publication may not be modified in any way without permission of the Industry Training Authority

Welder Foundation Industry Training Authority 1

04/20
 WELDER FOUNDATION
PROGRAM OUTLINE

APPROVED BY INDUSTRY
AUGUST 2016

BASED ON
WELDER NOA 2013
AND
CCDA HARMONIZATION
RECOMMENDATIONS 2015

Developed by
Industry Training Authority
Province of British Columbia

Welder Foundation Industry Training Authority 2

04/20
 Table of Contents

TABLE OF CONTENTS

Section 1 INTRODUCTION................................................................................................................ 4
Foreword ........................................................................................................................... 5
Acknowledgements ........................................................................................................... 6
How to Use this Document................................................................................................ 7

Section 2 PROGRAM OVERVIEW .................................................................................................... 8

Program Credentialing Model ........................................................................................... 9
Occupational Analysis Chart ........................................................................................... 10
Training Topics and Suggested Time Allocation: Foundation ........................................ 13

Section 3 PROGRAM CONTENT .................................................................................................... 16

Foundation ...................................................................................................................... 17

Section 4 ASSESSMENT GUIDELINES ....................................................................................... 111

Section 5 TRAINING PROVIDER STANDARDS .......................................................................... 113

Facility Requirements.................................................................................................... 114
Tools and Equipment .................................................................................................... 115
Reference Materials ...................................................................................................... 119
Instructor Requirements ................................................................................................ 122

Appendices .................................................................................................................................... 123

Appendix A: Previous Contributors ............................................................................... 124

Welder Foundation Industry Training Authority 3

04/20
 Introduction

Section 1
INTRODUCTION

Welder

Welder Foundation Industry Training Authority 4

04/20
 Introduction

Foreword

This Program Outline was developed to meet the needs of employers and other industry stakeholders.
It will be used as a guide for training providers delivering technical training for the Welder program and by
apprentices and employers in planning the workplace training.
Safe working practices, though not always specified in each of the competencies and learning tasks, are an
implied part of the program and should be stressed throughout the apprenticeship.
This document provides important information for a variety of audiences, including: training providers,
employers/sponsors, apprentices and program challengers. Refer to "How to Use this Document" for information
on how each section can be used by each intended audience.
Delivery of Technical Training:
The Welder Program has three levels of technical training. Practical demonstration and apprentice participation
should be integrated with classroom sessions.
This program is competency-based with many options available for the delivery of technical training.
For example, the Welder Apprenticeship Program may be offered as a:
• Full-time day school program (including block release and continuous entry)
• Continuous entry competency-based model
• Some theory may be offered as interactive synchronistic “on-line” delivery
This program outline also includes:
• A list of recommended curriculum and reference textbooks
• Training Provider Requirements for Instructor Qualifications, Facilities (classroom and shop sizes), as well as
the necessary Tools and Equipment
• Practical competencies as well as destructive and non-destructive testing
• Shop projects and weld destructive tests
• Pipe fabrication competencies
• Fabrication competencies

SAFETY ADVISORY
Be advised that references to the WorkSafeBC safety regulations contained within these materials do
not/may not reflect the most recent Occupational Health and Safety Regulation (the current
Standards and Regulation in BC can be obtained on the following website:
http://www.worksafebc.com. Please note that it is always the responsibility of any person using these
materials to inform him/herself about the Occupational Health and Safety Regulation pertaining to
his/her work.

Welder Foundation Industry Training Authority 5

04/20
 Introduction

Acknowledgements
Welder Program Review and Revision 2014 – 2016:
In 2014, Subject Matter Experts were convened to review and revise the BC Program Outline with reference to
changes identified in the Welder 2013 National Occupational Analysis (NOA). The following are the Subject
Matter Experts who participated in this review:
• Stan Boehm, SS Stainless Inc • Jim Carson, University of the Fraser Valley
• James Hillerby, Whistler Resorts (UFV)
• Mike Zenowski, Weldco-Beales • Mark Flynn, British Columbia Institute of
Technoloy (BCIT)
• Merv Kube, UA Piping Industry College of BC
(UAPIC BC)
In 2015, Subject Matter Experts were convened to review and re-sequence the Welder trade as part of the Pan-
Canadian Harmonization Initiative. The following are the Subject Matter Experts who participated in this review:
• Stan Boehm, SS Stainless Inc • Mark Flynn, British Columbia Institute of
• James Hillerby, Whistler Resorts Technoloy (BCIT)
• Merv Kube, UA Piping Industry College of BC • Al Sumal, Kwantlen Polytechnic University
(UAPIC BC) (KPU)
• Jim Carson, University of the Fraser Valley
(UFV)
In 2016, Subject Matter Experts were convened to review the BC Program Outline with respect to the Pan-
Canadian Harmonization Initiative changes. The following are the Subject Matter Experts who participated in this
review:
• Willem Swint, Victoria Shipyards • Mike Longo, Ideal Welders
• Mark Karpinski, Vancouver Shipyards • Gord Weel, Boilermakers 359
• Willy Manson, Stinger Welding • Palmer Allen, Boilermakers 359
• Chris Meikle, ADAM Integrated Industries • Gene Vonn Matt, Teck, Elk Valley Operations
• Jason Card, Macro Industries • Jackie Lundman, Independent
• Brad Harder, Penticton Fabrication • Ed Hurd, Technical Safety BC
• Matt Suddaby, Jewel Holdings

The Industry Training Authority would like to acknowledge the dedication and hard work of all the industry
representatives appointed to identify the training requirements of the Welder occupation.
Committee members and consultation groups involved with prior editions of the BC Program Outline can be
found in the Historical Program Review Participants in the appendix at the end of this document.

Welder Foundation Industry Training Authority 6

04/20
 Introduction

How to Use this Document

This Program Outline has been developed for the use of individuals from several different audiences. The table
below describes how each section can be used by each intended audience.

Employers/
Section Training Providers Sponsors Apprentices Challengers

Program Communicate Understand the length Understand the length Understand

Credentialing program length and and structure of the and structure of the challenger pathway to
Model structure, and all program program, and pathway Certificate of
pathways to to completion Qualification
completion

OAC Communicate the Understand the View the Understand the

competencies that competencies that an competencies they will competencies they
industry has defined apprentice is expected achieve as a result of must demonstrate in
as representing the to demonstrate in program completion order to challenge the
scope of the order to achieve program
occupation certification

Training Shows proportionate Understand the scope Understand the scope Understand the
Topics and representation of of competencies of competencies relative weightings of
Suggested general areas of covered in the covered in the various competencies
Time competency (GACs) technical training, the technical training, the of the occupation on
Allocation at each program level, suggested proportion suggested proportion which assessment is
the suggested of time spent on each of time spent on each based
proportion of time GAC, and the GAC, and the
spent on each GAC, percentage of that percentage of that
and percentage of time spent on theory time spent on theory
time spent on theory versus practical versus practical
versus practical application application
application

Program Defines the Identifies detailed Provides detailed Allows individual to

Content objectives, learning program content and information on check program
tasks, high level performance program content and content areas against
content that must be expectations for performance their own knowledge
covered for each competencies with a expectations for and performance
competency, as well practical component; demonstrating expectations against
as defining may be used as a competency their own skill levels
observable, checklist prior to
measurable signing a
achievement criteria recommendation for
for objectives with a certification (RFC) for
practical component an apprentice

Training Defines the facility Identifies the tools and Provides information Identifies the tools
Provider requirements, tools equipment an on the training facility, and equipment a
Standards and equipment, apprentice is expected tools and equipment tradesperson is
reference materials (if to have access to; provided by the expected to be
any) and instructor which are supplied by school and the competent in using or
requirements for the the training provider student, reference operating; which may
program and which the student materials they may be be used or provided in
is expected to own expected to acquire, a practical
and minimum assessment
qualification levels of
program instructors

Welder Foundation Industry Training Authority 7

04/20
 Program Overview

Section 2
PROGRAM OVERVIEW

Welder Foundation

Welder Foundation Industry Training Authority 8

04/20
 Program Overview

Program Credentialing Model

Apprenticeship Pathway
This graphic provides an overview of the Welder apprenticeship pathway.
C of Q = Certificate of Qualification
C of A = Certificate of Apprenticeship Multi-Process Alloy
C of C = Certificate of Completion Welding (MPAW)
WBT = Work-Based Training Endorsement

RECOMMENDATION FOR CERTIFICATION

Multi-Process Alloy Welding (MPAW)

OPTIONAL Endorsement
Technical Training: 150 hours (5 weeks*)
Post-C of Q Endorsement
Work-Based Training: 900 hours
ITA Standardized Written Exam
RED Logbook: Accumulate Hours
SEAL
SEAL C of Q C of A Technical Training Sign Off
Welder Welder

RECOMMENDATION FOR CERTIFICATION

Welder Level 3
Technical Training: 300 hours (10 weeks*)
Work-Based Training: 4,620 hours total
Interprovincial Red Seal Exam
Logbook: Accumulate Hours
Technical Training Sign Off

** 3,000 hours of work-based training recommended

C of C CREDIT
Welder
Foundation Technical Training: Level 1 &
Welder Level 2
Level 2
Technical Training: 240 hours (8 weeks*)
WBT: 300 hours
Work-Based Training: Accumulate hours
Logbook: Accumulate Hours
Welder Foundation Technical Training Sign Off
Technical Training: 840 hours ITA Standardized Written Exam
ITA Standardized Written Exam

Welder Level 1
Technical Training: 240 hours (8 weeks*)
Work-Based Training: Accumulate hours
Logbook: Accumulate Hours
Technical Training Sign Off
ITA Standardized Written Exam

APPRENTICESHIP - DIRECT ENTRY

** 3,000 hours of work-based training recommended prior to entering Level 3 Technical Training (hours to be verified by Sponsor/Employer)

CROSS-PROGRAM CREDITS
Individuals who hold the credentials listed below are entitled to receive partial credit toward the completion requirements of this program

None

Welder Foundation Industry Training Authority 9

04/20
 Program Overview

Occupational Analysis Chart

WELDER
Occupation Description: “Welder” means a person who has training in and is capable of welding ferrous and non-ferrous metals in all positions, on both
plate and/or pipe, using various welding processes. Certified welders qualify for testing with CSA, Technical Safety BC and for ASME procedures in British
Columbia.
EN = Endorsement
F = Foundation

Occupational Skills Describe welder Describe safe working Perform basic trade Use and maintain Use and maintain hand Use and maintain power
apprenticeship and the practices related mathematical measuring and layout tools tools (electric and
scope of the trade in BC calculations tools pneumatic)

A A1 A2 A3 A4 A5 A6
F F 1 F 1 F 1 F 1 F 1

Describe shop materials Apply lifting, hoisting and

rigging procedures

A7 A8
F 1 F 1 2

Cutting and Gouging Describe Oxy-Fuel Describe Oxy-Fuel Perform freehand and Use automatic and semi- Describe CAC-A and PAC Use CAC-A and PAC
Processes Cutting (OFC) processes Cutting (OFC) equipment guided cuts on low carbon automatic cutting processes, equipment cutting and gouging
and their applications and its operation steel (OFC) machines (OFC) and their applications processes and
equipment
B B1 B2 B3 B4 B5 B6
F 1 F 1 F 1 F 1 F 1 F 1

Fusion and Braze Describe fusion welding, Describe fusion welding, Describe filler metals, Describe joint design and Fusion weld on low Braze weld (TB) using
Welding (TB) Using the braze welding and braze welding and fluxes and tips used for weld positions for OFW carbon steel sheet the OFW process
Oxy-Fuel (OFW) brazing processes and brazing equipment and its fusion welding, braze
Process their applications operation welding and brazing
C C1 C2 C3 C4 C5 C6
F 1 F 1 F 1 F 1 F 1 F 1

Silver alloy braze on

similar and dissimilar
metals
C7
F 1

Welder Foundation Industry Training Authority 10

04/20
 Program Overview

Shielded Metal Arc Describe the SMAW Describe SMAW Select electrodes for Describe basic joint Describe weld faults and Use the SMAW process
Welding (SMAW) process equipment and its SMAW design and weld positions distortion in fabrications in on low carbon steel plate
operation for SMAW SMAW and pipe

D D1 D2 D3 D4 D5 D6
F 1 F 1 F 1 2 3 EN F 1 F 1 F 1 2 3 EN

Use the hardsurfacing Describe the SMAW Use the SMAW process
process on low carbon process on grey cast iron on stainless steel and/or
steel low carbon steel plate and
pipe
D7 D8 D9
F 1 F 2 F 1 EN

Semi-Automatic and Describe GMAW, GMAW- Describe semi-automatic Describe filler metal and Use the GMAW and Use the FCAW process Use the MCAW process
Automatic Welding P, FCAW, MCAW and and automatic welding shielding gases for semi- GMAW-P process
SAW processes and their equipment and its automatic and automatic
applications operation processes
E E1 E2 E3 E4 E5 E6
F 1 F 1 F 1 F 1 2 3 F 1 2 F 2

Use the SAW process Use combined GMAW,

MCAW and FCAW
processes

E7 E8
F 2 3

Gas Tungsten Arc Describe the GTAW Describe GTAW Describe the application Use the GTAW process Use the GTAW process Use the GTAW process
Welding (GTAW) process and its equipment and its of GTAW for ferrous for ferrous metals for stainless steel for aluminum
application operation metals

F F1 F2 F3 F4 F5 F6
F 2 F 2 F 2 F 2 3 F 2 EN 3

Specialized Processes Describe specialized

welding processes

G G1
EN

Basic Metallurgy Describe production Describe mechanical and Describe common Describe the grain Describe aluminum, Describe die castings
processes for physical properties of ferrous, non-ferrous and structure of metals aluminum alloys and their and their weldability
manufacturing metals ferrous and non-ferrous reactive metals and their weldability
metals weldability
H H1 H2 H3 H4 H5 H6
F 2 F 2 3 F 2 3 EN 3 3 EN

Welder Foundation Industry Training Authority 11

04/20
 Program Overview

Welding Drawings, Identify common welding Read and interpret Perform basic drafting Perform mathematical Interpret and apply Fabricate weldments
Layout and Fabrication symbols and bolted drawings calculations mechanical drawings and
connections layout components

I I1 I2 I3 I4 I5 I6
F 1 F 2 3 F 2 F 2 F 2 3 EN F 2 3 EN

Costing and estimating

I7
F 2 3

Quality Control and Describe basic welding Describe inspection and Describe the scope of the
Inspection quality control and testing procedures welding supervisor and
inspection requirements inspector responsibilities

J J1 J2 J3
3 3 3

Standards, Codes, Identify applicable Describe compliance with

Specifications and standards, codes, weld procedure
Welder Qualifications specifications and specifications (WPS) and
jurisdictional bodies data sheets
K K1 K2
3 3

Welder Foundation Industry Training Authority 12

04/20
 Program Overview

Training Topics and Suggested Time Allocation: Foundation

Welder – Foundation

% of Time Allocated to:

% of Time Theory Practical Total

Line A Occupational Skills 7% 50% 50% 100%

A1 Describe welder apprenticeship and the scope of the trade in 
BC
A2 Describe safe working practices 
A3 Perform basic trade related mathematical calculations 
A4 Use and maintain measuring and layout tools 
A5 Use and maintain hand tools  
A6 Use and maintain power tools (electric and pneumatic)  
A7 Describe shop materials  
A8 Apply lifting, hoisting and rigging procedures  

Line B Cutting and Gouging Processes 6% 20% 80% 100%

B1 Describe Oxy-Fuel Cutting (OFC) processes and their 
applications
B2 Describe Oxy-Fuel Cutting (OFC) equipment and its operation 
B3 Perform freehand and guided cuts on low carbon steel (OFC) 
B4 Use automatic and semi-automatic cutting machines (OFC) 
B5 Describe CAC-A and PAC processes, equipment and their 
applications
B6 Use CAC-A and PAC cutting and gouging processes and  
equipment

Line C Fusion and Braze Welding (TB) Using the Oxy-Fuel (OFW) 3% 20% 80% 100%
Process
C1 Describe fusion welding, braze welding and brazing 
processes and their applications
C2 Describe fusion welding, braze welding and brazing 
equipment and its operation
C3 Describe filler metals, fluxes and tips used for fusion welding, 
braze welding and brazing
C4 Describe joint design and weld positions for OFW 
C5 Fusion weld on low carbon steel sheet 
C6 Braze weld (TB) using the OFW process  
C7 Silver alloy braze on similar and dissimilar metals 

Welder Foundation Industry Training Authority 13

04/20
 Program Overview

Line D Shielded Metal Arc Welding (SMAW) 42% 20% 80% 100%
D1 Describe the SMAW process 
D2 Describe SMAW equipment and its operation 
D3 Select electrodes for SMAW 
D4 Describe basic joint design and weld positions for SMAW 
D5 Describe weld faults and distortion in fabrications in SMAW 
D6 Use the SMAW process on low carbon steel plate and pipe 
D7 Use the hardsurfacing process on low carbon steel 
D8 Describe the SMAW process on grey cast iron 
D9 Use the SMAW process on stainless steel and/or low carbon 
steel plate and pipe

Line E Semi-Automatic and Automatic Welding 30% 25% 75% 100%

E1 Describe GMAW, GMAW-P, FCAW, MCAW and SAW 
processes and their applications
E2 Describe semi-automatic and automatic welding equipment 
and its operation
E3 Describe filler metal and shielding gases for semi-automatic 
and automatic processes
E4 Use the GMAW and GMAW-P process 
E5 Use the FCAW process 
E6 Use the MCAW process 
E7 Use the SAW process 

Line F Gas Tungsten Arc Welding (GTAW) 4% 15% 85% 100%

F1 Describe the GTAW process and its application 
F2 Describe GTAW equipment and its operation 
F3 Describe the application of GTAW for ferrous metals 
F4 Use the GTAW process for ferrous metals 
F5 Use the GTAW process for stainless steel 

Line H Basic Metallurgy 1% 90% 10% 100%

H1 Describe production processes for manufacturing metals 
H2 Describe mechanical and physical properties of ferrous and 
non-ferrous metals
H3 Describe common ferrous, non-ferrous, reactive metals and  
their weldability

Welder Foundation Industry Training Authority 14

04/20
 Program Overview

Line I Welding Drawings, Layout and Fabrication 7% 15% 85% 100%

I1 Identify common welding symbols and bolted connections 
I2 Read and interpret drawings 
I3 Perform basic drafting  
I4 Perform mathematical calculations 
I5 Interpret and apply mechanical drawings and layout  
components
I6 Fabricate weldments  
I7 Costing and estimating  

Total Percentage for Welder Foundation 100%

Welder Foundation Industry Training Authority 15

04/20
 Program Content

Section 3
PROGRAM CONTENT

Welder Foundation

Welder Foundation Industry Training Authority 16

04/20
 Program Content
Foundation

Foundation

Welder Foundation Industry Training Authority 17

04/20
 Program Content
Foundation

Line (GAC): A Occupational Skills

Competency: A1 Describe welder apprenticeship and the scope of the trade in BC

Objectives
To be competent in this area, the individual must be able to:
• Describe the scope of the welder trade in BC.
• Describe the requirements and structure of the BC Welder Apprenticeship program.

LEARNING TASKS CONTENT

1. Describe the four levels of training in the BC • Historical structure

welder program • Current apprenticeship
o Foundation
o Level 1, Level 2, Level 3
o Level 4 (Endorsement)

2. Describe the requirements and procedure for • Skills and qualities of a welder
registration at each level • Specific job knowledge
o Equipment knowledge
o Metal identification
o Personal qualities
• Roles and responsibilities
o Employer responsibilities
o Apprentice responsibilities
• Logbook requirements
o Identification of the welder
o Registration seals
o Training endorsements
o Qualifications tests, general section
o Employment record
o W.P.Q.R.

3. Describe the Welder Learning Resource • The training program

modules • Training requirements
• P lines
• RK lines

4. Describe employment opportunities for each • High school, college or technical training
level of the training program and more institute
advanced training opportunities o Tacker
o Welding operator
o Welder
o Welder fabricator/fitter
• College, technical institute or university:
o Welding inspector level 1, 2 and 3
o Welding technician

Welder Foundation Industry Training Authority 18

04/20
 Program Content
Foundation

o Welder technologist
o Mechanical engineer
o Welding engineer

5. Identify industrial and construction fields that • Metal fabricating

provide employment opportunities for welders • Ship building
• Pulp and paper mills
• Wood products manufacture
• Machinery manufacture
• Equipment maintenance and repair
• Smelt and refining
• Motor vehicle, truck/trailer manufacture
• Mining
• Construction
• Iron and steel mills
• Special trades
• Mining services
• Coal mines
• Gas distribution and transmission
• Public administration and defence
• Machinery wholesalers
• Forestry and forest services
• Electric utilities
• Motor vehicle dealers and repairs
• Communications equipment and manufacture
• Pipeline
• Food and beverage industry

6. Communicate effectively • Resumes

• Cover letter
• Internet information sourcing
• Listening skills
• Effective verbal communication
• Non effective verbal communication
• Workplace culture

Welder Foundation Industry Training Authority 19

04/20
 Program Content
Foundation

Line (GAC): A Occupational Skills

Competency: A2 Describe safe working practices

Objectives
To be competent in this area, the individual must be able to:
• Describe regulations for health and safety in a welding workplace.
• Describe fire safety precautions, confined space entry and H2S requirements.

LEARNING TASKS CONTENT

1. Describe regulations for health and safety in a • WorkSafeBC

welding workplace o Employer responsibility and eligibility
o Worker responsibility and eligibility
o WorkSafeBC coverage
o Standards, codes and regulations
• Occupational Health and Safety (OH&S)
• Workplace Hazardous Material Information
System (WHMIS)
o Training
o Material Safety Data Sheets (MSDS)
o Labelling

2. Describe general safety precautions for welding • Worksite safety

o Safety meetings
o Emergency procedures
• Shop safety
• Electrical safety
• Safety requirements for welding processes

3. Describe fall protection requirements • Personal fall protection requirements

o Ladders and scaffolds
o Handrails and guardrails
o Harnesses and tethers
o Fall restraint
o Fall arrest
o Access equipment

Welder Foundation Industry Training Authority 20

04/20
 Program Content
Foundation

4. Describe physical hazards and select Personal • Hazards

Protective Equipment (PPE) o Radiation
o Extreme temperatures
o Noise
o Bodily injury hazards
o Chemical hazards
o Respiratory
• Personal protective equipment
o Protective clothing
o Skin protection (leathers)
o Head protection
o Hand protection
o Foot protection
o Hearing protection
o Welding screens and curtains
o Eye protection for welding
− Safety glasses and goggles
− Face shields
− Flash goggles
− Welding helmets
− Welding goggles
o Respiratory protection

5. Identify fire hazards and describe methods for • WorkSafeBC requirements for fire watch
preventing and extinguishing fires • Fire hazards
o Sparks
o Elements of a high hazard area
• Fire and explosion prevention
o Clean area of combustible debris
o Fire/water hose and/or fire extinguisher
set up before and after work
o Contain sparks by the use of fire-
retardant blankets
o Wet area down in high hazard area
before starting hot work
o Cover wall/floor openings with fire
retardant blanket
• Extinguishing fires
o Fire triangle
o The four classes of fires
o Types of fire extinguishers
• Toxic fumes/ventilation
o Cadmium
o Zinc
o Lead
o Beryllium
o Other alloys

Welder Foundation Industry Training Authority 21

04/20
 Program Content
Foundation

• Synthetic materials

6. Describe confined space entry • Employer/employee responsibilities

• Hazard assessment and work procedures
• Identification and entry permits
• Lockout and isolation
o Verification and testing
o Cleaning, purging, venting, inserting
o Standby persons
o Rescue
− Lifelines, harnesses and lifting
equipment
• Personal protective equipment and other
precautions

7. Describe requirements for H2S training • Properties, characteristics and locations of

H2S
• Health hazards
• MSDS requirements
o Initial response strategy
o Ventilation, controls and PPE
− Respiratory protective equipment
− Self-Contained Breathing Apparatus
(SCBA)
− Supplied Air Breathing Apparatus
(SABA)
• Detecting and monitoring for H2S
o Detector tube devices
o Electronic monitors
• Rescue techniques
o Rescue breathing
• Emergency response planning

Welder Foundation Industry Training Authority 22

04/20
 Program Content
Foundation

Line (GAC): A Occupational Skills

Competency: A3 Perform basic trade related mathematical calculations

Objectives
To be competent in this area, the individual must be able to:
• Perform basic welder trade related mathematical calculations.

LEARNING TASKS CONTENT

1. Solve trade related mathematical problems • Fractions

related to measurement o Basic mathematical functions
o Calculate averages
o Key terms and concepts
o Convert to percentages and decimals
• Decimals
o Basic mathematical functions
o Decimal fractions
o Convert decimals to common linear
measurements (i.e. feet and inches)
o Convert to percentages
• Whole numbers
• Ratio and proportion
• Metric and Imperial measurements
• Convert between units of measurement
o Linear measurements
o Volumetric measurements

2. Solve problems involving geometric formulas • Metric and Imperial measurements

• Geometric formulas
o Perimeter
o Area
o Volume
• Calculate the weight of a solid

Welder Foundation Industry Training Authority 23

04/20
 Program Content
Foundation

Line (GAC): A Occupational Skills

Competency: A4 Use and maintain measuring and layout tools

Objectives
To be competent in this area, the individual must be able to:
• Describe and demonstrate the safe use and care of measuring and layout tools.

LEARNING TASKS CONTENT

1. Identify, describe and select layout tools • Combination squares

o Square head
o Center head
o Protractor head
• Marking tools
o Soapstone
o Scriber or awl
o Chalkline
o Divider and trammel points
o Center punch
o Prick punch
o Spring loaded punch
o Transfer punch
o Number and letter stamps
o Pneumatic or electronic etching

2. Use and maintain layout tools • Selecting correct tool for task
• Proper usage
• General maintenance and storage

3. Identify, describe and select measuring tools • Systems of measuring

o Metric
o Imperial
• Measuring tools
o Pocket measuring tape
o Steel rule
o Torpedo level
o Spirit level
o Laser level
o Plumb bob
o Framing square
• Gauges
o Fillet weld
o Pipe internal alignment
o Single purpose weld
o Bridge cam

Welder Foundation Industry Training Authority 24

04/20
 Program Content
Foundation

4. Use and maintain measuring tools • Selecting correct tool for task
• Proper usage
• General maintenance and storage

Welder Foundation Industry Training Authority 25

04/20
 Program Content
Foundation

Line (GAC): A Occupational Skills

Competency: A5 Use and maintain hand tools

Objectives
To be competent in this area, the individual must be able to:
• Describe and demonstrate the safe use and care of hand tools.

LEARNING TASKS CONTENT

1. Identify, describe and select clamping tools • Vises

o Bench vise
o Machine vise
o Pipe vise
o Top screw bench chain vise
o Tri-stand yolk vise
• Clamps
• Pliers
o Combination
o Interlocking slip-joint
o Needle-nose and round-nose
o GMAW

2. Use and maintain clamping tools • Safety

• Selecting correct tool for task
• Proper usage
• General maintenance and storage

3. Identify, describe and select alignment tools • Drifts

• Pinch line up bars
• Pry bars
• Dogs and wedges
• External pipe alignment tools

4. Use and maintain alignment tools • Safety

• Selecting correct tool for task
• Proper usage
• General maintenance and storage

5. Identify, describe and select cutting tools • Hacksaws

• Files
• Manual sheers
• Cold chisels
• Bolt cutters
• Wire cutters

Welder Foundation Industry Training Authority 26

04/20
 Program Content
Foundation

6. Use and maintain cutting tools • Safety

• Selecting correct tool for task
• Proper usage
• General maintenance and storage

7. Identify, describe and select other common • Wire brushes

hand tools • Hammers
o Ball-peen
o Soft-faced
o Chipping hammers
o Sledge hammers
o Dead blow hammers
o Cross-peen
• Anvils
• Wrenches
o Open-end
o Box-end
o Combination
o Adjustable
o Cylinder
o Socket
o Pipe
o Hexagon key
• Screwdrivers
o Blade
o Phillips
o Robertson
o Torx

8. Use and maintain other common hand tools • Safety

• Selecting correct tool for task
• Proper usage
• General maintenance and storage

9. Identify, describe and select taps and dies • Taps

o Tap wrenches
o Dies
o Tapping internal threads
o Common tapping problems
• Cutting external threads

10. Use and maintain taps and dies • Safety

• Selecting correct tool for task
• Proper usage
• General maintenance and storage

Welder Foundation Industry Training Authority 27

04/20
 Program Content
Foundation

11. Identify, describe and select alignment tools • Drifts

• Pinch line up bars
• Pry bars
• Dogs and wedges

Achievement Criteria
Performance The learner will be evaluated on the ability to:
• Fabricate a welding bevel/drill bit point gauge.
• Layout a full-size pan.
Conditions As part of a practical shop project, given the required tools and materials.
Criteria • Welding bevel/drill bit point gauge will be evaluated for:
o Squareness and accuracy of dimensions
o Correct angles and correct placement of holes, stamps, graduations, etchings
o Overall appearance
• Pan layout will be evaluated for:
o Squareness and accuracy of measurement
o Accurate marking of break or cut lines
o Overall appearance
Completed within specifications, safety standards and time frames acceptable to industry.

Welder Foundation Industry Training Authority 28

04/20
 Program Content
Foundation

Line (GAC): A Occupational Skills

Competency: A6 Use and maintain power tools (electric and pneumatic)

Objectives
To be competent in this area, the individual must be able to:
• Describe and demonstrate the safe use and care of electric and pneumatic power tools.

LEARNING TASKS CONTENT

1. Identify, describe and select power drilling tools • Portable power drills
• Rechargeable drills
• Keyless chuck drills
• Hammer drills
• Magnetic base drills
• Drill presses
• Twist drill bits
• Hollow bits
• Hole saws
• Carbide tipped masonry bits

2. Use and maintain power drilling tools • Safety

• Selecting correct tool for task
• Set up and adjustment
• Proper usage
• General maintenance and storage

3. Identify, describe and select power grinding • Stationary grinders

tools • Portable grinders
• Stationary belt sanders
• Portable belt sanders
• Abrasives and disks
• Carbide burrs
• Mini belt sanders

4. Use and maintain power grinding tools • Safety

• Selecting correct tool for task
• Set up and adjustment
• Proper usage
• General maintenance and storage

5. Identify, describe and select power shearing • Power squaring shears

tools • Rotary throatless shears
• Universal machines
• Iron worker
• Nibblers
• Pipe cutters

Welder Foundation Industry Training Authority 29

04/20
 Program Content
Foundation

6. Use and maintain power shearing tools • Safety

• Selecting correct tool for task
• Set up and adjustment
• Proper usage
• General maintenance and storage

7. Identify, describe and select power sawing • Abrasive cut-off saw

tools • Power hacksaw
• Metal-cutting band saws
• Reciprocating saws
• Sabre
• Circular saws
• Blades for metal-cutting saws

8. Use and maintain power sawing tools • Safety

• Selecting correct tool for task
• Set up and adjustment
• Proper usage
• General maintenance and storage

9. Identify, describe and select specialty tools • Scaler

• Needle scaler

10. Use and maintain specialty tools • Safety

• Selecting correct tool for task
• Set up and adjustment
• Proper usage
• General maintenance and storage
Achievement Criteria
Performance The learner will be evaluated on the use of power tools, including:
• Sharpen twist drill bits using freehand method.
• Grind, drill, tap and cut low carbon steel flat bar.
Conditions As part of a practical shop project, given the required tools and materials.
Criteria • Sharpening of twist drill bits will be evaluated for:
o Accuracy of angles
o Absence of distempering, chips, cracks
o Cutting efficiency of sharpened drill bits
o Overall appearance
• Grind, drill, tap and cut low carbon steel flat bar will be evaluated for:
o Smooth surfaces/correct location of holes
o Internal threads, alignment and fit
o Correct location of cut
o Clean cut (absence of burrs and sharp edges)
o Accuracy of dimensions
o Overall appearance
Completed within specifications, safety standards and time frames acceptable to industry.

Welder Foundation Industry Training Authority 30

04/20
 Program Content
Foundation

Line (GAC): A Occupational Skills

Competency: A7 Describe shop materials

Objectives
To be competent in this area, the individual must be able to:
• Identify and describe common sheet, plate, pipe and structural shapes.

LEARNING TASKS CONTENT

1. Identify and describe materials • Plate and sheet

o Specifying sheet sizes
o Specifying plate sizes
• Steel bars
o Rectangular bar, flat bar and strip stock
o Square bar
o Round bar
o Half oval bar
o Hexagon bar
o Octagon bar
• Shapes
o W, S and M shapes
• Angles
o Equal leg lengths
o Unequal leg angles
o Structural tees
o Channel
• Structural tubing (hollow structural sections)
o Round tubing
• Structural pipe

2. Select materials • Read bill of materials

• Resource materials

3. Describe correct procedures for manually • Personal Protective Equipment (PPE)

handling and storing structural shapes • Correct body position/posture for lifting
• Center of gravity
• Block and store
o Location and environment

Welder Foundation Industry Training Authority 31

04/20
 Program Content
Foundation

Line (GAC): A Occupational Skills

Competency: A8 Apply lifting, hoisting and rigging procedures

Objectives
To be competent in this area, the individual must be able to:
• Apply safety procedures for rigging and material handling.
• Perform safe working load (SWL) calculations involving geometric formulas, volumes and capacities.
• Perform safe manual-lifting procedures.
• Describe wire rope, slings and rigging hardware.
• Use fibre ropes to tie knots.
• Operate hoisting equipment to perform lift.

LEARNING TASKS CONTENT

1. Describe and apply safety precautions for • WorkSafeBC regulations

rigging and hoisting • PPE
• Hand signals
• Manufacturers’ specifications
• Common safety hazards
o SWL not known
o Defective equipment and hardware
o Unrated lifting lugs
o Electrical contact
o Weather conditions

2. Describe the basic principles of lifting, hoisting • Center of gravity

and rigging • Safe working loads (SWL)
o Interpret safe working load charts
o WorkSafeBC regulations (part 15)

3. Describe and perform safe manual lifting • Personal Protective Equipment (PPE)
• Correct body position/posture for lifting
• Center of gravity
• Block and store

4. Identify common rigging hardware (below-the- • Hooks

hook lifting devices) o Hoisting hooks
o Choker hooks
• Clips
o Wire rope clips (number and spacing)
o Cable clips
• Attachments
o Swivels
o Shackles
o Eye bolts

Welder Foundation Industry Training Authority 32

04/20
 Program Content
Foundation

o Snatch blocks
o Turnbuckles
o Spreader and equalizer beams
o Plate clamps
• Magnets

5. Describe the characteristics, applications and • Wire ropes

care of wire rope, fibre rope and slings o Diameter
o SWL calculations
o Rejection criteria
• Sling types
o Synthetic web slings
o Wire rope slings
o Alloy steel chain slings
o Metal mesh slings
• Fibre ropes
o Parts of rope
o Basic knots and hitches
− Figure 8
− Square (reef) knot
− Clove hitch
− Sheetbend
− Round turn and two half hitches
− Bowline
− Half hitch
• Mandatory rating tags on slings
• Storage
• Visual inspection
• Rejection criteria
• Safe working loads (SWL)

6. Describe and demonstrate applications of • Tag lines (rigging)

knots, bends and hitches • Load lines (tie-down)
• Hoisting lines (materials)
• Safety harness
• Joining ropes
• Stopper knot

7. Describe common sling configurations and • Sling configurations

their application o Single vertical hitch
o Bridle hitch
o Single basket hitch
o Double basket hitch
o Double-wrap basket hitches
o Single choker hitch
o Double choker hitch
o Double-wrap chocker hitch
• Sling angles

Welder Foundation Industry Training Authority 33

04/20
 Program Content
Foundation

• Adjust rated capacity for sling configurations

8. Describe common types of hoisting equipment • Jacks (ratchet, hydraulic)

and their application • Jack stands
• Rollers
• Block and tackle
• Chain blocks
• Lever-operated hoists or come-a-longs
• Hoists
o Chain hoists
o Grip action hoists (Tirfors)
o Electric hoists and pendant cranes
o Floor hoists
• Winches
• Forklifts
• Crane types
o Gantry cranes
− Remote pendant control
− Overhead runways
o Jib cranes
o Overhead travelling cranes
o Mobile cranes
• Tower cranes

8. Determine weight, centre of gravity and safe • Load weight calculations

working loads (SWL) o Plate
o Structural steel shape
o Pipe
• Centre of gravity
• Safe working loads (SWL)
o Explain safe working load ratios
o WorkSafeBC regulations (part 15)
• Material and personnel

9. Operate hoisting equipment • Hoisting equipment

• Factors that reduce capacity
• Plan a lift
• Estimate weight of load
• Select proper rigging
• Attach proper rigging

10. Lift, hoist and move loads • Hoist (chain fall)

• Come-alongs
• Tirfor™ jack

Welder Foundation Industry Training Authority 34

04/20
 Program Content
Foundation

Achievement Criteria
Performance The learner will be evaluated on the ability to:
• Perform a manual lift.
• Identify and use the proper type of hoisting equipment to perform a lift.
Conditions As part of a practical shop project, given the required materials, equipment and pre-
calculated lift plan under supervision.
Criteria • Under supervision, manual lifting will be evaluated for:
o Personal Protective Equipment (PPE)
o Correct body position/posture for lifting
o Center of gravity
o Block and store
• Under supervision, using hoisting equipment will be evaluated for:
o Visual check of the lifting equipment before use
o Checking capacity of equipment
o Attaching correct rigging configuration
o Attaching load correctly to lifting hook
o Centering lifting hook above load before lifting
o Hoisting load correctly
o Lowering load correctly
o Returning rigging to designated storage place
o Using all equipment in a safe manner
o Following all shop safety rules

Completed within specifications, safety standards and time frames acceptable to industry.

Welder Foundation Industry Training Authority 35

04/20
 Program Content
Foundation

Line (GAC): B Cutting and Gouging Processes

Competency: B1 Describe Oxy-Fuel Cutting (OFC) processes and their applications

Objectives
To be competent in this area, the individual must be able to:
• Describe the Oxy-Fuel cutting and gouging (OFC) processes, components and applications.
• Describe techniques for cutting difficult-to-cut ferrous alloys.
• Describe thermal effects and safety precautions for Oxy-Fuel processes.

LEARNING TASKS CONTENT

1. Describe the Oxy-Fuel processes and their • Principles of OFC process

components • Common components
• Process specific components

2. Describe the applications of Oxy-Fuel • Cutting plate, pipe and structural shapes
processes • Washing bolts and rivets
• Gouging and scarfing
• Stack cutting
• Cutting machines

3. Describe the cutting characteristics of ferrous • Ferrous alloys

and non-ferrous metals o Techniques for cutting ferrous alloys
o Kindling point
o Preheating
o Waster plates
• Non-ferrous alloys
o Aluminum
o Copper
o Brass
o Bronze
o Magnesium

4. Describe the thermal effects of Oxy-Fuel • Distortion

processes • Surface hardening

5. Describe safety requirements for Oxy-Fuel • PPE

processes • Fire and explosion prevention
o Refer to WorkSafeBC for fire watch
regulations
• Toxic fumes/ventilation
o Cadmium
o Zinc
o Lead
o Beryllium
o Other alloys
o Synthetic materials

Welder Foundation Industry Training Authority 36

04/20
 Program Content
Foundation

Line (GAC): B Cutting and Gouging Processes

Competency: B2 Describe Oxy-Fuel Cutting (OFC) equipment and its operation

Objectives
To be competent in this area, the individual must be able to:
• Describe oxygen and fuel gases used in Oxy-Fuel processes.
• Describe gas cylinders and regulators, tips and attachments, and cutting machines used in Oxy-Fuel
processes.

LEARNING TASKS CONTENT

1. Describe the gases and their properties, used in • Oxygen

Oxy-Fuel processes • Acetylene
• Other fuel gases
o Methylacetylene-propadiene
o Natural gas
o Propane gas

2. Describe oxygen and fuel gas cylinders • Oxygen cylinders

• Oxygen cylinder valve
• Acetylene cylinders
• Acetylene cylinder valves
• Cylinder safety devices
• Liquid fuel cylinders
• Storage and handling of cylinders
o Storage
o Handling
o Safety precautions for using cylinders

3. Describe pressure regulators and their • Oxygen and acetylene regulators

functions • Single and two-stage regulators
o Single-stage regulator
o Two-stage regulator
o Safe use of regulators

4. Describe Oxy-Fuel hoses and fittings • Oxy-Fuel hose

o Safe handling of hose
o Hose fitting
• Torch line explosions – causes and
prevention
o Backfire
o Flashbacks
• Reverse flow check valves

Welder Foundation Industry Training Authority 37

04/20
 Program Content
Foundation

5. Describe torches and tips used in the Oxy-Fuel • Injector torch

processes • Equal pressure torch
• Torch types
o One-piece cutting torch
o Two-piece cutting torch
o Machine torch
• Cutting tips
o Cutting tip size
o Types of cutting tips
o Cutting tip maintenance
• Tips for special purposes
o Rivet-cutting tips
o Gouging tips
o Heating tips

6. Describe gas manifold systems • Oxygen manifold systems

• Acetylene manifold systems

7. Describe Oxy-Fuel gas cutting accessories and • Manual cutting guides

machines • Straight-line cutting guide
• Circle cutting guide
• Templates
• Cutting machines
o Straight-line cutting machines
o Shape-cutting machines
• Electronic eye tracer
• Magnetic tracer
• Pipe-bevelling machines

Welder Foundation Industry Training Authority 38

04/20
 Program Content
Foundation

Line (GAC): B Cutting and Gouging Processes

Competency: B3 Perform freehand and guided cuts on low carbon steel (OFC)

Objectives
To be competent in this area, the individual must be able to:
• Assemble the appropriate oxy-fuel cutting equipment, set pressures, light and adjust the cutting torch.
• Make freehand and guided cuts on low carbon steel plate.
• Make freehand cuts on round stock, structural shape and pipe.
• Pierce holes in low carbon steel plate.

LEARNING TASKS CONTENT

1. Assemble, ignite and shut down a portable • Portable oxyacetylene outfit

oxyacetylene outfit o Secure the cylinders
o Remove the caps
o Crack the valves
• Attach the regulators
• Install RFCV
o Connect the hoses
o Open the valves
o Purge the hoses
• Flashback arrestors
• Connect the cutting attachment
o Set working pressure
• Select and install the appropriate cutting tip
o Set working pressure
• Test for leaks
o Light and adjust flame
o Ignite the torch
o Add oxygen to the flame
• Shut down an oxyacetylene outfit
• Disassemble the oxyacetylene outfit

Welder Foundation Industry Training Authority 39

04/20
 Program Content
Foundation

2. Describe the characteristics of an acceptable • Characteristics of an acceptable cut

cut o Top edge square
o Vertical draglines
o Bottom edge sharp
• Factors that affect the quality of cut
o Speed of travel
o Surface condition of the metal
o Oxygen pressure
o Tip size
o Size of the preheat flames
o Thickness of the material
o Position of the cutting torch tip
o Position in relation to the work
o Starting cuts

3. Perform freehand cuts on low carbon steel • Low carbon steel sheet
o Freehand square cuts
o Freehand bevel cuts
• Low carbon steel plate
o Freehand square cuts
• Structural steel
o Freehand square cuts
o Freehand bevel cuts
• Nuts and weldments
o Wash nuts
o Gouge weldments
• Low carbon steel pipe
o Freehand square cuts
o Freehand bevel cuts

4. Perform guided cuts on low carbon steel • Low carbon steel plate
o Guided square cuts
o Guided bevel cuts
o Guided circular cuts
• Low carbon steel sheet
o Guided square cuts
• Steel pipe

5. Pierce holes in low carbon steel plate • Freehand piercing of miscellaneous shapes

6. Wash nuts off bolts and gouge weldments • Wash nuts off bolts
• Gouge weldments

Welder Foundation Industry Training Authority 40

04/20
 Program Content
Foundation

Achievement Criteria
Performance The learner will be evaluated on the ability to:
• Assemble, ignite and shutdown Oxy-Fuel equipment.
• Perform freehand and guided cuts on low carbon steel plate, sheet round stock,
structural shapes and pipe.
Conditions As part of a practical shop project, given the required tools and materials.
Criteria • Correct procedures followed for:
o Assembly, setup and shutdown
o Igniting and adjusting cutting and heating torches
o Cleaning gas cutting tips
o Repairing gas hose connection
• All cuts and holes pierced will be evaluated for:
o Top and bottom edges are sharp (not rounded)
o Slag is minimal and easily removed
o Cut is consistently square (90º, not bevelled)
o Draglines are perpendicular and not too pronounced
o Cut surface is flat and not rounded or concave
o Cut line is followed (cuts are straight - holes are desired size and round)
• Wash nuts off bolts will be evaluated for:
o Cut quality
o Slag is minimal and easily removed
o No damage to the bolt
o No damage to the plate surfaces

Completed within specifications, safety standards and time frames acceptable to industry.

Welder Foundation Industry Training Authority 41

04/20
 Program Content
Foundation

Line (GAC): B Cutting and Gouging Processes

Competency: B4 Use automatic and semi-automatic cutting machines (OFC)

Objectives
To be competent in this area, the individual must be able to:
• Set up and operate automatic and semi-automatic cutting machines and produce high quality straight
cuts, bevel cuts and pipe bevel cuts.

LEARNING TASKS CONTENT

1. Perform cuts with a straight-line cutting • Straight cuts

machine using Oxy-Fuel gas

2. Perform cuts with a shape-cutting machine • Bevel cuts

using Oxy-Fuel gas

3. Perform cuts with a pipe-bevelling machine • Pipe cuts

using Oxy-Fuel gas • Pipe bevel cuts

4. Use automatic and semi-automatic cutting • Set up

machines o Automatic cutting machines
o Semi-automatic cutting machines
• Perform cuts
o Straight cuts
o Bevel cuts
o Pipe bevel cuts

Achievement Criteria
Performance The learner will be evaluated on the ability to perform cuts with automatic and semi-
automatic cutting machines.
Conditions As part of a practical shop project, given the required tools and materials.
Criteria • Demonstrate correct setup and safe operation of straight line-cutting machine, shape-
cutting machine and pipe-bevelling machine
• Cut and bevels will be evaluated for:
o Top and bottom edges are sharp and square
o Slag is minimal and easily removed
o Cut is consistently square (90°) or bevelled (37.5° or 30°) as per directions
o Draglines are vertical and not too pronounced
o Cut surface is flat and not rounded or concave
o The cut is straight (cut line was followed)
o Preheat flame-to-work distance was the same all around the pipe
o Correct cutting sequence was followed

Completed within specifications, safety standards and time frames acceptable to industry.

Welder Foundation Industry Training Authority 42

04/20
 Program Content
Foundation

Line (GAC): B Cutting and Gouging Processes

Competency: B5 Describe CAC-A and PAC processes, equipment and their applications

Objectives
To be competent in this area, the individual must be able to:
• Describe CAC-A equipment and its cutting and gouging operations.
• Describe PAC equipment and its cutting and gouging operations.

LEARNING TASKS CONTENT

1. Describe the CAC-A process and equipment • Principles of CAC-A

• Components
o Power sources
o Air supply
o Power rating
o DC power sources
o Connecting two DC power sources in
parallel
o Power cables
o Electrode holder
• Electrode types, shapes and size
• Quality of cut surfaces
• Effects on the base metal

2. Describe the applications of CAC-A • Types of cuts

o Manual
o Machine
o Bevelling
o Washing
• Elements affecting cut
o Polarity
o Torch angle
o Travel speed
o Correct positioning of electrode
o Electrode stickout
o Operator comfort
o Operating sequence
o Gouging in other positions
− Vertical
− Horizontal
− Overhead
• Weld defects
• Disassembly and repair

3. Describe the PAC process and equipment • PAC process fundamentals

o Advantages
o Quality of cut

Welder Foundation Industry Training Authority 43

04/20
 Program Content
Foundation

− Air quality control

− Oil
− Moisture
− Contaminants
o Metallurgical effects
• PAC cutting system and equipment
o Electrodes
o Ventilation
o Power sources
o Control unit
o Torches
− Consumables
− Tip stand-off
− Air-cooled
− Water-cooled
o Gases (plasma and secondary)
o Water-table cutting
− Electric shock
− Ventilation
− Arc radiation
− Noise

4. Describe the applications of PAC • Types of cuts

o Machine
o Manual
o Stack
o Gouging
• Elements affecting cut
o Materials being cut
− Hard-to-cut metals
− Carbon steel
o Operating variables
− Air pressure
− Travel speed
− Double arcing
− Tip-to-work distance
− Travel direction
− Torch maintenance

5. Describe procedures for gouging cast iron • Polarity

• Pre and post heat

6. Describe safety requirements, precautions and • PPE

procedures for cutting and gouging o Eye protection for the electrical welding
processes
o Hearing protection
o Welding helmets
o Radiation protection
o Respiratory protection

Welder Foundation Industry Training Authority 44

04/20
 Program Content
Foundation

• Electric shock
o Damp conditions
o Treatment of electric shock victims
• Fire and explosion prevention
o Refer to WorkSafeBC for fire watch
regulations
• Safety requirements for operating electric
welding equipment
o Maintenance of equipment
o Welding cables and connections
o Electrode holder
o Ground clamp
o Electrode stub disposal
o Slag
• Toxic fumes/ventilation

Welder Foundation Industry Training Authority 45

04/20
 Program Content
Foundation

Line (GAC): B Cutting and Gouging Processes

Competency: B6 Use CAC-A and PAC cutting and gouging processes and equipment

Objectives
To be competent in this area, the individual must be able to:
• Set up CAC-A equipment and demonstrate its cutting and gouging operations.
• Set up PAC equipment and demonstrate its cutting and gouging operations.

LEARNING TASKS CONTENT

1. Use CAC-A process on low carbon steel • Set up equipment

• Gouge in all positions
• Bevel in the flat position
• Remove back-up strip/backing material
• Remove discontinuities and faults on groove
and fillet welds
• Prepare joints

2. Use PAC process on low carbon steel • Set up equipment

• Perform cuts
o Square cuts
− Ferrous and non-ferrous
o Bevel cuts
o Circular cuts
• Gouge in all positions
• Bevel in the flat position
• Prepare joints

Achievement Criteria
Performance The learner will be evaluated on the ability to:
• Use CAC-A equipment to prepare weld joints and to remove weld faults on low carbon
steel.
• Assemble PAC equipment and perform bevel cuts, square cuts and circular cuts on
both ferrous and non-ferrous metals.
Conditions As part of a practical shop project, given the required tools and materials.
Criteria • Weld joints will be evaluated for:
o Uniform width and depth
o Clean, smooth groove in a straight line
o Absence of arc strikes
o No traces of carbon deposit
o Overall appearance
• Removal of weld faults will be evaluated for:
o Complete removal of weld metal or weld defect
o Absence of arc strikes
o No traces of carbon deposit

Welder Foundation Industry Training Authority 46

04/20
 Program Content
Foundation

o No damage to base metal

o Clean, smooth gouge surfaces
o Shape of groove in respect to weld repair
o Overall appearance
• PAC cuts will be evaluated for:
o Top edge is sharp (not rounded)
o Slag is minimal and easily removed
o Square cuts are consistently square (90°, not bevelled)
o Bevelled cuts have a consistent bevel angle of 30°
o Draglines are consistent and not too pronounced
o Cut surface is flat and not rounded or concave
o Bottom edge is sharp
o Cut edge is straight (cut line was followed)

Completed within specifications, safety standards and time frames acceptable to industry.

Welder Foundation Industry Training Authority 47

04/20
 Program Content
Foundation

Line (GAC): C Fusion and Braze Welding (TB) Using the Oxy-Fuel (OFW)
Process

Competency: C1 Describe fusion welding, braze welding and brazing processes and
their applications

Objectives
To be competent in this area, the individual must be able to:
• Describe fusion welding, braze welding, brazing processes, their applications and safety precautions.

LEARNING TASKS CONTENT

1. Describe the fusion welding process and its • Principles of fusion welding
application • Filler rods
• Applications of fusion welding
• Maintenance or repair work
• Fabrication
• Safety requirements

2. Describe the braze welding process and its • Principles of braze welding
application • Filler rods
• Applications
• Maintenance or repair work
• Light gauge metals
• Dissimilar metals
• Grey cast iron
• Non-ferrous metals
• Safety requirements

3. Describe the brazing process and its • Principles of brazing

applications • Filler rods
• Applications
• Safety requirements

Welder Foundation Industry Training Authority 48

04/20
 Program Content
Foundation

Line (GAC): C Fusion and Braze Welding (TB) Using the Oxy-Fuel (OFW)
Process

Competency: C2 Describe fusion welding, braze welding and brazing equipment and its
operation

Objectives
To be competent in this area, the individual must be able to:
• Describe fusion and braze welding equipment and its operation.

LEARNING TASKS CONTENT

1. Describe OFW equipment and application • Fundamentals of OFW process

• Types of equipment
o Regulators
o Flashback arrestors
o Hoses
o Types of torch bodies
o Torch attachments
• Match equipment to application

2. Describe fuel gas precautions and procedures • Characteristics of fuel gases

• Fuel gas delivery systems
• Cylinder and gases handling procedures
• Cylinder and gases storage requirements
• Hazards associated with different fuel gases
• Match fuel gas to type of equipment
• Identify type of fuel gas from information on
label

3. Describe the main factors to consider in gas • Correct tip sizes

fusion welding • Correct flame setting
• Distance between work and flame
• Types of welding technique
• Torch angle
• Speed and travel movement
• Operator comfort and position

4. Describe tips and their application • Type of base metal

• Base metal thickness
• Tip functions
• Required weld
• Types of tips
• Match tip to base metal and required weld
• Differentiate between tips

Welder Foundation Industry Training Authority 49

04/20
 Program Content
Foundation

5. Describe consumables and requirements • Fluxes

• Filler metals

6. Describe operating parameters • Base metal thickness

• Welding tip sizes
• Gas regulators
• Manufacturers’ recommendations
• Other task specific guidelines
• Reference information

7. Describe setting up OFW equipment • Set-up procedures

• OFW safe practices
• Equipment leak test procedures
• Safety precautions
• Reference manufacturers’ instructions

8. Describe operating OFW equipment • Required task-specific PPE

• Safe operating practices
o Prevent flashback
− Recognize flashback
− Flashback conditions
o Prevent backfire burnback
− Recognize backfire burnback
− Backfire burnback conditions
• Welding techniques
• Metallurgy
• Types of flames
• Braze welding techniques
• Brazing fluxes
• Flame temperatures
• Metal fusion techniques
• Light and adjust torch
• Detecting defects in weld

9. Describe process related weld discontinuities • Weld defects

and their causes • Lack of penetration
• Lack of fusion
• Undercut
• Reinforcement on groove welds
• Correct weld profile for fillet weld

Welder Foundation Industry Training Authority 50

04/20
 Program Content
Foundation

Line (GAC): C Fusion and Braze Welding (TB) Using the Oxy-Fuel (OFW)
Process

Competency: C3 Describe filler metals, fluxes and tips used for fusion welding, braze
welding and brazing

Objectives
To be competent in this area the individual must be able to:
• Identify filler metals, fluxes and tips used for fusion welding, braze welding and brazing.

LEARNING TASKS CONTENT

1. Describe the filler rods for fusion welding, braze • Filler rods for fusion welding
welding and brazing • Low carbon steel rods
o RG 45
o RG 60
o RG 65
• Filler rod size
• Brazing and braze welding alloys
o Silver (BAg)
o Aluminum-silicon (BA 1Si)
o Precious-metals (BAu)
o Copper and copper-zinc (BCu and
RBCuZn) brass
o Copper-phosphorous (BCuP)
o Magnesium (BMg)
o Nickel (BNi)
o Cobalt (BCo)
• Choosing a brazing filler rod
o Braze welding filler rods

2. Describe the flux for fusion welding, braze • Purpose of flux

welding and brazing o Welding flux
o Brazing flux
• High temperature
• Special purpose or low temperature
• General purpose flux
• Choosing the correct brazing flux
o Using flux
o Removing flux

3. Describe tips for fusion welding, braze welding • Welding tips

and brazing o Selecting the correct welding tip
o Welding tip maintenance

Welder Foundation Industry Training Authority 51

04/20
 Program Content
Foundation

Line (GAC): C Fusion and Braze Welding (TB) Using the Oxy-Fuel (OFW)
Process

Competency: C4 Describe joint design and weld positions for OFW

Objectives
To be competent in this area, the individual must be able to:
• Identify basic joint designs, weld positions and the associated abbreviations.

LEARNING TASKS CONTENT

1. Describe the five basic joints • Corner joint

• Lap joint
• Tee joint
• Butt joint
• Edge joint

2. Describe the four basic welding positions and • Flat position (1F, 1G)
abbreviations • Horizontal position (2F, 2G)
• Vertical position (3F, 3G)
• Overhead position (4F, 4G)

Welder Foundation Industry Training Authority 52

04/20
 Program Content
Foundation

Line (GAC): C Fusion and Braze Welding (TB) Using the Oxy-Fuel (OFW)
Process

Competency: C5 Fusion weld on low carbon steel sheet

Objectives
To be competent in this area, the individual must be able to:
• Use the OFW process to fusion weld stringer beads on low carbon steel sheet.
• Use the OFW process to fusion weld fillet welds on low carbon steel sheet.
• Use the OFW process to fusion weld groove welds on low carbon steel sheet.

LEARNING TASKS CONTENT

1. Fusion weld stringer beads using the OFW • In the flat position
process o Without a filler rod
o With a filler rod

2. Fusion weld fillet welds using the OFW process • In the flat (1F) position
o Lap joint
o Corner joint
• In the horizontal (2F) position
o Lap joint
• In the vertical (3F) position
o Lap joint

3. Fusion weld groove welds using the OFW • In the flat (1G) position
process

Achievement Criteria
Performance The learner will be evaluated on the ability to fusion weld on low carbon steel sheet:
• Stringer beads, with and without filler metal, in the flat position.
• Fillet welds in the 1F, 2F and 3F (uphill) positions.
• Groove welds in the 1G position.
Conditions As part of a practical shop project, given the required tools and materials.
Criteria • Stringer beads will be evaluated for:
o Correct bead width
o Convex weld bead profile (welds with filler metal rod)
o Even ripples
o Reasonable uniform straight beads
o Complete fusion
o Overall appearance
• Fillet welds and groove welds will be evaluated for:
o Correct sheet alignment
o Correct bead width
o Slightly convex weld bead profile
o Even ripples

Welder Foundation Industry Training Authority 53

04/20
 Program Content
Foundation

o Uniform, straight bead

o Absence of undercut
o Complete fusion
o Overall appearance

Completed within specifications, safety standards and time frames acceptable to industry.

Welder Foundation Industry Training Authority 54

04/20
 Program Content
Foundation

Line (GAC): C Fusion and Braze Welding (TB) Using the Oxy-Fuel (OFW)
Process

Competency: C6 Braze weld (TB) using the OFW process

Objectives
To be competent in this area, the individual must be able to:
• Braze weld fillet welds on low carbon steel sheet using OFW process.

LEARNING TASKS CONTENT

1. Describe the procedures for braze welding low • Pre-cleaning and edge preparation
carbon steel sheet • Flame setting
• Filler rods and flux
• Number of passes
• Determining the quality of work

2. Describe braze welding groove welds on grey • Braze weld grey cast iron
cast iron using the OFW process • Pre-cleaning
• Pre-heating
• Special factors in welding grey cast iron
• Welding technique

3. Braze weld fillet welds using the OFW process • On low carbon steel sheet
o In the flat (1F) position
− Tee joint
o In the horizontal (2F) position
− Lap joint

Achievement Criteria
Performance The learner will be evaluated on the ability to braze weld:
• Fillet welds on low carbon steel sheet.
Conditions As part of a practical shop project and given the required tools and equipment.
Criteria • Welds will be evaluated for:
o Correct sheet alignment
o Correct bead width
o Slightly convex weld bead profile
o Even ripples
o Uniform, straight bead
o Good adhesion
o Overall appearance

Completed within specifications, safety standards and time frames acceptable to industry.

Welder Foundation Industry Training Authority 55

04/20
 Program Content
Foundation

Line (GAC): C Fusion and Braze Welding (TB) Using the Oxy-Fuel (OFW)
Process

Competency: C7 Silver alloy braze on similar and dissimilar metals

Objectives
To be competent in this area, the individual must be able to:
• Describe silver alloy brazing on similar and dissimilar metals using OFW processes.

LEARNING TASKS CONTENT

1. Describe the materials, equipment and • Joint preparation and design

procedures for silver brazing • Flux selection
• Filler alloys (rods)
• Flame for brazing
• Silver brazing procedure

Welder Foundation Industry Training Authority 56

04/20
 Program Content
Foundation

Line (GAC): D Shielded Metal Arc Welding (SMAW)

Competency: D1 Describe the SMAW process

Objectives
To be competent in this area, the individual must be able to:
• Describe the SMAW process.
• Describe SMAW safety requirements and precautions.

LEARNING TASKS CONTENT

1. Describe the SMAW process and its • Principles of SMAW

applications • The arc welding circuit

2. Describe safety requirements, precautions and • PPE

procedures for SMAW o Eye protection for the electrical welding
processes
o Welding helmets
o Hearing protection
o Radiation protection
o Respiratory protection
• Electric shock
o Damp conditions
o Treatment of electric shock victims
• Fire and explosion prevention
o Refer to WorkSafeBC for fire watch
regulations
• Safety requirements for operating electric
welding equipment
o Maintenance of equipment
o Welding cables and connections
o Electrode holder
o Ground clamp
o Electrode stub disposal
o Slag
o Toxic fumes/ventilation

Welder Foundation Industry Training Authority 57

04/20
 Program Content
Foundation

Line (GAC): D Shielded Metal Arc Welding (SMAW)

Competency: D2 Describe SMAW equipment and its operation

Objectives
To be competent in this area, the individual must be able to:
• Describe SMAW equipment and its operation.
• Describe the principles of electricity and types of current.
• Describe AC and DC welding power source, electrode holders, ground clamps and welding cables.

LEARNING TASKS CONTENT

1. Explain basic principles of electricity • Resistance

• Effects of resistance
• Electromagnetism
• Transformers
• Reactor

2. Describe types of current and their applications • Alternating current

• Direct current
• Polarity
• Arc blow
• Dealing with arc blow

3. Describe the effects of a volt-ampere curve on • Volt-ampere curve

the welding arc • Interpreting the volt-ampere curve
• Constant current welding power sources
• Constant potential welding power sources
• Adjusting the voltage
• Adjusting the amperage

4. Describe AC and DC welding power sources • Transformer type welding power sources
o AC transformers
− AC transformer control
o Transformer/rectifiers
− Transformer/rectifier control
o AC/DC transformers/rectifiers
o Advantages of transformer type welding
power sources
o Disadvantages of transformer type
welding power sources
• Generator/alternator type welding power
sources
• Electric motor drive DC welding power
sources
o Fuel engine driven AC, DC and AC/DC
welding power sources
o Controls

Welder Foundation Industry Training Authority 58

04/20
 Program Content
Foundation

o Advantages of generator/alternator type

welding power sources
o Disadvantages of generator/alternator
type welding power sources
• Multi-operator sets
o Inverters
o Advantages of inverter type welding
power sources
• Remote control devices
• Ratings for welding power sources
• Power requirements
• Duty cycle
• Choosing between AC and DC welding power
sources
• General maintenance of welding power
sources

5. Describe and select electrode holders, ground • Electrode holder

clamps and welding cables o Jaw
o Twist head
• Ground clamps
o Spring-loaded
o C-clamp
o Rotary
o Magnetic
• Welding cables
o Size
o Connections

Welder Foundation Industry Training Authority 59

04/20
 Program Content
Foundation

Line (GAC): D Shielded Metal Arc Welding (SMAW)

Competency: D3 Select electrodes for SMAW

Objectives
To be competent in this area, the individual must be able to:
• Describe low carbon steel filler metal electrodes.
• Describe hardsurfacing filler metal electrodes.
• Describe stainless steel filler metal electrodes.
• Describe the selection and applications of filler metal electrodes.
• Describe basic care, handling and storage of filler metal electrodes.

LEARNING TASKS CONTENT

1. Describe the operation of common electrodes • Functions of electrode coatings

for SMAW • Types of electrodes
o F1 (fast-fill)
o F2 (fill-freeze)
o F3 (fast-freeze)
o F4 (low hydrogen/basic electrode)
• Electrode coating composition
o Cellulose
o Rutile
o China clay, silica and mica
o Potassium
o Ferro-magnanese
o Iron oxide (magnetite, hematite)
o Iron powder
o Sodium silicate
• Metal transfer with SMAW electrodes
• Gravity
• Gas expansion
• Electro-magnetic force
• Electromotive force
• Surface tension

2. Describe the classifications of low carbon • Standards of coated electrode manufacture

steel electrodes • CSA and AWS designations
• Electrode length
• Electrode diameter

Welder Foundation Industry Training Authority 60

04/20
 Program Content
Foundation

3. Describe the selection of filler metal • Principles of electrode selection

electrodes for SMAW • Properties of the base metal
• Joint design and fit up
• Welding position and thickness of weld deposit
• Welding current
• Service conditions
• Production factors
• Common low carbon steel filler metal
electrodes
o E4310 (E6010)
o E4311 (E6011)
o E4313 (E6013)
o E4914 (E7014)
o E4924 (E7024)
o E4918 (E7018)
o E4928 (E7028)
• Common hardsurfacing filelr metal electrodes
• Stainless steel filler metal electrodes
o E309-15, -16, -17
• Common filler metal electrodes for grey cast
iron

4. Describe correct handling and storage of • Handling of electrodes before and after use
common electrodes • Storage of electrodes
• Electrode ovens
• Handling of electrodes in use

Welder Foundation Industry Training Authority 61

04/20
 Program Content
Foundation

Line (GAC): D Shielded Metal Arc Welding (SMAW)

Competency: D4 Describe basic joint design and weld positions for SMAW

Objectives
To be competent in this area, the individual must be able to:
• Describe basic joint design and weld positions for fillet welds using the SMAW process.
• Describe groove welds using the SMAW process.

LEARNING TASKS CONTENT

1. Describe the five basic joint types as they apply • Lap

to SMAW processes • Tee
• Corner
• Edge
• Butt

2. Describe weld types, their sizes and profiles • Bead welds

• Tack welds
• Fillet welds
• Groove welds
o Square
o Single-v and double-v
o Single bevel and double bevel
o Single U and double U
o Single J and double J
• Profiles, sizes, plate thickness transitions on
butt joints
• Plug and slot welds
• Continuous and intermittent welding

Welder Foundation Industry Training Authority 62

04/20
 Program Content
Foundation

Line (GAC): D Shielded Metal Arc Welding (SMAW)

Competency: D5 Describe weld faults and distortion in fabrications in SMAW

Objectives
To be competent in this area, the individual must be able to:
• Describe weld faults and their causes.
• Describe distortions and methods of prevention.

LEARNING TASKS CONTENT

1. Describe the process-related weld faults and • Dimensional defects

their causes • Incorrect weld size
• Overlap
• Structural discontinuities in the weld
• Under cut
• Incomplete penetration
• Lack of fusion
• Porosity
• Slag inclusion
• Cracking (internal/external)
• Insufficient throat/underfill

2. Identify distortions and determine methods of • Types of distortion

prevention and control o Longitudinal distortion
o Transverse distortion
o Angular distortion
• Distortion control
o Use mechanical methods
o Design methods
o Procedural methods
o Rate of heat input/joules
o Distribute the heat input as uniformly as
possible
o Pre-heat and post-heat when necessary

Welder Foundation Industry Training Authority 63

04/20
 Program Content
Foundation

Line (GAC): D Shielded Metal Arc Welding (SMAW)

Competency: D6 Use the SMAW process on low carbon steel plate and pipe

Objectives
To be competent in this area, the individual must be able to:
• Describe primary adjustable variables.
• Use the SMAW process to weld bead welds in the flat position.
• Use the SMAW process to perform single-pass fillet welds on low carbon steel sheet.
• Use the SMAW process to perform multi-pass fillet welds on low carbon steel plate, structural shape
to plate and on pipe to plate.
• Use the SMAW process to perform multi-pass groove welds on low carbon steel plate, structural
shape to plate, and on pipe to plate.
• Perform multi-pass groove welds without backing on low carbon steel plate.
• Perform guided bend tests.

LEARNING TASKS CONTENT

1. Describe main factors of the SMAW process • Operator comfort and position
• Machine setting
• Arc length
• Electrode angle
• Speed of travel
• Electrode oscillation

2. Describe primary adjustable variables • Arc blow

• Dealing with arc blow
• Volt-ampere curve
• Interpreting the volt-ampere curve
• Constant current welding power sources
• Adjusting the voltage
• Adjusting the amperage
• Transformer type welding power sources
• Generator/alternator type welding power
sources
• Multi-process welding power sources
o Inverters
o Advantages of inverter type welding
power sources
• Remote control devices
• Ratings for welding power sources
• Power requirements
• Duty cycle
• Choosing between AC and DC welding power
sources
• General maintenance of welding power
sources

Welder Foundation Industry Training Authority 64

04/20
 Program Content
Foundation

3. Weld beads in the flat position • Strike an arc using scratch and tap method
• Weld stringer beads in the flat position
• Weld beads in the flat position using the
weave method

4. Weld single-pass fillet welds • On low carbon steel sheet

o Horizontal (2F) position
− Lap joint
− Tee joint
o Vertical (3F) position - downhill
− Lap joint
− Tee joint

5. Weld multi-pass fillet welds • On low carbon steel plate

o Flat (1F) position
− Lap joint
− Tee joint
− Corner joint
o Horizontal (2F) position
− Lap joint
− Tee joint
− Corner joint
o Vertical (3F) position
− Lap joint - uphill
− Tee joint - uphill
− Corner joint – uphill
o Vertical (4F) position
− Lap joint
− Tee joint
− Corner joint
• On structural shape to plate
o Horizontal (2F) position
• On pipe to plate
o Horizontal (2F) position
o Fixed vertical (5F) position

6. Weld multi-pass fillet groove welds on single • On low carbon steel plate
bevel butt joints (with backing) using the SMAW o Flat (1GF) position
process o Horizontal (2GF) position
o Vertical (3GF) position - uphill
o Overhead (4GF)

7. Weld multi-pass groove welds on single-v butt • On low carbon steel plate
joints (without backing) using the SMAW o Flat (1G) position
process

8. Perform guided bend tests • Guided bend test equipment

• Types of guided bend tests
• Face bend tests

Welder Foundation Industry Training Authority 65

04/20
 Program Content
Foundation

• Root bend tests

• Side bend tests
• Causes of failure

Achievement Criteria 1
Performance The learner will be evaluated on the ability to use the SMAW process to:
• Strike an arc using the tap and scratch methods.
• Weld stringer beads in the flat position and weave beads in the flat position.
• Weld fillet welds in all positions on low carbon steel plate.
• Weld fillet welds in the 2F and 3F positions on low carbon steel sheet.
Conditions As part of a practical shop project, given the required tools and materials.
Criteria • Strike and maintain arc smoothly
• Stringer bead and weave bead welds will be evaluated for:
o Correct bead width
o Reasonable smooth straight beads
o Absence of arc strikes
o Overall appearance
o Weave bead welds will also be evaluated for crown-to-crown bead placement
• Fillet welds will be evaluated for:
o Correct alignment
o Good penetration and fusion
o Reasonable smoothness
o Legs of equal length
o Slightly convex profile
o Absence of porosity, irregularities, undercut and arc strikes
o Overall appearance

Completed within specifications, safety standards and time frames acceptable to industry.

Achievement Criteria 2
Performance The learner will be evaluated on the ability to weld using the SMAW process, including:
• Multi-pass fillet welds on pipe to plate in the 2F and 5F positions.
• Groove welds on low carbon steel plate in the 1G, 1GF, 2GF, 3GF and 4GF positions.
Conditions As part of a practical shop project and given the required tools and equipment.
Criteria • Fillet welds will be evaluated for:
o Correct alignment
o Good penetration and fusion
o Reasonable smoothness
o Legs of equal length
o Slightly convex profile
o Absence of porosity, irregularities, undercut and arc strikes
o Overall appearance
• Groove welds will be evaluated for:
o Correct alignment
o Acceptable smoothness and uniformity

Welder Foundation Industry Training Authority 66

04/20
 Program Content
Foundation

o Absence of irregularitites, distortion, undercutting at weld edge and stray strike

marks
o Good fusion (wetting) of the deposit (or cover pass) to base metal
o Maximum face reinforcement of 3.2 mm (1/8”).
o Maximum root reinforcement of 2.5 mm (3/32”).
• Coupons will be evaluated in accordance with Section IX ASME code, CSA W47.1,
W59.1 and/or applicable standards
o Weld and heat-affected zone of a transverse weld-bend specimen shall be
completely within the bent portion specimen after testing
o Guided-bend specimens shall have no open defects in the weld or heat-affected
zone exceeding 3.2 mm (1/8”) in any direction on the convex surface of the
specimen after bending
o Cracks occurring on the corners of the specimen during testing shall not be
considered unless there is definite evidence that they result from slag inclusions
on other external defects.

Completed within specifications, safety standards and time frames acceptable to industry.

Welder Foundation Industry Training Authority 67

04/20
 Program Content
Foundation

Line (GAC): D Shielded Metal Arc Welding (SMAW)

Competency: D7 Use the hardsurfacing process on low carbon steel

Objectives
To be competent in this area, the individual must be able to:
• Describe hardsurfacing preparation.
• Describe problems encountered while hardsurfacing.
• Use hardsurfacing on low carbon steel plate.

LEARNING TASKS CONTENT

1. Describe hardsurfacing preparation and • Welding polarity

procedures • Types of wear
o Abrasion
o Impact
o Erosion
o Corrosion
o Oxidation
o Compression
o Thermal shock
• Electrodes
o High-speed steels
o Austenitic manganese steels
o Chromium carbides
o Tungsten carbides
o Copper alloys
o Nickel chromium alloys
• Depositing filler metal
• Surface preparations
o Buildup
o Preheating
o Cooling rate
o Types of patterns
o Stringer beads

2. Describe problems encountered in • Dilution

hardsurfacing • Spalling
• Underbead cracking
• Stress failure
• Weld cracking
• Transverse or cross cracking
• Longitudinal or centre-line cracking
• Distortion

Welder Foundation Industry Training Authority 68

04/20
 Program Content
Foundation

3. Demonstrate build-up and hardsurfacing on low • Build up

carbon steel plate o Flat (1S) position
• Hardsurface
o Flat (1S) position
• Hardsurface buttons
o Flat (1S) position

Achievement Criteria
Performance The learner will be evaluated on the ability to use the SMAW process to buildup and hard
surface on low carbon steel plate in the flat position.
Conditions As part of a practical shop project, given the required tools and materials.
Criteria • Buildup and hardsurfacing a waffle pattern will be evaluated for:
o Correct alignment
o Good penetration
o Good fusion
o Slightly convex profile
o Reasonable smoothness
o Maximum and minimum buildup according to specifications
o Absence of irregularities, porosity, undercut and arc strikes
o Overall appearance
• Hardsurfacing a button pattern will be evaluated for:
o Good fusion
o Reasonable smoothness
o Absence of irregularities, porosity and arc strikes
o Overall appearance

Completed within specifications, safety standards and time frames acceptable to industry.

Welder Foundation Industry Training Authority 69

04/20
 Program Content
Foundation

Line (GAC): D Shielded Metal Arc Welding (SMAW)

Competency: D8 Describe the SMAW process on grey cast iron

Objectives
To be competent in this area, the individual must be able to:
• Describe the SMAW process to prepare and apply filler metal to grey cast iron.

LEARNING TASKS CONTENT

1. Describe the procedure for SMAW on grey cast • Welding techniques

iron o Hot welding
o Cold welding
o Peening to control bead shrinkage
o Patching with low carbon steel
• Electrodes
o ECI group
o EST group
o ENI group
• Joint preparation
• Problems welding grey cast iron
o Contamination
o Porosity
o Cracking
o Lack of fusion

Welder Foundation Industry Training Authority 70

04/20
 Program Content
Foundation

Line (GAC): D Shielded Metal Arc Welding (SMAW)

Competency: D9 Use the SMAW process on stainless steel and/or low carbon steel plate
and pipe

Objectives
To be competent in this area, the individual must be able to:
• Describe proper handling of stainless steel plate and consumables.
• Use the SMAW process to apply stainless steel filler metal to low carbon steel plate.

LEARNING TASKS CONTENT

1. Describe specific safety precautions when • PPE specific to stainless steel

welding stainless steel • Toxic fumes/ventilation
• Electrode coatings
o Chromium
o Nickel
• Reflective radiation

2. Describe proper handling and preparation • Material handling contamination

procedures for materials and consumables • Abrasives and hand brushes
• Rigging and tooling
• Work area
• Chemical cleaners

3. Describe the principal considerations in the • Machine settings

SMAW welding of stainless steel • Heat input
• Weld contamination
• Surface oxidation of weld area
• Distortion

4. Weld multi-pass fillet welds using stainless • Horizontal (2F) position

steel electrodes on low carbon steel plate

Welder Foundation Industry Training Authority 71

04/20
 Program Content
Foundation

Achievement Criteria
Performance The learner will be evaluated on the ability to weld multi-pass fillet welds on low carbon
steel plate in the horizontal (2F) position using stainless steel filler metal electrodes.
Conditions As part of a practical shop project, given the required tools and materials.
Criteria • Multi-pass fillet welds will be evaluated for:
o Correct alignment
o Good penetration
o Reasonable smoothness
o Legs of equal length
o Slightly convex profile
o Absence of irregularities, porosity, undercut and arc strikes
o Overall appearance

Completed within specifications, safety standards and time frames acceptable to industry.

Welder Foundation Industry Training Authority 72

04/20
 Program Content
Foundation

Line (GAC): E Semi-Automatic and Automatic Welding

Competency: E1 Describe GMAW, GMAW-P, FCAW, MCAW and SAW processes and
their applications

Objectives
To be competent in this area, the individual must be able to:
• Describe semi-automatic processes and their applications.
• Describe modes of metal transfer.
• Describe safety precautions.
• Describe weld discontinuities.

LEARNING TASKS CONTENT

1. Describe the safety considerations for semi- • PPE

automatic welding processes • Prevention of electric shock
• Fire and explosion prevention
• Maintenance of equipment
• Toxic fumes/ventilation
• Aluminum specific considerations
o Ozone
o Chemical cleaners
• Stainless steel specific considerations
o Chromium
o Nickel
o Chemical cleaners

2. Describe the GMAW process and its • Principles of GMAW

application • Application
o Advantages and disadvantages
• Components
• Modes of metal transfer
o Pinch effect
o Short-circuit transfer
o Globular transfer
o Spray transfer
o Transition currents

3. Describe the GMAW-P process and its • Principles of GMAW-P

application • Application
o Advantages and disadvantages
• Components
• Modes of metal transfer
o Pinch effect
o Globular transfer
o Spray transfer
o Transition currents

Welder Foundation Industry Training Authority 73

04/20
 Program Content
Foundation

o Pulsed spray transfer

4. Describe the FCAW process and its • Principles of FCAW

application • Application
o Advantages and disadvantages
• Components
• Modes of metal transfer
o Globular transfer
o Spray transfer

5. Describe the MCAW process and its • Principles of MCAW

application • Application
o Advantages and disadvantages
• Components
• Modes of metal transfer
o Globular transfer
o Spray transfer

7. Describe the SAW process and its application • Principles of SAW

• Application
o Advantages and disadvantages
• Components
• Filler metals
• Fluxes

8. Describe weld discontinuities in semi- • Dimensional defects

automatic and automatic welding • Incorrect weld size
• Overlap
• Structural discontinuities in the weld
• Under cut
• Incomplete penetration
• Lack of fusion
• Porosity
• Slag inclusion
• Cracking (internal/external)
• Insufficient throat/underfill

Welder Foundation Industry Training Authority 74

04/20
 Program Content
Foundation

Line (GAC): E Semi-Automatic and Automatic Welding

Competency: E2 Describe semi-automatic and automatic welding equipment and its
operation

Objectives
To be competent in this area, the individual must be able to:
• Describe semi-automatic and automatic equipment and its operation.
• Describe weld discontinuities.

LEARNING TASKS CONTENT

1. Identify power sources for semi-automatic and • Constant voltage/current power sources
automatic welding o Arc voltage
o Slope
o Inductance
• Inverter power sources
• Types of controls on power sources
o Voltage controls
o Slope controls
o Inductance controls
o Current controls
o Voltmeters and ammeters
o Remote controls and dual schedules
o Pulsed power sources
• Wire feed speed (WFS)

2. Identify the equipment for semi-automatic and • Types of systems

automatic wire-feed systems o Push
o Pull
o Push-pull
• Wire-feed controls
• Drive roll types
• Constant and variable speed wire-feeders
• Aluminum specific considerations

3. Describe welding gun assemblies for semi- • Welding gun types

automatic and automatic processes o Amperage rating
o Water cooled
o Gas cooled
o Spool
• Welding gun consumables
• Cable assembly – size and adaptors
• Liners
• Preventive maintenance
• Aluminum specific considerations

Welder Foundation Industry Training Authority 75

04/20
 Program Content
Foundation

4. Describe equipment for semi-automatic and • Welding guns

automatic welding processes o Amperage rating
o Water cooled
o Gas cooled
o Spool
o Welding gun consumables
o Welding cables
• Aluminum specific considerations
• Preventative maintenance
• Filler metal
• Shielding gases and flow devices
• Troubleshooting
o Mechanical
o Electrical
o Shielding gases

5. Describe process variables for semi-automatic • Primary process variables

and automatic welding o Voltage
o Wire feed speed
o Welding current
o Trim or arc length (GMAW-P)
• Secondary process variables
o Electrode extension (stickout)
o Arc length
o Contact tip to work distance
o Push/pull technique
o Gun to work angles
o Nozzle to work distance
o Travel speed

6. Identify process related weld discontinuities and • Dimensional defects

their causes o Incorrect weld size
o Insufficient throat/underfill
• Structural discontinuities in the weld
o Undercut
o Incomplete penetration
o Lack of fusion
o Cold lap
o Porosity
o Cracking (internal/external)
• Slag inclusions

Welder Foundation Industry Training Authority 76

04/20
 Program Content
Foundation

Line (GAC): E Semi-Automatic and Automatic Welding

Competency: E3 Describe filler metal and shielding gases for semi-automatic and
automatic processes

Objectives
To be competent in this area, the individual must be able to:
• Describe filler metal and shielding gases for semi-automatic and automatic processes.
• Describe the CSA and AWS filler metal classification systems and specifications for semi-automatic
and automatic processes.
• Describe the application for commonly used semi-automatic and automatic processes.
• Describe the basic care, handling and storage procedures for filler metals used with semi-automatic
and automatic processes.

LEARNING TASKS CONTENT

1. Describe filler metal for GMAW • Low carbon steel filler metal classification
systems
o CSA
o AWS
• Application of most common GMAW wires
o ER49S-1 to 7 (ER70S-1 to 7)
o ER49S-G (ER70S-G)
• Handling and storage
• Aluminum filler metal classification
• Stainless steel filler metal classification

2. Describe low carbon steel filler metals for • Major classifications of FCAW low carbon
FCAW and MCAW steel filler metals
o Gas-shielded wire (T-1 and T-9)
o Self-shielded wire (T8 and T11)
• Major classifications of MCAW low carbon
steel filler metals
• Filler metal handling procedures
• Filler metal storage requirements

3. Describe low carbon steel filler metals for SAW • Types

• Classifications
• Handling and storage requirements

4. Describe fluxes for SAW • Types

• Classifications
• Handling and storage requirements

5. Describe the shielding gases for semi- • Types of shielding gases

automatic and automatic processes o Single gas
− Carbon dioxide
− Inert (argon and helium)
o Mixed gas

Welder Foundation Industry Training Authority 77

04/20
 Program Content
Foundation

−Argon-oxygen mixtures
−Helium-argon mixtures
−Specific gas mixtures to suit
applications
− Quaternary mixtures
• Properties
o Density
o Thermal conductivity
o Ionization potential
o Flowrates for shielding gases
− Solutions for regulator “freeze-up”
o Cathode jet
• Components of shielding gas systems
o Shielding gas cylinders
o Carbon dioxide cylinders
o Regulators
o Flowmeters
o Manifold systems
o Gas mixers
• Safe handling

Welder Foundation Industry Training Authority 78

04/20
 Program Content
Foundation

Line (GAC): E Semi-Automatic and Automatic Welding

Competency: E4 Use the GMAW and GMAW-P process

Objectives
To be competent in this area, the individual must be able to:
• Use the GMAW process to weld on low carbon steel plate.
• Use the GMAW process to weld on aluminum plate.
• Use spray transfer.
• Use the GMAW and GMAW-P processes to weld fillet welds on aluminum and stainless steel plate.
• Use the GMAW-P processes to weld fillet welds on aluminum and stainless steel plate.
• Use the GMAW processes to weld groove welds on low carbon steel plate and sheet
• Perform troubleshooting and maintenance of GMAW equipment.

LEARNING TASKS CONTENT

1. Set up GMAW equipment using a DC • CV power source

constant voltage power source • Wire feeder
• Drive rolls
• Welding gun
• Cable
• Wire
• Cylinder gas
• Flow meter
• Ground clamp

2. Weld stringer beads using the GMAW • On low carbon steel plate
process o In the flat (1S) position

3. Weld single-pass fillet welds using the • On low carbon steel sheet
GMAW process o In the horizontal (2F) position
− Lap
− Tee
o In the vertical (3F) position
− Lap (downhill)
− Tee (downhill)
• On low carbon steel plate
o In the flat (1F) position
− Lap
− Tee
− Corner
o In the horizontal (2F) position
− Lap
− Tee
− Corner
o In the vertical (3F) position
− Lap (uphill and downhill)

Welder Foundation Industry Training Authority 79

04/20
 Program Content
Foundation

− Tee (uphill and downhill)

• On aluminum plate
o In the horizontal (2F) position
− Lap

4. Weld multi-pass fillet welds using the GMAW • On low carbon steel plate
short circuit transfer process o In the vertical (3F) position
− Tee (uphill and downhill)

5. Weld multi-pass fillet welds using the GMAW • On low carbon steel plate
spray transfer process o In the flat (1F) position
− Lap
− Tee
o In the horizontal (2F) position
− Lap
− Tee
• On aluminum plate
o In the horizontal (2F) position
− Tee

6. Describe the principal considerations for • Set welding variables

welding aluminum using the GMAW process • Heat input
• Shielding gases
• Weld contamination
• Surface oxidation of weld area
• Distortion

7. Identify welding variables for GMAW-P • Pre-selected variables

o Equipment selection
o Filler metal selection
o Mode of metal transfer and shielding
gas
• Primary adjustable variables
o Welding current
o Trim
• Secondary adjustable variables
o Pushing and pulling techniques
o Travel speed
o Stickout
o Gun angle
• Troubleshooting
o Dimensional defects
o Incorrect weld size
o Overlap
o Excessive reinforcement
o Structural discontinuities in the weld
o Under cut
o Incomplete penetration

Welder Foundation Industry Training Authority 80

04/20
 Program Content
Foundation

o Lack of fusion
o Porosity
o Cracking (internal/external)
• Insufficient throat/underfill

8. Set up GMAW-P equipment • Assemble GMAW-P equipment

o Wire feeder requriements
• Power source requirements

9. Describe the principle considerations for • Set welding variables

welding different types of metals using the • Heat input
GMAW and GMAW-P processes
• Types of metals
• Low carbon steel sheet and plate
• Stainless steel
• Aluminum

10. Weld single-pass fillet welds using the • On low carbon steel sheet
GMAW-P process o Horizontal (2F) position
− Lap joint
− Tee joint
o Vertical (3F) position - downhill
− Lap joint
− Tee joint

11. Weld multi-pass fillet welds using the • On low carbon steel plate
GMAW-P process o Horizontal (2F) position
− Lap joint
o Vertical (3F) position - uphill
− Lap joint
− Tee joint
o Overhead (4F) position
− Lap joint

12. Weld multi-pass fillet welds using the GMAW • On low carbon steel sheet or plate
spray transfer process o Horizontal (2F) position
− Tee joint

13. Weld single-pass square groove welds using • On low carbon steel sheet
the GMAW short circuit transfer process o Flat (1G) position
o Vertical (3G) position - downhill

14. Weld single-pass square groove welds using • On low carbon steel sheet
the GMAW-P process o Horizontal (2G) position

15. Weld multi-pass groove welds using the • On low carbon steel plate with single
GMAW spray transfer process bevel butt joint (with backing)
o Flat (1GF) position

16. Weld multi-pass groove welds using the • On low carbon steel plate with single-vee
GMAW short circuit transfer process butt joint

Welder Foundation Industry Training Authority 81

04/20
 Program Content
Foundation

o Flat (1G) position

o Vertical (3G) position - downhill

17. Weld multi-pass fillet welds using the GMAW • On aluminum plate
and GMAW-P processes on aluminum plate o Horizontal (2F) position
− Lap joint
− Tee joint
o Vertical (3F) position – uphill
− Lap joint
− Tee joint
o Overhead (4F) position
− Tee joint

18. Weld single-pass fillet welds using the • On stainless steel plate
GMAW and GMAW-P processes on stainless o Horizontal (2F) position
steel plate − Lap joint
− Tee joint

Achievement Criteria 1

Performance The learner will be evaluated on the ability to use the GMAW process to:
• Set up GMAW equipment using a DC constant voltage welding power source.
• Weld beads in the 1S position and fillet welds in the 1F, 2F and 3F uphill positions on
low carbon steel plate.
• Weld fillet welds in the 2F and 3F downhill positions and on low carbon steel sheet.
• Weld fillet welds in the 2F positions on alunimum plate.
Conditions As part of a practical shop project, given the required tools and materials.
Criteria • Beads will be evaluated for:
o Correct bead width
o Reasonable straight and uniform weld beads
o Absence of irregularities and arc strikes
o Overall appearance
• Fillet welds will be evaluated for:
o Correct weld alignment
o Correct fillet leg length
o Slightly convex weld bead profile
o Absence of irregularities, porosity, undercut and arc strikes
o Good fusion
o Overall appearance
o In addition to the above, welds on alumimum will be evaluated for weld spatter

Completed within specifications, safety standards and time frames acceptable to industry.

Achievement Criteria 2
Performance The learner will be evaluated on the ability to use GMAW and GMAW-P to weld:
• Fillet welds on aluminum and stainless steel plate
• Groove and fillet welds on low carbon steel plate and sheet.

Welder Foundation Industry Training Authority 82

04/20
 Program Content
Foundation

Conditions As part of a practical shop project, using the GMAW and GMAW-P processes and
materials
Criteria • Groove welds will be evaluated for:
o Correct alignment
o Acceptable smoothness and uniformity
o Absence of irregularitites, distortion, undercutting at weld edge and stray strike
marks
o Good fusion (wetting) of the deposit (or cover pass) to base metal
o Maximum face reinforcement of 3.2 mm (1/8”).
o Maximum root reinforcement of 2.5 mm (3/32”).
• Coupons will be evaluated in accordance with CSA W47.1 and/or Section IX ASME
code
o Weld and heat-affected zone of a transverse weld-bend specimen shall be
completely within the bent portion specimen after testing
o Guided-bend specimens shall have no open defects in the weld or heat-affected
zone exceeding 3.2 mm (1/8”) in any direction on the convex surface of the
specimen after bending
o Cracks occurring on the corners of the specimen during testing shall not be
considered unless there is definite evidence that they result from slag inclusions
on other external defects.

Completed within specifications, safety standards and time frames acceptable to industry.

Welder Foundation Industry Training Authority 83

04/20
 Program Content
Foundation

Line (GAC): E Semi-Automatic and Automatic Welding

Competency: E5 Use the FCAW process

Objectives
To be competent in this area, the individual must be able to:
• Use the FCAW gas-shielded process to weld fillet welds on low carbon steel plate.
• Use the FCAW self-shielded process to weld fillet welds on low carbon steel plate.
• Use the FCAW process to weld fillet welds using stainless steel filler on low carbon steel plate.
• Describe hardsurfacing for FCAW.

LEARNING TASKS CONTENT

1. Identify welding variables for the FCAW • Pre-selected variables

process o Equipment selection
o Filler metal selection
o Mode of metal transfer
o Primary adjustable variables
o Welding current
o Arc voltage
• Secondary adjustable variables
o Pushing and pulling techniques
o Travel speed
o Stickout
o Gun angle

2. Weld stringer beads using the FCAW process • On low carbon steel plate using self-
shielding filler metal
o Flat (1S) position
• On low carbon steel plate using gas-
shielded filler metal
o Flat (1S) position

3. Weld single-pass fillet weld • On low carbon steel sheet

o Horizontal (2F) position
− Lap joint

4. Weld multi-pass fillet weld using the FCAW • On low carbon steel plate
process and self-shielding filler metal o Flat (1F) position
− Lap joint
o Horizontal (2F) position
− Tee joint
o Vertical (3F) position
− Tee joint - uphill
• On structural shape to plate
o Overhead (4F) position

5. Weld multi-pass fillet weld using the FCAW • On low carbon steel plate
process and gas-shielded filler metal o Flat (1F) position

Welder Foundation Industry Training Authority 84

04/20
 Program Content
Foundation

− Tee joint
o Horizontal (2F) position
− Lap joint
− Tee joint
o Vertical (3F) position
− Lap joint
− Tee joint - uphill
o Overhead (4F) position
− Tee joint
• On structural shape to plate
o Horizontal (2F) position

6. Describe the principal considerations in the • Set welding variables

FCAW welding of stainless steel • Heat input
• Shielding gases
• Weld contamination
• Surface oxidation of weld area
• Distortion

7. Weld multi-pass fillet weld using the FCAW • On low carbon steel plate
process using stainless steel filler metal o Horizontal (2F) position
(optional) − Tee joint

8. Weld multi-pass groove welds • On low carbon steel plate

o Flat (1G) position
− Butt joint (both sides)
− Gouge to Sound Metal (GTSM)
o Side bend tests
• On low carbon steel plate with single
bevel butt joint with backing
o Flat (1GF) position
o Horizontal (2GF) position
o Vertical (3GF) position - uphill
o Overhead (4GF) position

9. Describe hardsurfacing for FCAW • Types of hardsurfacing materials

• Application
Achievement Criteria
Performance The learner will be evaluated on the ability to use the FCAW process to:
• Weld stringer beads in the flat position on low carbon steel plate.
• Weld fillet welds in a variety of positions on low carbon steel plate using self-shielded
filler metal wire and using gas-shielded filler metal wire.
• Weld fillet welds in the 3F and 4F positions on tee joints.
• Weld fillet welds using stainless steel filler metal on low carbon steel plate. (optional)
• Weld multi-pass groove welds 1GF, 2GF, 3GF, 4GF on low carbon steel plate.
• Weld a square groove butt joint in the flat 1G position.
Conditions As part of a practical shop project, given the required tools and equipment.

Welder Foundation Industry Training Authority 85

04/20
 Program Content
Foundation

Criteria • Stringer beads will be evaluated for:

o Correct bead width
o Reasonable straight and uniform weld beads
o Absence of irregularities and arc strikes
o Overall appearance
• Fillet welds will be evaluated for:
o Correct weld alignment and
o Equal leg length
o Slightly convex weld bead profile
o Absence of irregularities, porosity, undercut and arc strikes
o Aceptable smoothness, uniformity and straightness of weld passes
o Good fusion
o Overall appearance
o In addition, fillet welds on alunimum will be evaluted for weld spatter
• Groove welds will be evaluated for:
o Correct alignment
o Acceptable smoothness and uniformity
o Absence of irregularitites, distortion, undercutting at weld edge and stray strike
marks
o Good fusion (wetting) of the deposit (or cover pass) to base metal
o Maximum face reinforcement of 3.2 mm (1/8”)
o Maximum root reinforcement of 2.5 mm (3/32”)
• Coupons will be evaluated in accordance with CSA W47.1 and/or Section IX ASME
code
o Weld and heat-affected zone of a transverse weld-bend specimen shall be
completely within the bent portion specimen after testing
o Guided-bend specimens shall have no open defects in the weld or heat-affected
zone exceeding 3.2 mm (1/8”) in any direction on the convex surface of the
specimen after bending
o Cracks occurring on the corners of the specimen during testing shall not be
considered unless there is definite evidence that they result from slag inclusions
on other external defects.
Completed within specifications, safety standards and time frames acceptable to industry.

Welder Foundation Industry Training Authority 86

04/20
 Program Content
Foundation

Line (GAC): E Semi-Automatic and Automatic Welding

Competency: E6 Use the MCAW process

Objectives
To be competent in this area, the individual must be able to:
• Select filler metals and shielding gases for MCAW.
• Describe the welding variables for using the MCAW process on low carbon steel plate.
• Use the MCAW process to weld fillet welds and groove welds on low carbon steel plate.

LEARNING TASKS CONTENT

1. Identify welding variables for MCAW on low • Pre-selected variables

carbon steel plate o Equipment selection
o Filler metal selection
o Mode of metal transfer
o Primary adjustable variables
o Welding current
o Arc voltage
• Secondary adjustable variables
o Pushing and pulling techniques
o Travel speed
o Stickout
o Gun angle

2. Weld multi-pass fillet welds using the MCAW • On low carbon steel plate
process o Flat (1F) position
− Lap joint
− Tee joint
o Horizontal (2F) position
− Lap joint
− Tee joint

3. Weld multi-pass square groove welds using the • On low carbon steel plate
MCAW process o Flat (1G) position
− Butt joint (both sides)
− Gouge to Sound Metal (GTSM)
o Side bend tests

4. Weld multi-pass groove welds using the MCAW • On low carbon steel plate with single bevel
process butt joint (with backing)
o Flat (1GF) position
• Face and root bend tests

Welder Foundation Industry Training Authority 87

04/20
 Program Content
Foundation

Achievement Criteria
Performance The learner will be evaluated on the ability to use the MCAW process to:
• Weld fillet welds in the 1F and 2F positions on low carbon steel plate.
• Weld groove welds in the 1G position on low carbon steel plate.
• Successful face, root and side bent tests.
Conditions As part of a practical shop project, given the required tools and materials.
Criteria • Fillet welds will be evaluated for:
o Correct alignment
o Equal leg length
o Slightly convex profile
o Acceptable smoothness, uniformity and straightness of weld passes
o Absence of porosity
o Absence of undercut
o Absence of stray arc strikes
• Groove welds will be evaluated for:
o Correct alignment
o Straightness of cover pass
o Good fusion (wetting) of cover pass to base metal
o Acceptable smoothness and uniformity
o Absence of undercut and stray arc strikes
o Maximum reinforcement of 3.2 mm (1/8”)
• Coupons will be evaluated for successful completion of guided bend tests on face and
root or side bends will be evaluated to CSA W47.1

Completed within specifications, safety standards and time frames acceptable to industry.

Welder Foundation Industry Training Authority 88

04/20
 Program Content
Foundation

Line (GAC): E Semi-Automatic and Automatic Welding

Competency: E7 Use the SAW process

Objectives
To be competent in this area, the individual must be able to:
• Describe the welding variables for using the SAW process on low carbon steel plate.
• Use the SAW process to weld fillet welds on low carbon steel plate.

LEARNING TASKS CONTENT

1. Identify welding variables for SAW on low • Pre-selected variables

carbon steel plate o Equipment selection
o Filler metal selection
o Mode of metal transfer
o Primary adjustable variables
o Welding current
o Arc voltage
• Secondary adjustable variables
o Pushing and pulling techniques
o Travel speed
o Stickout
o Gun angle

2. Weld multi-pass fillet welds using the SAW • On low carbon steel plate
process o Flat (1F) position
− Tee joint

Achievement Criteria
Performance The learner will be evaluated on the ability to use the SAW process to:
• Weld fillet welds in the 1F position on low carbon steel plate.
Conditions As part of a practical shop project, given the required tools and materials.
Criteria • Fillet welds will be evaluated for:
o Correct alignment
o Equal leg length
o Slightly convex profile
o Acceptable smoothness, uniformity and straightness of weld passes
o Absence of porosity
o Absence of undercut
o Absence of stray arc strikes

Completed within specifications, safety standards and time frames acceptable to industry.

Welder Foundation Industry Training Authority 89

04/20
 Program Content
Foundation

Line (GAC): F Gas Tungsten Arc Welding (GTAW)

Competency: F1 Describe the GTAW process and its application

Objectives
To be competent in this area, the individual must be able to:
• Describe the GTAW process.
• Describe the function of electrodes and shielding gases.
• Describe the basic components of a GTAW work station.
• Identify the applications of GTAW and the safety requirements.

LEARNING TASKS CONTENT

1. Describe the GTAW process, equipment and • Components of a GTAW workstation

applications o Electrodes
o Filler rods
o Shielding gases
• GTAW process
o Applications
o Advantages
o Disadvantages

2. Identify safety requirements for GTAW • Safe working practices

• Special PPE requirements
• Ozone

3. Describe purging requirements and techniques • Purging

o Purpose
o Types of purging gas
− Argon
− Nitrogen
o Equipment
− Dams
− Flow regulators
• Purging calculation charts
• Techniques

Welder Foundation Industry Training Authority 90

04/20
 Program Content
Foundation

Line (GAC): F Gas Tungsten Arc Welding (GTAW)

Competency: F2 Describe GTAW equipment and its operation

Objectives
To be competent in this area, the individual must be able to:
• Identify types of GTAW power sources.
• Describe shielding gases and systems.
• Describe torches and their components.
• Describe tungsten electrodes used for GTAW.
• Correctly assemble GTAW equipment.

LEARNING TASKS CONTENT

1. Describe GTAW power sources and their • Welding current for GTAW
operation • Controls on GTAW power source
o Current controls
o High-frequency controls
o Shielding gas controls
o Water flow controls
o Remote controls and contact switches

2. Describe shielding gases and equipment used • Types of shielding gases

in GTAW o Argon
o Helium
• Gas regulators
• Flowmeters
• Hoses

3. Describe GTAW torches and their components • Types of torches

o Air-cooled
o Water-cooled
• Torch components
o Torch body
o Collet body
o Gas lens
o Collet
o Back cap
o Gas nozzles or cups
− Ceramic gas cups
− Alumina cups
− Fused-quartz cups
• Water radiator

4. Describe tungsten electrodes used for GTAW • Types of electrodes

o Pure tungsten electrodes
o Thoriated tungsten
− Non-radioactive

Welder Foundation Industry Training Authority 91

04/20
 Program Content
Foundation

(Ceriated, Lanthanated)
o Zirconium alloyed tungsten
o Electrode finishes
• Electrode selection
o Size
o Current
• Profile preparation of tungsten electrodes
o Balled or rounded ends
o Tapered or pointed ends
• Proper use
o Preventing contamination
o Avoiding heat build up

5. Select and assemble GTAW welding equipment • Torches

• Tungsten electrodes
• Maintenance, care and storage

Achievement Criteria
Performance The learner will be evaluated on the ability to select and assemble gas tungsten arc
welding equipment and correctly prepare tungsten electrodes for the GTAW process.
Conditions As part of a practical shop project, given the required tools and equipment.
Criteria Equipment must be assembled correctly, within specifications, safety standards and time
frames acceptable to industry.

Welder Foundation Industry Training Authority 92

04/20
 Program Content
Foundation

Line (GAC): F Gas Tungsten Arc Welding (GTAW)

Competency: F3 Describe the application of GTAW for ferrous metals

Objectives
To be competent in this area, the individual must be able to:
• Describe the GTAW process on low carbon steel.
• Identify discontinuities.
• Identify the main factors of GTAW.

LEARNING TASKS CONTENT

1. Describe the GTAW process • Low carbon steel

o Filler metals
− Deoxidized filler rod
− Handling and storing filler rod
o Welding low carbon steel

2. Identify discontinuities in the GTAW process • Incomplete and insufficient penetration

• Excessive penetration
• Undercut
• Porosity and dark appearance
• Burn-through
• Root side concavity (suck-back)
• Tungsten inclusion
• Weld cracking

3. Identify the main factors of GTAW • Power source setting

• Welding torch, electrode and filler rod
variables
• Electrode stickout
• Arc length
• Torch angle and filler metal angle
o Butt joints
o Lap joints
o Tee joints
o Corner joints
• Shielding gas flow
• Speed of travel
• Operator comfort and position

Welder Foundation Industry Training Authority 93

04/20
 Program Content
Foundation

Line (GAC): F Gas Tungsten Arc Welding (GTAW)

Competency: F4 Use the GTAW process for ferrous metals

Objectives
To be competent in this area, the individual must be able to:
• Use the GTAW process to strike an arc using three methods.
• Use the GTAW process to weld stringer beads and fillet welds on low carbon steel sheet.
• Use the GTAW process to weld groove welds on low carbon steel sheet.
LEARNING TASKS CONTENT

1 Strike an arc using three methods • Methods

o Scratch start
o Lift arc
o High frequency

2. Weld stringer beads • Flat (1S) position

3. Weld single-pass fillet welds • On low carbon steel sheet:
o Flat (1F) position
− Corner joints
o Horizontal (2F) position
− Lap joints
− Tee joints
o Vertical (3F) position - uphill
− Lap joints
− Tee joints
4. Weld single-pass groove welds • On low carbon steel sheet
o Flat (1G) position
Achievement Criteria
Performance The learner will be evaluated on the ability to:
• Strike an arc using the touch start methods and high frequency start method.
• Weld stringer beads in the 1S flat position on low carbon steel sheet.
• Weld fillet welds in the 1F, 2F and 3F uphill positions on lap and tee joints on low
carbon steel sheet.
• Weld single-pass groove weld in the 1G position on low carbon steel sheet.
Conditions As part of a practical shop project and given the required tools and equipment.
Criteria • Striking an arc must follow correct procedure and establish a weld pool of desirable
size.
• Stringer beads will be evaluated for:
o Good fusion
o Smooth, slightly convex beads
o Absence of stray strike marks
o Absence of irregularities, porosity and undercut
• Fillet welds will be evaluated for each of the criteria above, plus they must have legs
of equal length
• Groove welds will be evaluated for each of the criteria above, plus they must have
complete root penetration
Completed within specifications, safety standards and time frames acceptable to industry.

Welder Foundation Industry Training Authority 94

04/20
 Program Content
Foundation

Line (GAC): F Gas Tungsten Arc Welding (GTAW)

Competency: F5 Use the GTAW process for stainless steel

Objectives
To be competent in this area the individual must be able to:
• Describe the GTAW process and procedures on stainless steel.
• Use the GTAW process to weld fillet welds on stainless steel sheet.
• Use the GTAW process to weld groove welds on stainless steel sheet.

LEARNING TASKS CONTENT

1. Describe the GTAW process and procedures • Stainless steel filler metal
on stainless steel • Welding stainless steel
• Joint design for stainless steel
• Preparation of stainless steel:
o Pre-cleaning
o Post-cleaning
• Recognize weld defects

2. Describe purging and fluxing requirements • Purging

and techniques o Purpose
o Types of purging gas
− Argon
− Nitrogen
o Equipment
− Dams
− Flow regulators
• Purging calculation charts
• Techniques
• Solar flux

3. Weld single-pass fillet welds • On stainless steel sheet

o Horizontal (2F) position
− Lap joints
− Tee joints
o Vertical (3F) position - uphill
− Lap joints
− Tee joints

4. Weld single-pass groove welds • On stainless steel sheet

o Flat (1G) position

Welder Foundation Industry Training Authority 95

04/20
 Program Content
Foundation

Achievement Criteria
Performance The learner will be evaluated on the ability to use the GTAW process to:
• Weld fillet welds in the 2F, 3F uphill position on lap and tee joints on stainless steel
sheet.
• Weld groove welds in the 1G position on stainless steel sheet.
Conditions As part of a practical shop project and given the required tools and equipment.
Criteria • All welds will be evaluated for:
o Good fusion
o Smooth, slightly convex beads
o Absence of irregularities, porosity, undercut and stray strike marks
• Fillet welds will be evaluated for each of the criteria above, and they must have legs of
equal length
• Groove welds will be evaluated for each of the criteria above, and they must have
complete joint penetration

Completed within specifications, safety standards and time frames acceptable to industry.

Welder Foundation Industry Training Authority 96

04/20
 Program Content
Foundation

Line (GAC): H Basic Metallurgy

Competency: H1 Describe production processes for manufacturing metals

Objectives
To be competent in this area, the individual must be able to:
• Describe the production processes for manufacturing metals.

LEARNING TASKS CONTENT

1. Describe types of iron and current production • Blast furnace – pig iron
methods • Cast irons
• Grey cast iron
• White cast iron
• Malleable cast iron
• Nodular iron (ductile iron)

2. Describe current steel production and forming • Open hearth furnace

methods • Basic oxygen furnace
• Electric furnace
• Bessemer converter
• Ingots
• Rimmed, killed and semi-killed steel
• Continuous casting process
• Blooms, billets and slabs
• Hot and cold-rolled sheet products
• Galvanized sheet steel products
• Tin mill products
• Structural shapes and bars
• Steel plate and large diameter pipe
o Pipe and tubing
o ERW
o Seamless
• Forging process
o Open-die forging
o Closed-die forging
• Casting process
o Sand casting
o Centrifugal casting
o Die casting

Welder Foundation Industry Training Authority 97

04/20
 Program Content
Foundation

3. Describe types of steel and steel classifications • Main elements of carbon steels
• Types of steel
o Low carbon
o Medium carbon
o High carbon (tool)
• Alloying elements
o Chromium
o Cobalt
o Copper
o Magnesium
o Nickel
o Titanium
o Tungsten
o Vandium
• Steel classification
o CSA standards
o UNS numbering system
• SAE and AISI systems
o First digit
o Second digit
o Third and fourth digits
• ASTM classification
• Manufacturer’s certification and identification
markings
o Colour coding
o Numbering systems
o Heat numbers
• Mill certification

Welder Foundation Industry Training Authority 98

04/20
 Program Content
Foundation

Line (GAC): H Basic Metallurgy

Competency: H2 Describe mechanical and physical properties of ferrous and non-
ferrous metals

Objectives
To be competent in this area, the individual must be able to:
• Identify the mechanical and physical properties of metals.

LEARNING TASKS CONTENT

1. Define the terms relating to mechanical and • Metallurgy

physical properties of metals • Alloys
• Ferrous metals
• Wrought iron
• Cast iron
• Carbon steels
• Low alloy steels
• Alloy steels
• Non-ferrous metals
o Aluminum
o Copper
o Lead
o Magnesium
o Nickel
o Silver
o Tin
o Zinc

2. Describe the mechanical properties of metals • Tensile strength

• Elasticity, yield point, ultimate tensile strength
• Elongation
• Impact strength
• Compressive strength
• Fatigue strength
• Toughness
• Hardness
• Ductility
• Malleability
• Brittleness

3. Describe the physical properties of metals • Density

• Resistance to corrosion
• Electrical conductivity
• Thermal conductivity
• Thermal expansion
• Melting point

Welder Foundation Industry Training Authority 99

04/20
 Program Content
Foundation

Line (GAC): H Basic Metallurgy

Competency: H3 Describe common ferrous, non-ferrous and reactive metals and their
weldability
Objectives
To be competent in this area, the individual must be able to:
• Identify metals by their visual appearance, relative weight, typical shape and texture.
• Describe tests for identifying metals.

LEARNING TASKS CONTENT

1. Describe types of metals by their physical • Steel

characteristics (visual appearance, colour, • Cast steel
relative weight, typical shape and texture)
• Cast irons
• Copper
• Brass and bronze
• Aluminum
• Stainless steel
• Lead
• Magnesium
• Zinc
• Titanium

2. Describe mechanical and thermal tests for • Chip

identifying metals • Spark
• Hardness
• Files
• Center punch
• Chisel
• Flame
• Magnetic
• Non-magnetic
• Slightly magnetic
• Melting point

3. Describe weldability and pre and post heat • Low carbon steel
treatment • Cast iron
• Aluminum
• Stainless steel
Achievement Criteria
Performance The learner will be evaluated on the ability to inspect metals for identification.
Conditions As part of a practical shop project, given the required tools and materials.
Criteria • Identify metals by visual inspection
• Perform flame, chip, spark and file tests
Completed within specifications, safety standards and time frames acceptable to industry.

Welder Foundation Industry Training Authority 100

04/20
 Program Content
Foundation

Line (GAC): I Welding Drawings, Layout and Fabrication

Competency: I1 Identify common welding symbols and bolted connections

Objectives
To be competent in this area, the individual must be able to:
• Identify standard welding symbols and supplementary welding symbols.
• Describe the dimensioning of fillet and groove weld symbols.
• Describe other weld symbols and the dimensioning of threaded fasteners used in structural steel
construction.

LEARNING TASKS CONTENT

1. Describe standard welding symbols • Welding symbols

o Arrows
o Supplementary weld symbols
o Weld-all-around symbol
o Field weld symbol
o Contour and finish symbols
o Location of weld symbol

2. Describe the dimensioning of fillet and groove • Filet welds

welds o Size
o Length
o Intermittent fillet welds
• Groove welds
o Groove size (depth of operation)
o Effective throat size (depth of
penetration)
o Root opening
o Groove or included angle
o Backing or spacer material symbol
• Complete penetration welds
o Back gouging and its application to
groove welds
o Back welds and backing welds
o Melt-thru welds

Welder Foundation Industry Training Authority 101

04/20
 Program Content
Foundation

3. Identify other basic weld symbols and their • Plug welds

dimensions o Plug size
o Angle of countersink
o Depth of filling
• Slot welds
• Spot welds
o Size and strength of spot welds
o Pitch of spot welds
o Number of spot welds
• Seam welds
o Size and strength of seam welds
• Scarf for brazed joint
• Flange welds
• Surface welds

4. Identify the dimensioning of bolted connections • Thread symbols on drawings

• Designation of UNC and UNF threads
• Metric thread designations

Welder Foundation Industry Training Authority 102

04/20
 Program Content
Foundation

Line (GAC): I Welding Drawings Layout and Fabrication

Competency: I2 Read and interpret drawings

Objectives
To be competent in this area, the individual must be able to:
• Read structural drawings.

LEARNING TASKS CONTENT

1. Identify types of structural drawings • Engineering drawings

• Site plans
• Foundation plans
• Framing plans
• Elevation plans
• Sections
• Connection detail drawings
• Shop drawings
• Detail drawings
• Assembly drawings
• Detail assembly drawings

2. Identify bills of material and other information • Title block

found on structural drawings • Revisions block
• Notes and specifications
• Material list
• Item number
• Quantity
• Description
• Length
• Specifications
• Material
• Remarks

Welder Foundation Industry Training Authority 103

04/20
 Program Content
Foundation

Line (GAC): I Welding Drawings Layout and Fabrication

Competency: I3 Perform basic drafting

Objectives
To be competent in this area, the individual must be able to:
• Describe types of drawings, basic lines used on drawings, and auxiliary and sectional views.
• Sketch orthographic projections of basic objects.
• Sketch isometric and dimensioned drawings of basic objects.

LEARNING TASKS CONTENT

1. Describe types of drawings • Orthographic

• Pictorial
• Isometric

2. Identify basic lines used in drawings • Object lines

• Hidden lines
• Centre lines
• Dimension and extension lines
• Leader lines
• Phantom lines
• Cutting plane lines
• Section lines
• Break lines

3. Draw orthographic projections • Freehand sketching to approximate scale

• Graph paper
• Sketching orthographic views
• Scale rule

4. Describe and draw auxiliary and sectional • Auxiliary views

views • Sectional views
• Locating sectional views
• Showing sectional views
• Types of sectional views
o Full sections
o Half-sections
o Broken sections
o Revolved sections

5. Identify systems of measurements used on • SI metric units of measurement

drawings • Imperial system of measurement
• Dual dimensioning
• Position method
• Bracket method
• Conversion chart method

Welder Foundation Industry Training Authority 104

04/20
 Program Content
Foundation

6. Describe methods of dimensioning • Types of dimensions

• Rules for placing dimensions
• Dimensioning curved surfaces
• Angular dimensioning
• Tolerance dimensions
• Dimensioning external chamfers and bevels

7. Sketch isometric drawings of basic objects • Simple rectangular objects

• Figures using isometric lines
• Objects with circular features

8. Sketch a dimensioned drawing of a simple • Dimensioned drawing

object

Achievement Criteria
Performance The learner will be evaluated on the ability to reproduce drawings with proper dimensioned
parts made to scale.
Conditions As part of a practical shop project, given the required tools and materials.
Criteria Completed within specifications, safety standards and time frames acceptable to industry.

Welder Foundation Industry Training Authority 105

04/20
 Program Content
Foundation

Line (GAC): I Welding Drawings, Layout and Fabrication

Competency: I4 Perform mathematical calculations

Objectives
To be competent in this area, the individual must be able to:
• Perform mathematical calculations involving angles, triangles and geometric construction.

LEARNING TASKS CONTENT

1. Solve problems involving angles, triangles and • Basic terms

geometric construction • Lines and points
• Angles and angle terms
• Basic theorems
• Apply the principles of angles
• Read protractor
• Calculate angles
• Right angle triangles
• Apply geometric constructions
• Exponents

Welder Foundation Industry Training Authority 106

04/20
 Program Content
Foundation

Line (GAC): I Welding Drawings, Layout and Fabrication

Competency: I5 Interpret and apply mechanical drawings and layout components

Objectives
To be competent in this area, the individual must be able to:
• Source required information and materials.
• Prepare work area and layout materials.

LEARNING TASKS CONTENT

1. Source required information for selecting • Material information sources

materials and equipment o Location of information
o Identify unique or special information
o Type of materials
o Material selection
• Documentation and markings
o Mill test reports
o Traceability methods
o Traceability requirements
• Equipment information sources
o Equipment selection

2. Describe work area requirements • Good housekeeping practices

• Access and egress
• Material and equipment
• Identify safety hazards

3. Plan sequence of operation • Assembly requirements

• Codes
• Weld procedure specifications (WPS)
• Final product
• Welding sequence
• Possible distortion
• Organize sequence of work
• Visualize final components

4. Gather work materials and equipment • Work plan

• Finished component
• Assembly of requirements

5. Develop templates and transfer drawings to • Construct template

materials o Template materials
o Measuring tools
o Conform to dimensional tolerances
• Transfer methods
o Layout tools
• Checking layout

Welder Foundation Industry Training Authority 107

04/20
 Program Content
Foundation

6. Select cutting equipment and cut materials to • Cutting equipment

dimensions • Materials
• Tolerances
• Cutting sequence

7. Identify preparation and marking requirements • Galvanizing

for specialty processes • Heat treatment
• Paint and/or finishing
• Annodizing

8. Describe the preparation of materials for • Grinding of materials

assembly o Type of base metal
o Abrasive selection
• Application of identification markings
o Paint mark
o Stamp

Welder Foundation Industry Training Authority 108

04/20
 Program Content
Foundation

Line (GAC): I Welding Drawings, Layout and Fabrication

Competency: I6 Fabricate weldments

Objectives
To be competent in this area, the individual must be able to:
• Fabricate weldments using selected processes and materials.

LEARNING TASKS CONTENT

1. Fit and tack structural components • Select fitting equipment

o Dogs and wedges
o Clamps
o Jigs and fixtures
o Hydraulic porta-power
o Hand tools
• Welding process and consumables
• Organize work in sequential order
• Fitting
o Techniques
o Equipment
o Distortion control
o Specifications

2. Weld weldments • Preheating procedures

• Welding procedures

3. Finish final product • Conforms to dimensions

• Conforms to specifications

Achievement Criteria
Performance The learner will demonstrate the ability to fabricate weldments.
Conditions Given a practical project using a selected process and materials.
A minimum of two shop projects is recommended.
Criteria Completed within specifications, safety standards and time frames acceptable to industry.

Welder Foundation Industry Training Authority 109

04/20
 Program Content
Foundation

Line (GAC): I Welding Drawings Layout and Fabrication

Competency: I7 Costing and estimating

Objectives
To be competent in this area, the individual must be able to:
• Identify project costs.
• Calculate project cost for simple fabrication.

LEARNING TASKS CONTENT

1. Identify project costs • Materials

o Weight
o Wastage
• Labour
• Consumables
• Transportation
o Shipping
o Material handling
• Lead time

2. Calculate project cost for simple fabrication • Weight

• Estimate labour and consumables

Achievement Criteria
Performance The learner will be evaluated on the ability to cost a simple fabrication project consisting of
3 structural columns complete with base plates.
Conditions Given project specifications and fixed costs.
Criteria Completed within specifications, safety standards and time frames acceptable to industry.

Welder Foundation Industry Training Authority 110

04/20
 Assessment Guidelines

Section 4
ASSESSMENT GUIDELINES

Welder Foundation Industry Training Authority 111

04/20
 Assessment Guidelines

Assessment Guidelines
Foundation Grading Sheet: Subject Competency and Weightings
PROGRAM: WELDER
IN-SCHOOL TRAINING: FOUNDATION

THEORY PRACTICAL
LINE SUBJECT COMPETENCIES
WEIGHTING WEIGHTING

A Occupational Skills 17% 8%

B Cutting and Gouging Processes 10% 5%

Fusion and Braze Welding (TB) Using the Oxy-Fuel (OFW)
C 5% 3%
Process
D Shielded Metal Arc Welding (SMAW) 25% 37%

E Semi-Automatic and Automatic Welding 25% 35%

F Gas Tungsten Arc Welding (GTAW) 3% 4%

H Basic Metallurgy 5% 2%

I Welding Drawings, Layout and Fabrication 10% 6%

Total 100% 100%

In-school theory / practical subject competency weighting 20% 80%

Final in-school percentage score IN-SCHOOL %

In-school Percentage Score

80%
Combined theory and practical subject competency multiplied by

Standard Level Exam Percentage Score

20%
The exam score is multiplied by

Final Percentage Score FINAL%

Welder Foundation Industry Training Authority 112

04/20
 Training Provider Standards

Section 5
TRAINING PROVIDER STANDARDS

Welder Foundation Industry Training Authority 113

04/20
 Training Provider Standards

Facility Requirements
Classroom Area
All levels
• Comfortable seating and tables suitable for training, teaching, lecturing
• Compliance with all local and national fire code and occupational safety requirements
• Lighting controls to allow easy visibility of projection screen while also allowing students to take notes
• Windows must have shades or blinds to adjust sunlight
• Heating/Air conditioning for comfort all year round
• In-room temperature regulation to ensure comfortable room temperature
• In-room ventilation sufficient to control training room temperature
• Acoustics in the room must allow audibility of the Instructor
• White marking board with pens and eraser (optional: flipchart in similar size)
• Projection screen or projection area at front of classroom
• Overhead projector and/or multi-media projector

Shop Area (fixed properties)

• One welding booth per student (minimum booth size must be 6’ x 6’) fully equipped with:
o Welding table (minimum recommended size 18” x 20”)
o Industrial grade multi-process welding power source or equipment suitable for all Foundation
required welding processes
o One height adjustable positioning arm
o One height adjustable positioning arm for pipe
o One 115 volt receptacle or pneumatic air supply for grinders
o Ventilation as per WorkSafeBC standards
o Task lighting
o Suitable demonstration area of approximately 7’ x 14’
o Aisles size must be a minimum of 6’ wide
o The grinding and test coupon preparation area must be a minimum 300 square feet
o Material storage area (including a separate, secured cylinder storage area)
o Ceiling shall be a minimum height of 16’ or as varied by good engineering practices and code

Lab Requirements
• N/A

Student Facilities
• Adequate lunch room as per WorkSafeBC requirements
• Adequate washroom facilities as per WorkSafeBC requirements
• Personal storage lockers

Instructor’s Office Space

• As required

Welder Foundation Industry Training Authority 114

04/20
 Training Provider Standards

Tools and Equipment

Shop Equipment
• One floor model drill press, 1/2 hp minimum, 1/2” x 8”
• One 3’ x 6’ work bench with two vices
• One pedestal grinder, 12” x 2” stone
• One pedestal belt sander with a minimum 3” belt
• One floor model vertical band saw
• One horizontal band saw
• One abrasive chop saw
• Two track cutters
• Four 7” grinders (electric or pneumatic) for general shop use
• Electrode stabilizing oven (minimum 250 lbs)
• One semi-automatic or automatic submerged arc welder
• One guided bend test jig as per CSA W47.1 dimensional specifications
• One 5” grinders per student (one grinding, one bead brush)

Hoisting, Rigging and Lifting Equipment

• One ton overhead jib crane or overhead crane • Come-alongs (chain and cable)
• Overhead hoist • Connectors
• Rigging hardware - shackles, swivels, eyebolts, turn • Tirfor jacks
buckles, snatch blocks, etc. • Chain block hoist
• Plate clamps • Chokers
• Cable clamps • Forklift
• Chain, wire rope and synthetic slings • Portable boom
• Chains • Spreader bars
• Chain fall • Stands
• Rope • Supports
• Slings • Tuggers

Welder Foundation Industry Training Authority 115

04/20
 Training Provider Standards

Optional Equipment
• One 1/4” x 4’ hydraulic shear
• One iron worker
• One press brake (minimum 4’ x 12 gauge mechanical pan brake)

Basic Tools and Equipment

• Adjustable wrenches (various sizes) • Mop
• Allen wrenches (metric and imperial) • Oil can
• Ammeter • Pails (plastic and metal)
• Bench vise • Paint brushes
• Broom • Pipe cutters
• Brushes (various bristle brushes for cleaning and • Pipe stands
scrubbing) • Pipe wrenches
• “C” clamps • Pliers (needle nose, slip joint)
• Center head • Positioners
• Centering pins • Pry bars
• Chain hoists • Punches
• Chalk line • Rollers
• Chokers • Scaffolding (safety)
• Cold chisels (various sizes) • Scrapers (various sizes)
• Combination wrenches (metric and imperial) • Screwdrivers (flat, Phillips, Robertson,
• Come-alongs various sizes)
• Contour marker • Shovels (flat mouthed)
• Cylinder carts • Slings
• Cylinder cradles • Snips (heavy duty sheet metal cutting)
• Dollies • Soapstone markers
• Electric cords • Socket sets (metric and imperial)
• Files (flat, half-round, rat-tail, bastard) • Soldering iron
• Flange pins • Stamping tools
• Flashlight • Temperature sticks
• Friction lighter • Tip cleaners
• Funnels • Tool boxes
• Hack saw • Vice grips
• Hammers (chipping, ball peen, claw, sledge, various • Vices (chain vice, pipe vice)
sizes) • Water hose
• Hand shears • Wrap arounds
• Jacks • Wire brush
• Knives • Wire cutter
• Ladders • Wrench sets (open and closed ends,
• Magnets both metric and imperial)
• Metal markers

Welder Foundation Industry Training Authority 116

04/20
 Training Provider Standards

Measuring Tools
• Calculator • Scribers
• Calipers • Spirit level
• Depth gauge • Squares
• Feeler gauges • Stop watch
• Fillet gauges • Straight edges
• Laser level • Tape measure
• Torpedo level • Tri squares
• Micrometer • Vernier calipers
• Plumb bob • Welding gauges
• Protractor

Testing Equipment
• Adapter fittings • Pressure difference gauges
• Ammeter • Pressure gauge kit
• Calibrating gauges • Temperature gauges
• Infrared pyrometer • Temperature sticks

Safety Equipment
• Air hoods • Fire extinguishers
• Aprons • Fire hoses
• Body harness • Gloves
• Boots • Goggles
• Coveralls • Masks (particle, vapour)
• Ear-plugs and muffs • Respirators
• Eye wash station • Safety glasses
• Face shields • Safety helmet
• Fire blankets • Welding shield

Welder Foundation Industry Training Authority 117

04/20
 Training Provider Standards

Power Tools and Equipment

• Air hose and nozzle • Hydraulic shear
• Air monitoring device • Hydrostatic equipment
• Arc welder • Impact wrenches (electric or
• Oxy-fuel cutting equipment pneumatic)
• Band saw • Nibblers
• Buffers • Ovens
• Chop saw (cut-off saw) • Oxyacetylene brazing torch
• Circular saw • Oxyacetylene cutting torch
• Coil heating equipment • Pipe-bevelling machine
• Compressors • Pipe cutters
• Cranes (overhead, gantry-type, monorail, boom) • Plasma console
• Drills (portable, magnetic base, drill press) • Pneumatic equipment
• Electric drills • Power hack saw
• Electronic measuring device (hand-held “electronic • Power vice
tape measure” type) • Propane torch
• Feeders-wire • Reamer (hand held or mounted on
• Fork lifts power threader)
• Gas detector • Reciprocating saw
• Grinders (wire brush, angle grinders) • Routers
• Guns-welding • Sand-blast equipment
• Hammer drill • Sanders
• Hand-held and stationary radios • Scissor lift
• Headphones • Testing pump
• Heated hoppers • Torches
• Heaters (electric, natural gas, oil, propane) • Vacuum (wet/dry)
• Heating torch • Winches
• Hydraulic press brake • Wire wheel (body grinder or angle
grinder with wire brush)

Resource Material
• Code books • Prints
• Drawings • Regulatory information
• Engineering specifications • Safety manuals
• Job schedules • Service bulletins
• Manufacturers’ specifications, manuals and charts • Shop manuals
• Material Safety Data Sheets • Specifications
• Packing slips • Waybills
• Pamphlets • Written informational or instructional
material

Welder Foundation Industry Training Authority 118

04/20
 Training Provider Standards

Reference Materials
THIS SECTION IS CURRENTLY UNDER REVIEW, PLEASE SEE YOUR TRAINING PROVIDER FOR A
LIST OF REQUIRED MATERIALS

Required Reference Materials

Foundation, Level 1, 2, 3 and Endorsement
• WELDER TRAINING PROGRAM LEVEL C PACKAGE (CPUB230M) (7960000058) ISBN 0-7719-
1783-X
This package contains the following modules:
o P01 Introduction and Program Orientation (MN1807) (7960002678)
o P02 Oxy-fuel Cutting (MN1808) (7960002679)
o P03 Gas Welding and Braze Welding (MN1809) (7960002680)
o P04 Shielded Metal Arc Welding (SMAW I) (MN1810) (7960002681)
o P05 Air Carbon Arc Gouging (MN1811) (7960002682)
o P06 Gas Metal Arc Welding (GMAW I) & Flux Cored Arc Welding (FCAW I)
(MN1812)(7960002683)
o RK01 Material Handling (MN1813) (7960002684)
o RK02A Blueprint Reading I (MN1814) (7960002685)
o RK02B Mathematics (MN1815) (7960002686)
o RK03 Welding Metallurgy I (MN1816) (7960002687)

Foundation, Level 2, 3 and Endorsement

WELDER TRAINING PROGRAM LEVEL B
• P07 Shielded Metal Arc Welding (SMAW II)
Goal/Competency P07-P01 to 02 (MN1927)(7850002773) .................................................... ISBN 0-7719-1670-1
• P07 Shielded Metal Arc Welding (SMAW II)
Goal/Competency P07-P01 to 02 (MN1927) (7850002591) .................................................. ISBN 0-7719-1670-1
• P08 Gas Metal Arc Welding (GMAW II)
Goal/Competency P08-01 to 05 (MN1927) (7960002787)..................................................... ISBN 0-7719-1671-X
• P09 Flux Cored Arc Welding (FCAW II)
Goal/Competency P09-01 to 04 (MN1929) (7960002788)...................................................... ISBN 0-7719-1672-8
• P10 Gas Tungsten Arc Welding (GTAW I)
Goal/Competency P10-01 to 08 (MN1930) (7960002789)...................................................... ISBN 0-7719-1673-6
• RK04 Welding Quality Control and Inspection Procedures
Goal/Competency RK04 (MN1931) (7960002790) ................................................................. ISBN 0-7719-1674-4
• RK05 Welding Quality Codes, Standards and Specifications
Goal/Competency RK (MN1932) (7960002791) .................................................................... ISBN 0-7719-1675-2
• RK06 Blueprint Reading II
Goal/Competency RK06-01 to 02 Perform Basic Pipe (MN1933) (7960002792) .................. ISBN 0-7719-1676-0
• RK07 Welding Metallurgy II
Goal/Competency RK07-01 to 03 (MN1934) (7960002793) ................................................... ISBN 0-7719-1676-0

Welder Foundation Industry Training Authority 119

04/20
 Training Provider Standards

Recommended Resources
Foundation, Level 1, 2, 3 and Endorsement
• Welding Principles and Applications, Fifth edition, by Larry Jeffus
Delmar Learning ..................................................................................................................... ISBN 1-4018-1046-2
• GMAW-P: Pulsed Spray Transfer
Miller Electric Mfg. Co ........................................................................................................... ©1994, Revised 11/95
• Procedure Handbook of Arc Welding Design and Practics
Lincoln Electric Company
• Pipefitters and Welder’s Pocket Manual, all new 2nd edition
Audel ................................................................................................................................ ISBN 0-7645-4205-2 LB
• The Procedure Handbook of Arc Welding, 14th edition
The James F. Lincoln Welding Foundation
• Modern Welding, 10th edition, by Andrew Daniel Althouse
Goodheart-Willcox Company .................................................................................................. ISBN 0-87006-210-7
• Alberta Individual Learning Modules
Available through Queens Printer/Crown Publications ............................................................... ISBN not available
• Welding Skills, 5th edition, by B. J. Moniz
American Technical Publishers ........................................................................................ ISBN 978-0-8269-3084-2

Welder Foundation Industry Training Authority 120

04/20
 Training Provider Standards

Foundation, Level 2, 3 and Endorsement

• Measurement and Calculations for the Trades
Sue Grecki .............................................................................................................................. ISBN 0-9685027-9-2
• Formulas at Work: Tradesworkers on the Job
Sue Grecki ............................................................................................................................. ISBN 978-0-9739-6-1
• ASME Boiler and Pressure Vessel Code – Section IX
• ASME Power Piping (B31.1) Process Piping (B31.3)
• CSA Standards W59, W47.1, Z662
• Metal Trades Training Manual (Steel Fabrication)
IPT Publishing & Training LTD.
• Pipe Trades Training Manual (Pipefitting)
IPT Publishing & Training LTD.
• Safety First Training Manual
IPT Publishing & Training Ltd.

Websites
For all levels
• Lincoln Electric: www.lincolnelectric.com
• Hobart Welders: www.hobartwelders.com
• Miller Welding Equipment: www.millerwelds.com
• WorkSafeBC – publications: www.worksafebc.com/publications/default.asp

Foundation, Level 2, 3 and Endorsement

• Queens Printers: http://www.publications.gov.bc.ca
• Canadian Welding Bureau (CWB) Group: http://www.cwbgroup.org/
• American Welding Society (AWS): http://www.aws.org/w/a/
• Skill Plan: http://www.skillplan.ca
• IPT List of Publications: http://www.iptbooks.com/

NOTE:
This list of Reference Materials is for training providers. Apprentices should contact their
preferred training provider for a list of recommended or required texts for this program.

Welder Foundation Industry Training Authority 121

04/20
 Training Provider Standards

Instructor Requirements

Occupation Qualification
The instructor must possess for all levels:
• Welder – Certificate of Qualification with Interprovincial Red Seal endorsement
• BC PWP7 and PWP10 pressure tickets

Work Experience
• A minimum of 5 years’ experience working in the industry as a journeyperson
• Must have diverse industry experience including code work such as shop fabrication, heavy
construction and maintenance/repair (ASME or CSA W59)

Instructional Experience and Education

It is preferred that the instructor also possesses one of the following:
• Instructors Certificate (minimum 30 hr course)
• Instructor’s Diploma or be registered in an Instructor’s Diploma Program to be completed within a 5
year period;
OR
• Bachelors or Masters degree in Education

Welder Foundation Industry Training Authority 122

04/20
 Appendices

Appendices

Welder Foundation Industry Training Authority 123

04/20
 Appendices
Historical Program Review
Participants

Appendix A: Previous Contributors

Welder Program Review and Revision 2009 – 2010:
In 2009 – 2010, a Program Review Committee was established to oversee and advise on the review of
the Welding Training Program. The PRC was made up of the following members:
• Dennis Brode, The Gisborne Group
• Tim Cross, Fleet Maintenance Facility Cape Breton
• Jerry Dardengo, WMG Victoria Shipyards
• Kerry Jothen, Human Capital Strategies, Chair
• Bernie Kragt, Arc Right Fabrication Ltd.
• Jeff Lekstrom, Northern Lights College
• Al Philips, Piping Industry Apprenticeship Board (PIAB) Trade School
• Jim McCarthy, United Steel Workers
• Ken Pearce, Canadian Welding Bureau
• Mike Parson, EnCana Corporation
• Rob Scales, Industry Training Authority
• Brian Shale, Tolko Industries Ltd.
• Gene von Matt, Teck Coal Limited, Elkview Operations

In addition, consultations were held with bodies representing the training providers:
• Trades Training Consortium
• Welding Articulation Committee (WAC)
• Presidents’ Council

A complete list of the regional consultation session participants appears in Appendix 2 of the B.C.
Welding Review Final Report (July 2010).

Initial Welder Program Outline Development:

Representatives from industry, labour and training providers were included in the makeup of the project
committees. Members of the primary committees were selected with consideration to capturing
representation from across the province, as well as representation of large and small companies.

Project Steering Committee (2008) members included:

• Sheldon Frank, Chair, Welding Articulation Committee; Instructor, University College of the Fraser
Valley
• Jim Carson, Instructor, University College of the Fraser Valley
• Ralph Finch, Dean of Trades, Thompson Rivers University
• Les Wiebe, Instructor, Thompson Rivers University
• Lindsay Langill, Director, Industry Training Authority
• Jeff Lekstrom, Dean of Trades and Apprenticeship Training, Northern Lights College; System Liaison
Person for the Welding Articulation Committee
• Peter Haigh, Instructor, Northwest Community College
• Curt Cain, Director, Resource Training Organization ex officio

Welder Foundation Industry Training Authority 124

04/20
 Appendices
Historical Program Review
Participants

• Raili Sharron McIvor, Articulation Coordinator, B.C. Council on Admissions and Transfer
• Sherry Brown, Director, Queen’s Printer Publication Services
• Graham Duncan, Director, Open School BC, Queen’s Printer
• Eleanor Liddy, Manager of Content, Open School BC, Queen’s Printer
• Solvig Norman, Senior Project Manager, Open School BC, Queen’s Printer
• Adrian Hill, Project Manager, Open School BC, Queen’s Printer
• Kai Robinson, Business Project Coordinator, Open School BC, Queen’s Printer
Standards Review Committee (2008) members included:
• Ian MacDonald, Highland Valley Copper
• Stan Boehm, SS Stainless Steel Inc.
• Stan McArthur, Catalyst Paper (Campbell River)
• Tim Cross, FMF Cape Breton
• Greg Burkett, Okanagan College
• Al Wood, BCIT
• Mervyn Kube, PIAB/UA Trade School
• Dan Burroughs, Sheet Metal Workers’ Local 280
• Ron McKeown, Kwantlen College Faculty Association
• Al Constable, ILWU Local 50
Project Review Committee members included:
• Lindsay Langill, ITA
• Brad Smith, Catalyst Paper (Campbell River)
• Judy Kujundzic, Victoria Shipyards
• Sheldon Frank, University College of the Fraser Valley
• Al Phillips, PIAB/UA Trade School
• Ed Ferrero, Technical Safety BC
• Ken Bauder, ILWU Canada

Welder Foundation Industry Training Authority 125

04/20