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Model Curriculum Construction Welder (Electives: MIG/TIG/SMAW) SECTOR: Construction SUB-SECTOR: Real Estate and Infrastructure Construction OCCUPATION: Fabrication REF ID: CON/Q01252, V1.0 NSQF LEVEL: 4

Construction Welder(Electives: MIG/TIG/SMAW) 1

Construction Welder(Electives: MIG/TIG/SMAW) 2

TABLE OF CONTENTS

1. Curriculum 01 2. Trainer Prerequisites 08 3. Annexure: Assessment Criteria 09

Construction Welder(Electives: MIG/TIG/SMAW) 3

Construction Welder (Electives: MIG/TIG/SMAW) CURRICULUM / SYLLABUS

This program is aimed at training candidates for the job of a “Construction Welder (Electives: MIG/TIG/SMAW)”, in the “Construction” Sector/Industry and aims at building the following key competencies amongst the learner

Program Name Construction Welder(Electives: MIG/TIG/SMAW)

Qualification Pack Name & Reference ID. CON/Q1252, v1.0 ID

Version No. 1.0 Version Update Date 25-10-2019

Pre-requisites to 10th standard pass with 3 years site experience as a Tack Welder or Training equivalent Training Outcomes After completing this programme, participants will be able to:

Compulsory:  Carry out grinding activities on structural steel elements:  Work effectively in a team to deliver desired results at the workplace:  Work according to personal health, safety and environment protocol at construction site:

Electives (mandatory to select at least one)

Elective 1: Construction Welder MIG  Carry out preparatory works for MIG welding operations:  Carry out MIG welding as per requirement in fabrication workshop or construction site: Elective 2: Construction Welder TIG  Carry out preparatory works for TIG welding operations:  Carry out tungsten inert gas welding as per requirement in fabrication workshop or construction site Elective 3: Construction Welder SMAW  Carry out preparatory work for shielded metal arc welding operations  Carry out shielded metal arc welding as per requirement in fabrication workshop or construction site

Construction Welder(Electives: MIG/TIG/SMAW) 1

This course encompasses 3 out of s3 Compulsory NOS (National Occupational Standards), 3 out of 3 Electives of “Construction Welder (Electives: MIG/TIG/SMAW)” Qualification Pack issued by “Construction Skill Development Council of India”. Compulsory NOS Sr. Equipment Module Key Learning Outcomes No. Required 1 Introduction  Introduction to role and responsibilities  class room of the job role  White board Theory Duration  Introduction to various types of  Computer (hh:mm) welding  Projector 08:00  Introduction to different processes  Charts and Practical Duration involved in fabrication & their purpose displays (hh:mm)  need and importance of tack welding regarding MIG 00:00  Brands of welding equipments & their and SMAW power ratings welding Corresponding NOS  Various hazards in fabrication Yards Code  Occupational Disease related to Bridge Module welding works and their symptoms  Importance of following safety precautions while welding  Introduction to Shop drawings (symbols and details etc.)  Basic math  units of measurement and conversion  career growth paths 2 Carry out grinding Theory: Tools: activities on structural  Application of grinding in welding  Portable/ steel element works Hand/ Angle  Types of grinders applicable for grinder Theory Duration welders, their components, different  Chalk/ marker (hh:mm) consumables and safety guidelines  Measuring 36:00  Different type of finishing done on tapes Practical Duration welds  Hammer (hh:mm)  Knowledge to optimizing the use of  Tweezers 84:00 consumables Safety Equipment  Procedure of using angle grinders  Safety Helmet Corresponding NOS (including explanation of important  Hand gloves Code parameters like angle of grinding,  Nose mask CON/N1206 application of pressure etc.)  Ear muffs  Knowledge of thickness of materials to  Googles grinded off in different patterns.  Jump suit Practical:  Safety The skills will be developed and practiced harness while carrying out following trade related  Safety shoes activities in stimulated site condition:

 Identify and confirm the thickness to be removed and the pattern of grinding  Check the accessibility of the joint for grinding  select the consumables and working conditions of the machine  follow proper procedure to grind off o excessive root reinforcements o defective weld joints

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3 Work effectively in a Theory:- team to deliver desired Understand the concept of: results at the  Method of oral and written workplace communication skills with co-workers, trade seniors while handling and carrying out visual checks on Theory Duration materials, tools and equipment (hh:mm)  How to interpret scope of joint 07:00 preparation and repair activities, material/ tools handling by adhering to instructions or consulting with seniors Practical Duration  Method of reporting to seniors clearly (hh:mm) and promptly 17:00  Seek necessary support and complete assigned tasks within stipulated time Corresponding NOS duration Code  Keep good relation and maintain well behavior with co-workers CON/N8001 Demonstration/ Practical:- The skills will be developed and practiced while carrying out following trade related activities 1. Selection of materials, tools or devices for defined purpose under 2. observing joint preparation, bolting and welding activities 4 Work according to Theory: - Safety Equipment personal health, safety  Types of hazards involved in  Leather Hand and environment construction sites Gloves protocol at  Types of hazards involved in of  Jump suit construction site Grinding and welding works  Wire brush  Importance of proper ventilation and  Hand & Leg Theory Duration illumination while conducting welding guards leather (hh:mm) works  Safety 07:00  Hazards of welding fumes goggles  Emergency safety control measures  Nose mask Practical Duration and actions to be taken under  Ear protection (hh:mm) emergency situation, concept of  Fire 17:00 safety evacuation plan extinguishers

 Knowledge of various occupational  Sand buckets Corresponding NOS diseases related to welding Flashback Code  Knowledge of checking leakage in arrestors CON/N9001 gas pipelines and cylinder used for  Welding welding helmet  Knowledge of situations under which  Welding glass a fire hazard can occur and conditions to avoid fire  Concept of :- 1. First Aid process 2. Use of fire extinguisher 3. Classification of fires and fire extinguisher 4. Safety drills  PPEs to be used for welding works, importance of selecting proper welding glass and mask

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 Reporting procedure to the concerned authority in emergency situations  Standard procedure of handling, storing and stacking material, fabrication accessories  What is safe disposal of waste, type of waste and their disposal  basic ergonomic principles as per applicability

Demonstration/ Practical (D/P) :- The skills will be developed and practiced while carrying out following trade related activities in a predictable and familiar working condition. 1. Selection of PPEs and use them appropriately as per working need of scaffolding activities like: a. Performing welding using various techniques on various types of base metals b. performing grinding works for finishing or repairing welds 2. Selection of fire extinguisher based on classification of fire, standard practice of storing & stacking firefighting equipments/ materials at work locations 3. Perform checks so as to ensure that there is no gas leakage 4. Disposal of waste materials as per their nature and effects on weather COMPULSORY NOS: Unique Equipment Required: Total Duration class room, White board , Computer, Projector, Charts and Theory Duration displays regarding MIG and SMAW welding 58:00 Portable/ Hand/ Angle grinder, Chalk/ marker, Measuring tapes, Practical Duration Hammer, Tweezers, Safety Helmet, Hand gloves, Nose mask, 118:00 Ear muffs, Googles , Jump suit, Safety harness, Safety shoes Electives (mandatory to select at least one Title) Elective 1: Construction Welder MIG 5 Carry out preparatory Theory: Preparatory Tools: works for MIG welding Prepare welding Equipment:  Wire brush operations  Read and interpret the WPS to identify  Cloth the initial setting of the machine,  Cleaning Theory Duration electrode specifications, temperature solutions (hh:mm) and other relevant details  Light source 60:00  Knowledge to assemble the  Ventilation/ equipment and make connections to exhaust fan Practical Duration auxiliary equipment’s  Clamps, jigs (hh:mm)  Knowledge to confirm and/or select and fixtures 140:00 correct consumables like gas, filler  Anchors

etc.  Ball Peen Corresponding NOS  Knowledge of consumable Hammer Code specification, types and use  Needle Nose CON/N1253 Pliers

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 Knowledge of Properties of different  Lineman’s types of shield gases and their Pliers application  Tape Measure  Knowledge of polarity of the welding  Combination machine Square  Knowledge to check the working  Chipping conditions of the welding torch, gas Hammer valves, gas lines. Electric cables, filler  Flat Cross-Cut wire feeding machine, work clamps Bastard File etc.  Round Cross-  Knowledge to detect leakage of gases Cut Bastard Prepare base metal File  Knowledge to check and ensure that  Scribe the surface is cleaned and free from  Soap Stone moisture Welding Tools:  Importance of proper illumination and  GMAW ventilation welding  Knowledge of operation of welding machine gauges and measurement inclusive of  Knowledge of various type of joints regulators, and welding for the same Gas hose & all standard Demonstration/ Practical (D/P):- accessories. The skills will be developed and practiced  Welding while carrying out following trade related Transformer activities in stimulated site condition: with all 1. Preparation of Welding machine: accessories Carry out following connections &  Filler wire Perform checks spool  Connect all electrical connections  Wire feeding keeping in mind the polarity machine  Check the welding gun, nozzle and  Welding Gun gauges for damage  Shielding Gas  Check and confirm that flashback  Shielding gas arrestor is installed trolley with  Make adjustments to wire feed rate, chains shielding gas flow rate, current and  Arc welding voltage etc. in the welding machine cables 2. Prepare Area and Base metal for  Work clamps welding:  Check and confirm that proper  Universal lighting and ventilation Weld arrangements are made measuring  Check and confirm that all electrical gauge connections are properly terminated  Temp stick  Check and confirm that gas Safety Equipment cylinders are stacked properly  Leather Hand  Confirm that the electrodes used are Gloves as per requirement  Jump suit  Confirm the base metal is free from  Wire brush oil, grease, paint or any other  Hand & Leg impurity guards leather  Check and confirm visually that the  Safety root gap and bevel angle is as goggles mentioned in the drawings  Nose mask  Check and confirm that the base  Ear protection metal is properly anchored

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 Fire extinguishers  Sand buckets Flashback arrestors  Welding helmet  Welding glass 6 Carry out MIG welding Theory: Welding Tools: as per requirement in  Read and interpret  GMAW fabrication workshop  Welding specifications and welding or construction site parameters from WPS machine  Welding details ( symbols, location, inclusive of Theory Duration length, position etc.) from shop regulators, (hh:mm) drawings Gas hose & all 67:00  Manufactures guidelines relating to standard specifications of consumables, accessories. Practical Duration equipment etc.  Welding (hh:mm)  Fit up details/ reports to understand Transformer 157:00 the specification of joints with all  Knowledge of welding in different accessories Corresponding NOS positions  Filler wire Code  Knowledge of different types of spool CON/N1254 welding patters  Wire feeding  Detailed knowledge of components of machine welding equipment along with their  Welding Gun specifications  Shielding Gas  Detailed knowledge of various types  Shielding gas of shielding gases and their trolley with applications chains  Knowledge of different types of joints  Arc welding  Knowledge of various effects of cables welding on dirty surface (effect on  Work clamps welds and effect on health)  Universal  Detailed knowledge of various types Weld of defects in welding, their causes and measuring remedy gauge  Temp stick Demonstration/ Practical (D/P) :- Safety Equipment The skills will be developed and practiced  Leather Hand while carrying out following trade related Gloves activities in stimulated site condition:  Jump suit  Wire brush  Perform preheating of the base metal  Hand & Leg  Perform MIG welding on groove and guards leather fillet joints in 1G,1F, 2G, 2F, 3G,3F  Safety positions using instructed pattern of goggles welding on different sections like  Nose mask angle, plate, pipe, channels, I sections  Ear protection etc. of varying thickness (3mm, to 50  Fire mm) extinguishers  The welding should be performed as  Sand buckets per the WPS provided Flashback  Demonstrate assembling, dismantling arrestors and cleaning of the equipment  Welding  Demonstrate how to helmet

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 Ensure proper penetration of weld  Welding glass  Covering the weld pool with shielding gas  Check root pass for cracks  Perform visual inspections of weld for spatters, cracks, craters, undercuts etc.

ELECTIVE 1: Total Unique Equipment Required: Duration Preparatory Tools Theory Duration Wire brush, Cloth, Cleaning solutions, Light source, Ventilation/ 127:00 exhaust fan, Clamps, jigs and fixtures, Anchors, Ball Peen, Practical Duration Hammer, Needle Nose Pliers, Lineman’s Pliers, Tape Measure, 297:00 Combination Square, Chipping Hammer, Flat Cross-Cut, Bastard File, Round Cross-Cut Bastard File, Scribe, Soap stone

Welding Tools GMAW welding machine inclusive of regulators, Gas hose & all standard accessories, Welding Transformer with all accessories, Filler wire spool, Wire feeding machine, Welding Gun, Shielding Gas, Shielding gas trolley with chains, Arc welding cables, Work clamps , Universal Weld measuring gauge, Temp stick

works for TIG welding  Wire brush operation Prepare TIG welding Equipment:  Cloth  Read and interpret the WPS to identify  Cleaning Theory Duration the initial setting of the machine, solutions (hh:mm) electrode specifications, temperature  Light source 60:00 and other relevant details  Ventilation/  Knowledge to assemble the exhaust fan Practical Duration equipment and make connections to  Clamps, jigs (hh:mm) auxiliary equipment’s and fixtures 140:00  Knowledge to confirm and/or select  Anchors

correct consumables like gas, filler  Ball Peen Corresponding NOS etc. Hammer Code  Knowledge of consumable  Needle Nose CON/N1255 specification, types and use Pliers  Knowledge of Properties of different  Lineman’s types of shield gases and their Pliers application  Tape Measure  Knowledge of polarity of the welding  Combination machine Square  Knowledge to check the working  Chipping conditions of the welding torch, gas Hammer valves, gas lines. Electric cables, filler  Flat Cross-Cut wire feeding machine, work clamps Bastard File etc.  Round Cross-  Knowledge to detect leakage of gases Cut Bastard File

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 Knowledge to understand the correct  Scribe polarity of the setup and effects of  Soap Stone reverse polarity.  Knowledge of relationships between Welding Tools: various welding parameters like wire  GTAW feed, speed control voltage, gas welding regulation, rate of flow of shielding gas machine etc. on quality of welds and control of inclusive of these parameters to achieve desired regulators, quality Gas hose & all  Knowledge of selecting and preparing standard tungsten electrodes, correct method of accessories. preparing the electrode based upon  Welding the joint type Transformer  Knowledge of different types of filler with all electrodes and their specifications accessories  Filler wire Prepare base metal spool  Welding Gun  Knowledge to check and ensure that  Shielding Gas the surface is cleaned and free from  Shielding gas moisture trolley with  Importance of proper illumination and chains ventilation  Arc welding  Knowledge of operation of welding cables gauges and measurement  Work clamps  Knowledge of various type of joints  Universal and welding for the same Weld measuring Demonstration/ Practical (D/P):- gauge The skills will be developed and practiced  Temp stick while carrying out following trade related  Tungsten activities in stimulated site condition: Electrode 1. Preparation of TIG Welding machine: Safety Equipment  Carry out following connections &  Leather Hand Perform checks Gloves  Connect all electrical connections  Jump suit keeping in mind the polarity  Wire brush  Check the welding gun, nozzle and  Hand & Leg gauges for damage guards leather  Check and confirm that flashback  Safety arrestor is installed goggles  Make adjustments to wire feed rate, shielding gas flow rate, current and  Nose mask voltage etc. in the welding machine  Ear protection  Check and prepare the tungsten  Fire electrode as per specification extinguishers  Select and confirm that the filler  Sand buckets material is as per specification Flashback 2. Prepare Area and Base metal for arrestors welding:  Welding  Check and confirm that proper helmet lighting and ventilation  Welding glass arrangements are made  Check and confirm that all electrical connections are properly terminated

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 Check and confirm that gas cylinders are stacked properly  Confirm that the electrodes used are as per requirement  Confirm the base metal is free from oil, grease, paint or any other impurity  Check and confirm visually that the root gap and bevel angle is as mentioned in the drawings  Check and confirm that the base metal is properly anchored 8 Carry out tungsten Theory: Welding Tools: inert gas welding as  Read and interpret  GTAW per requirement in  Welding specifications and welding fabrication workshop parameters from WPS machine or construction site  Welding details (symbols, location, inclusive of length, position etc.) from shop regulators, Theory Duration drawings Gas hose & all (hh:mm)  Manufactures guidelines relating to standard 67:00 specifications of consumables, accessories. equipment etc.  Welding Practical Duration  Fit up details/ reports to understand Transformer (hh:mm) the specification of joints with all 157:00  Knowledge of operation of various accessories auxiliary equipment of TIG welding  Filler wire Corresponding NOS machine spool Code  Detailed knowledge of the procedure  Welding Gun CON/N1256 of TIG welding including the method of  Shielding Gas metal transfer, physical and chemical  Shielding gas changes occurring during welding, trolley with effects of heating metals. chains  Knowledge of welding in different  Arc welding positions cables  Knowledge of different types of  Work clamps welding patters  Universal  Detailed knowledge of components of Weld welding equipment along with their measuring specifications gauge  Detailed knowledge of various types  Temp stick of shielding gases and their  Tungsten applications Electrode  Knowledge of different types of joints Safety Equipment  Knowledge of various effects of  Leather Hand welding on dirty surface (effect on Gloves welds and effect on health)  Jump suit  Detailed knowledge of various types  Wire brush of defects in welding, their causes and  Hand & Leg remedy guards leather Demonstration/ Practical (D/P):-  Safety The skills will be developed and practiced goggles while carrying out following trade related  Nose mask activities in stimulated site condition:  Ear protection  Perform TIG welding on groove and  Fire fillet joints in 1G,1F, 2G, 2F, 3G,3F extinguishers positions using instructed pattern of welding on different sections like

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angle, plate, pipe, channels, I sections  Sand buckets etc. of varying thickness (3mm, to 50 Flashback mm) arrestors  The welding should be performed as  Welding per the WPS provided helmet  Demonstrate assembling, dismantling  Welding glass and cleaning of the equipment  Demonstrate how to   Ensure proper penetration of weld  Covering the weld pool with shielding gas  Check root pass for cracks  Perform visual inspections of weld for spatters, cracks, craters, undercuts etc. ELECTIVE 2: Total Unique Equipment Required: Duration Preparatory Tools Theory Duration Wire brush, Cloth, Cleaning solutions, Light source, Ventilation/ 127:00 exhaust fan, Clamps, jigs and fixtures, Anchors, Ball Peen, Practical Duration Hammer, Needle Nose Pliers, Lineman’s Pliers, Tape Measure, 297:00 Combination Square, Chipping Hammer, Flat Cross-Cut, Bastard File, Round Cross-Cut Bastard File, Scribe, Soap stone

Safety Equipment Leather Hand Gloves, Jump suit, Wire brush, Hand & Leg guards leather, Safety goggles, Nose mask, Ear protection, Fire extinguishers, Sand buckets Flashback arrestors, Welding helmet, Welding glass Elective 3: Construction Welder SMAW 9 Carry out preparatory Theory: Preparatory Tools: work for shielded Prepare SMA welding Equipment:  Wire brush metal arc welding  Read and interpret the WPS to identify  Cloth operations the initial setting of the machine,  Cleaning electrode specifications, temperature solutions Theory Duration and other relevant details  Light source (hh:mm)  Knowledge to assemble the  Ventilation/ 60:00 equipment and make connections to exhaust fan auxiliary equipment’s  Clamps, jigs Practical Duration  Knowledge to confirm and/or select and fixtures (hh:mm) correct consumables like gas, filler  Anchors 140:00 etc.  Ball Peen

 Knowledge of consumable Hammer Corresponding NOS specification, types and use  Needle Nose Code  Knowledge of Properties of different Pliers CON/N1257 types of shield gases and their  Lineman’s application Pliers  Knowledge of polarity of the welding  Tape Measure machine  Combination  Knowledge to check the working Square conditions of the welding torch, gas

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valves, gas lines. Electric cables, filler  Chipping wire feeding machine, work clamps Hammer etc.  Flat Cross-Cut  Knowledge to detect leakage of gases Bastard File  Knowledge to understand the correct  Round Cross- polarity of the setup and effects of Cut Bastard reverse polarity. File  Knowledge of relationships between  Scribe various welding parameters like wire  Soap Stone feed, speed control voltage, gas regulation, rate of flow of shielding gas Welding Tools: etc. on quality of welds and control of  SMAW these parameters to achieve desired welding quality machine  Knowledge of selecting and preparing inclusive of tungsten electrodes, correct method of regulators, preparing the electrode based upon Gas hose & all the joint type standard  Knowledge of different types of filler accessories. electrodes and their specifications  Welding Prepare base metal Transformer  Knowledge to check and ensure that with all the surface is cleaned and free from accessories moisture  Filler wire  Importance of proper illumination and spool ventilation  Welding Gun  Knowledge of operation of welding  Arc welding gauges and measurement cables  Knowledge of various type of joints  Work clamps and welding for the same  Universal Weld Demonstration/ Practical (D/P):- measuring The skills will be developed and practiced gauge while carrying out following trade related  Temp stick activities in stimulated site condition: Safety Equipment 1. Preparation of SMA Welding  Leather Hand machine: Gloves  Carry out following connections &  Jump suit Perform checks  Wire brush  Connect all electrical connections  Hand & Leg keeping in mind the polarity guards leather  Check the electrode holder for  Safety workability goggles  Make adjustments to current and  Nose mask voltage etc. in the welding machine  Check and prepare the electrode as  Ear protection per specification  Fire 2. Prepare Area and Base metal for extinguishers welding:  Sand buckets  Check and confirm that proper Flashback lighting and ventilation arrestors arrangements are made  Welding  Check and confirm that all electrical helmet connections are properly terminated  Welding glass  Confirm that the electrodes used are as per requirement

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 Confirm the base metal is free from oil, grease, paint or any other impurity  Check and confirm visually that the root gap and bevel angle is as mentioned in the drawings  Check and confirm that the base metal is properly anchored 10 Carry out shielded Theory: metal arc welding as  Read and interpret  Wire brush per requirement in  Welding specifications and  Cloth fabrication workshop parameters from WPS  Cleaning or construction site  Welding details ( symbols, location, solutions length, position etc.) from shop  Light source Theory Duration drawings  Ventilation/ (hh:mm)  Manufactures guidelines relating to exhaust fan 67:00 specifications of consumables,  Clamps, jigs equipment etc. and fixtures Practical Duration  Fit up details/ reports to understand  Anchors (hh:mm) the specification of joints  Ball Peen 157:00  Knowledge of operation of various Hammer

auxiliary equipment of SMA welding  Needle Nose Corresponding NOS machine Pliers Code  Detailed knowledge of the procedure CON/N1258  Lineman’s of SMA welding including the method Pliers of metal transfer, physical and  Tape Measure chemical changes occurring during  Combination welding, effects of heating metals. Square  Knowledge of welding in different  Chipping positions Hammer  Knowledge of different types of  Flat Cross-Cut welding patters Bastard File  Detailed knowledge of components of  Round Cross- welding equipment along with their Cut Bastard specifications File  Knowledge of different types of joints  Scribe  Knowledge of various effects of  Soap Stone welding on dirty surface (effect on

welds and effect on health) Welding Tools:  Detailed knowledge of various types  SMA welding of defects in welding, their causes and machine remedy inclusive of

regulators, Demonstration/ Practical (D/P):- Gas hose & all The skills will be developed and practiced standard while carrying out following trade related accessories. activities in stimulated site condition:  Welding Transformer  Perform SMA welding on groove and with all fillet joints in 1G,1F, 2G, 2F, 3G,3F accessories positions using instructed pattern of welding on different sections like  Welding Gun angle, plate, pipe, channels, I sections  Arc welding etc. of varying thickness (3mm, to 50 cables mm)  Work clamps  The welding should be performed as  Universal per the WPS provided Weld

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 Demonstrate assembling, dismantling measuring and cleaning of the equipment gauge  Demonstrate how to  Temp stick  Ensure proper penetration of weld  Wire brush  Check root pass for cracks  Cloth  Perform visual inspections of weld  Ball Peen for spatters, cracks, craters, Hammer undercuts etc.  Needle Nose Pliers  Lineman’s Pliers  Chipping Hammer  File Safety Equipment  Leather Hand Gloves  Jump suit  Wire brush  Hand & Leg guards leather  Safety goggles  Nose mask  Ear protection  Fire extinguishers  Sand buckets Flashback arrestors  Welding helmet  Welding glass

ELECTIVE 3: Total Unique Equipment Required: Duration Preparatory Tools Theory Duration Wire brush, Cloth, Cleaning solutions, Light source, Ventilation/ 127:00 exhaust fan, Clamps, jigs and fixtures, Anchors, Ball Peen, Practical Duration Hammer, Needle Nose Pliers, Lineman’s Pliers, Tape Measure, 297:00 Combination Square, Chipping Hammer, Flat Cross-Cut, Bastard File, Round Cross-Cut Bastard File, Scribe, Soap stone

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Grand Total Duration Unique Equipment Required: Minimum Duration for class room, White board, Computer, Projector, Charts and QP: 600 displays regarding MIG and SMAW welding Theory:185 Different types of cleaners and accessories, Clamps and vices, Practical: 415 Spark lighter, Welding Transformer with all accessories, Maximum Duration for Welding Transformer (or) Inverter based welding machine with QP: 1780 all accessories, D.C Arc welding rectifiers set with all Theory: 717 accessories, AC/DC SMAW and GTAW welding machine with Practical: 1063 water or air cooled torch and standard accessories, Argon regulator, Gas hose, water circulating system (if required), Trolley for cylinder, Clamps, Tapes, Electrode holders, Gas regulators, Flashback arrestors, welding helmet, Welding glass Chipping hammer, Chisel, Leather Hand Gloves, Jump suit, Wire brush, Hand & Leg guards leather, Safety goggles, Nose mask, Ear protection, Fire extinguishers, Sand buckets Chipping hammer, Chisel, Leather Hand Gloves, Jump suit Wire brush, Hand & Leg guards leather, Safety goggles Nose mask, Ear protection, Fire extinguishers, Clamps and vices, Spark lighter, Sand buckets, Temperature measuring gun or chalks, Oxygen Gas Pressure regulator, Acetylene Gas Pressure regulator, Portable gas cutting machine, Trolley for cylinder, Oxy Acetylene Gas cutting blow pipe , Oxygen, Acetylene Cylinders, Flashback arrestors Leather Hand Gloves, Jump suit, Wire brush, Hand & Leg guards leather, Safety goggles, Nose mask, Ear protection Fire extinguishers, Sand buckets Flashback arrestors, Welding helmet, Welding glass

(This syllabus/ curriculum has been approved by Construction Skill Development Council of

India)

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Trainer Prerequisites for Job role: “Construction Welder (Electives: MIG/TIG/SMAW) Welder” mapped to Qualification Pack: “CON/Q1252 , v1.0”

Sr. Area Details No. 1 Description To deliver accredited training service, mapping to the curriculum detailed above, in accordance with the Qualification Pack “CON/Q1252”. 2 Personal Aptitude for conducting training, and pre/ post work to ensure competent, Attributes employable candidates at the end of the training. Strong communication skills, interpersonal skills, ability to work as part of a team; a passion for quality and for developing others; well-organised and focused, eager to learn and keep oneself updated with the latest in the mentioned field 3 Minimum ITI/12th Educational Qualifications 4a Domain Trainer/Assessor-80% in each NOS of Qualification Pack “MEP/Q0102” or Certification “MEP/Q0104” and Lead trainer/Lead Assessors- 90% in each NOS of Qualification Pack “MEP/Q0101” or “MEP/Q0103” 4b Platform Trainer/Assessor-50% in each NOS of Qualification Pack “MEP/Q0101” or Certification “MEP/Q0103”& 80% overall, Lead trainer/ Lead Assessors- 50% in each NOS of Qualification Pack “MEP/Q0101” or “MEP/Q0103”and overall 90% 5 Experience i. Technical Degree holder with minimum three years of Field experience and preferably two years of teaching experience or, ii. In case of a Diploma Holder five years of field experience and preferably two years of teaching experience or, iii. In case of ITI/12th pass minimum eight years of field experience and preferably two years of teaching Experience.

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CRITERIA FOR ASSESSMENT OF TRAINEES Job Role Construction Welder(Electives: MIG/TIG/SMAW) Qualification Pack CON/Q1252 Sector Skill Council Construction

Guidelines for Assessment

1. Criteria for assessment for each Qualification Pack will be created by the Sector Skill Council. Each Performance Criteria (PC) will be assigned marks proportional to its importance in NOS. SSC will also lay down proportion of marks for Theory and Skills Practical for each PC. 2. The assessment for the knowledge part will be based on knowledge bank of questions created by Assessment Bodies subject to approval by SSC 3. Individual assessment agencies will create unique question papers for knowledge/theory part for assessment of candidates as per assessment criteria given below 4. Individual assessment agencies will create unique evaluations for skill practical for every student at each examination/training centre based on assessment criteria. 5. The passing percentage for each QP will be 70%. To pass the Qualification Pack, every trainee should score a minimum of 70% individually in each NOS. 6. The Assessor shall check the final outcome of the practices while evaluating the steps performed to achieve the final outcome. 7. The trainee shall be provided with a chance to repeat the test to correct his procedures in case of improper performance, with a deduction of marks for each iteration. 8. After the certain number of iteration as decided by SSC the trainee is marked as fail, scoring zero marks for the procedure for the practical activity. 9. In case of successfully passing only certain number of NOS's, the trainee is eligible to take subsequent assessment on the balance NOS's to pass the Qualification Pack within the specified timeframe set by SSC. 10. Minimum duration of Assessment of each QP shall be of 4hrs/trainee.

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Compulsory NOS Marks Allocation Total Mark : 300

Assessment Total Skills Assessment Criteria for outcomes Out Of Theory outcomes Mark Practical CON/N1206: PC1. ensure that the grinder is in proper working condition 8 2 6 Carry out grinding activities on PC2. check that guard is installed on the machine and is 6 2 4 structural steel secure and effective. elements PC3. check and notify any inadequacy like incorrect type of grinder, incorrect consumable issued etc. in the grinding tool 8 2 6 to appropriate authority PC4. check the accessibility (in between joints, large distance 8 2 6 from power source etc.)of the grinder for the work PC5. identify the location of surface to be grinded. 8 2 6 PC6. clean the metal surface to remove any foreign matter 6 2 4 like dust, rust, paint, oil etc. PC7. clamp and fix the metal before grinding 8 2 6 100 PC8. select appropriate consumables as per work 8 2 6 PC9. gather and identify information from superiors regarding the dimensions of grinding, angle of grinding etc. 8 2 6 PC10. select proper body position so that hand movements are comfortable and smooth PC11. move the grinding tool in desired patterns as per work 8 2 6 requirements PC12. provide proper pressure at correct angle as per work 8 2 6 requirement to minimize the waste age of consumables PC13. grind off defective weld joints to required depth joints 8 2 6 PC14. grind off excessive root reinforcements in welded joint 8 2 6 if required. Total 100 30 70 CON/N8001: PC1. pass on work related information/ requirement clearly 7 2 5 Work effectively to the team members in a team to PC2. inform co-workers and superiors about any kind of 7 2 5 deliver desired deviations from work results at the PC3. address the problems effectively and report if required 10 3 7 workplace to immediate supervisor appropriately PC4. receive instructions clearly from superiors and respond 100 7 2 5 effectively on same PC5. communicate to team members/subordinates for 10 3 7 appropriate work technique and method PC6. seek clarification and advice as per requirement and 7 2 5 applicability PC7. hand over the required material, tools tackles, 27 8 19 equipment and work fronts timely to interfacing teams

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PC8. work together with co-workers in a synchronized 27 8 19 manner Total 100 30 70 CON/N9001: PC1. identify and report any hazards, risks or breaches in site 7 2 5 Work according to safety to the appropriate authority personal health, PC2. follow emergency and evacuation procedures in case of 7 2 5 safety and accidents, fires, natural calamities environment PC3. follow recommended safe practices in handling protocol at construction materials, including chemical and hazardous 10 3 7 construction site material whenever applicable PC4. participate in safety awareness programs like Tool Box 7 2 5 Talks, safety demonstrations, mock drills, conducted at site PC5. identify near miss , unsafe condition and unsafe act 7 2 5 PC6. use appropriate Personal Protective Equipment (PPE) as per work requirements including: • Head Protection (Helmets) • Ear protection • Fall Protection 10 3 7 • Foot Protection 100 • Face and Eye Protection • Hand and Body Protection • Respiratory Protection (if required) PC7. handle all required tools, tackles , materials & 7 2 5 equipment safely PC8. follow safe disposal of waste, harmful and hazardous 7 2 5 materials as per EHS guidelines PC9. install and apply properly all safety equipment as 13 4 9 instructed PC10. follow safety protocol and practices as laid down by 13 4 9 site EHS department PC11. collect and deposit construction waste into identified containers before disposal, separate containers that may be 7 2 5 needed for disposal of toxic or hazardous wastes PC12. apply ergonomic principles wherever required 7 2 5

Total 100 30 70

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ELECTIVES Elective 1: Construction Welder MIG Total Marks: 200 Marks Allocation Skills Assessment Total Theory Assessment Criteria for outcomes Out Of Practical outcomes Mark

CON/1253: Carry PC1. use and identify proper personal protective equipment out preparatory such as hand gloves, nose mask, ear plugs, head protection, 100 3 1 2 works for MIG safety harness etc. welding PC2. use appropriate welding masks operations 3 1 2

PC3. check for any gas leakages prior to striking arc 3 1 2 PC4. check the electrical connections for tightness and 3 1 2 termination PC5. inspect the lighting arrangement for adequacy 4 1 3 PC6. inspect and Clear the work area of any flammable objects like boxes, plastic etc. 4 1 3 PC7. ensure that subordinates are following safety norms 4 1 3

PC8. attend any and all prep talks and tool box talks 4 1 3 organized on site PC9. use and identify proper personal protective equipment such as hand gloves, nose mask, ear plugs, head protection, 4 1 3 safety harness etc. PC10. use appropriate welding masks 4 1 3

PC11. check for any gas leakages prior to striking arc 4 1 3 PC12. ensure that the gas cylinders are in upright positions 4 1 3 PC13. inspect electric collections for adequately tight and 4 1 3 secure prior to commencing the work PC14. ensure that work clamps are adequately secured and in correct polarity (-ve on welding bed and +ve on electrode) 4 1 3

PC15. ensure that welding tip and welding cup are in order 4 1 3

PC16. make initial adjustments of electrode consumption rate and voltage as per requirement. 4 1 3

PC17. ensure proper lighting 4 1 3 PC18. inspect that the gas valves are properly functioning 4 1 3 and adjust the same as per instructions PC19. ensure that electrodes are compatible with base metal 4 1 3 requirement ventilation arrangement is available PC20. check the electrodes comply with weld requirements 4 1 3 PC21. clean the surface to be welded before starting the 4 1 3 welding operations PC22. check that adequate root gap is available 4 1 3 PC23. check the bevel angle visually 4 1 3

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PC24. make sure that surface is smooth and free of 4 1 3 irregularities PC25. remove any oxides, dust or foreign particles from the 4 1 3 surface PC26. ensure that the surface is not painted or galvanized 4 1 3 Total 100 30 70 CON/N1254: PC1. interpret weld requirements from fabrication drawings 2 1 1 Carry out MIG PC2. confirm the weld specifications if required from welding as per 3 1 2 superiors requirement in PC3. understand the weld requirements like position of fabrication 5 2 4 weld, type of joint, number of passed required etc. workshop or PC4. estimate the number or length of filler material construction site 5 2 4 required to complete the weld

PC5. pre heat the base material before welding if required 5 2 4 PC6. maintain correct body posture as per requirement of weld 5 2 4 PC7. adjust the wire stick out and regulate the gas flow rate accordingly 5 2 4 PC8. use appropriate patterns of welding as per position and 5 2 4 type of joints PC9. hold the welding gun at proper angle as per requirement 5 2 4 PC10. make required number of passes 5 2 4 100 PC11. make steady passes of weld to ensure proper heat generation and penetration 5 2 4 PC12. make adjustments in welding machine if required 5 2 4

PC13. disconnect the equipment correctly and store the same as per manufacture guidelines and site safety 5 2 4 parameters PC14. clean the welded joint 5 2 4

PC15. ensure proper penetration of weld 5 2 4 PC16. ensure that the weld is properly shielded by shielding gas 5 2 4 PC17. ensure proper heat input through arc 5 2 4 PC18. reduce the spatter spray during the welding 5 2 4 PC19. check the root pass for cracks 5 2 4 PC20. visually check for spatters, craters, undercuts 5 2 4 PC21. visually check the welded joint for cracks 5 2 4 Total 100 30 70

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ELECTIVES Elective 2: Construction Welder TIG Total Marks: 200 Marks Allocation Skills Assessment Total Theory Assessment Criteria for outcomes Out Of Practical outcomes Mark

CON/1255: Carry PC1. use and identify proper personal protective equipment out preparatory such as hand gloves, nose mask, ear plugs, head protection, 3 1 2 works for TIG safety harness etc. welding PC2. use appropriate welding masks operations 3 1 2

PC3. check for any gas leakages prior to striking arc 3 1 2 PC4. check the electrical connections for tightness and 3 1 2 termination PC5. inspect the lighting arrangement for adequacy 3 1 2 PC6. inspect and clear the work area of any flammable objects like boxes, plastic etc. 3 1 2 PC7. ensure that subordinates are following safety norms 3 1 2

PC8. attend any and all prep talks and tool box talks 3 1 2 organized on site PC9. Participate in all safety drills organized on site 3 1 2 PC10. use appropriate fire safety equipment and procedure 3 1 2 in case of fire PC11. identify and report any other unsafe act or condition 3 1 2 to appropriate authority PC12. keep the shielding gas cylinders in upright position 3 1 2 only 100 PC13. ensure that shielding gas is purely inert e. g argon 3 1 2 PC14. check the pipes, valves/ regulator and flow meter is 3 1 2 securely connected PC15. taper the tungsten rod and sharpen the point of the electrode for better arc stability. The electrode should be 4 1 3 grinded parallel to length PC16. clean the electrode prior to use to remove any foreign 3 1 2 matter P17. adjust the tungsten stick out as per requirement based upon type of joint, base metal properties etc. 4 1 3 PC18. stack required number of filler rods\ electrodes as per instructions 3 1 2 PC19. clean the filler rod to remove any foreign particles in order to avoid weld contamination 3 1 2

PC20. ensure that filler material are compatible with base 3 1 2 metal and as per weld specifications PC21. ensure that work clamps are adequately secured and 4 1 3 in correct polarity (+ ve on welding bed and -ve on electrode) PC22. ensure that electrical connections are tight, secure 3 1 2 and compatible with the equipment

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PC23. clean the surface to be welded before starting the 3 1 2 welding operations PC24. check that adequate root gap is available 3 1 2 PC25. check the bevel angle visually 3 1 2 PC26. make sure that surface is smooth and free of 3 1 2 irregularities PC27. remove any oxides, dust or foreign particles from the 3 1 2 surface PC28. ensure that the surface is not painted or galvanized 3 1 2 PC29. ensure that the joint is properly secured against any 3 1 2 movement PC30. identify the joints to be welded, their location and 3 1 2 position of welding PC31. extract the weld specifications like type of joint, throat for fillet, number of passes required, specifications of filler 4 1 3 rod, required heat input, preheat temperature etc. form relevant charts and drawings PC32. estimate the number or length of filler material 3 1 2 required to complete the weld Total 100 30 70 CON/N1256: PC1. ignite the arc by superimposing the high frequency 4 1 3 Carry over high voltage out tungsten PC2. avoid touching the tungsten rod to the base metal 4 1 3 inert gas welding PC3. ensure that the filler rod is always inside the sheilding 5 2 4 as per gas cover to avoid contamination during welding operation requirement in PC4. select proper body position so that hand movements 100 4 1 3 fabrication are comfortable and smooth workshop or PC5. position head such that weld is clearly visible construction site 4 1 3 PC6. ensure that weld location is properly illuminated and ventilated 4 1 3 PC7. use appropriate patterns of welding as per position and 5 2 4 type of joints PC8. hold the welding gun at proper angle as per requirement(70-80 ⁰ from base plate) 5 2 4 PC9. ensure that the arc length is not too large and is as per heat requirement 5 2 4 PC10. adjust the travel speed of weld to ensure proper penetration 5 2 4 PC11. make required number of passes 4 1 3

PC12. make steady passes of weld to ensure proper heat generation and penetration 5 2 4 PC13.make required adjustments in welding machine 5 2 4

PC14. disconnect the equipment correctly and store the same as per manufacture guidelines and site safety 5 2 4 parameters

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PC15. clean the welded joint 4 1 3

PC16. ensure proper penetration of weld 5 2 4

PC17. ensure that the weld is properly shielded by shielding gas 5 2 4 PC18. ensure proper heat input through arc 5 2 4

PC19. reduce the spatter spray during the welding 5 2 4

PC20. check the root pass for cracks 4 1 3

PC21. visually check for spatters, craters, undercuts 4 1 3

PC22. visually check the welded joint for cracks 4 1 3

Total 100 30 70

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ELECTIVES Elective 3: Construction Welder SMAW Total Marks: 200 Marks Allocation Skills Assessment Total Theory Assessment Criteria for outcomes Out Of Practical outcomes Mark

CON1257: Carry PC1. Use and identify proper personal protective equipment out preparatory such as hand gloves, nose mask, ear plugs, head protection, 4 1 3 works for safety harness etc. Shielded metal PC2. Use appropriate welding masks 4 1 3 Arc welding PC3. Check the electrical connections for tightness and 4 1 3 operations termination PC4. Inspect the lighting arrangement for adequacy 4 1 3 PC5. Inspect and Clear the work area of any flammable 100 4 1 3 objects like boxes, plastic etc. PC6. Ensure that subordinates are following safety norms 4 1 3 PC7. Attend any and all perp talks and tool box talks 4 1 3 organized on site PC8. Participate in all safety drills organized on site 4 1 3 PC9. Use appropriate fire safety equipments and procedure 4 1 3 in case of fire PC10. Identify and report any other unsafe act or condition 4 1 3 to appropriate authority PC11. inspect electric collection to be adequately tight and 4 1 3 secure prior to commencing the work PC12. attach the work clamps to the base metal 4 1 3 PC13. select the polarity depending upon the thickness of 4 1 3 material and other parameters of work requirement PC14. store the electrodes correctly as per manufactures 4 1 3 guidelines PC15. clean the surface to be welded before starting the 4 1 3 welding operations PC16. check that adequate root gap is available 4 1 3 PC17. check the bevel angle visually 4 1 3 PC18. make sure that surface is smooth and free of 4 1 3 irregularities PC19. remove any oxides, dust or foreign particles from the 4 1 3 surface PC20. ensure that the temperature at joint is as per 4 1 3 specifications PC21. ensure that the surface is not painted or galvanized 4 1 3 PC22. ensure that the joint is properly secured against any 4 1 3 movement PC23. identify the joints to be welded, their location and 4 1 3 position of welding PC24. extract the weld specifications like type of joint, throat for fillet, number of passes required, specifications of filler 4 1 3 rod, required heat input, preheat temperature etc. form relevant charts and drawings PC25. estimate the number or length of filler material 4 1 3 required to complete the weld

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Total Marks Total 100 25 75 CON/N1258: PC1. ignite the arc by striking the electrode on the base metal 3 1 2 Carry out shielded like a match metal arc welding PC2. select proper body position so that hand movements 5 2 4 as per are comfortable and smooth requirement in PC3. position head such that weld is clearly visible 3 1 2 fabrication PC4. ensure that weld location is properly illuminated and 5 2 4 workshop or ventilated construction site PC5. use appropriate patterns of welding as per position and 5 2 4 type of joints 100 PC6. push or drag the arc as per requirement 5 2 4 PC7. ensure that the Arc length is not too large and is as per 5 2 4 heat requirement PC8. adjust the travel speed of weld to ensure proper 5 2 4 penetration PC9. make required number of weld passes 5 2 4 PC10. make steady passes of weld to ensure proper heat 5 2 4 generation and penetration PC11. clean the weld after each pass to scrap out the slag 5 2 4 formed on the surface of weld PC12. make required adjustments in welding machine 5 2 4 PC13. disconnect the equipment correctly and store the same as per manufacture guidelines and site safety 5 2 4 parameters PC14. efficiently dispose of the stubs of electrode left after 3 1 2 completing the welding PC15. clean the welded joint by removing slag formed during 5 2 4 the welding process PC16. ensure proper penetration of weld 5 2 4 PC17. ensure that the weld is properly shielded throughout 5 2 4 the operation PC18. ensure proper heat input through arc 5 2 4 PC19. reduce the spatter spray during the welding 5 2 4 PC20. check the root pass for cracks 5 2 4 PC21. visually check for spatters, craters, undercuts 3 1 2 PC22. visually check the welded joint for cracks 3 1 2 Total Marks Total 100 30 70

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