Welder 6 MONTHS 800hrs

GOVERNMENT OF THE PUNJAB

TECHNICAL EDUCATION & VOCATIONAL TRAINING AUTHORITY

CURRICULUM FOR

000000000000

WELDER

(6 –Months Course)

(Revised May 2009)

CURRICULUM SECTION

ACADEMICS DEPARTMENT

96-H, GULBERG-II, LAHORE Ph # 042-9263055-9, 9263064

[email protected], [email protected]

CURRICULUM FOR

mailto:[email protected]

mailto:[email protected]

Welder (6-Month Course)

Developed by Curr icu lum Sect ion, Academics Department TEVTA.

2

TRAINING OBJECTIVES: Construction industry is expending by day by day due to enhanced development in

industrial, commercial and real estate enterprises. As a result of this fact, the job

demand of trained labour and field staff have been increased.

This curriculum has been developed keeping in view the requirements of

construction industry by more focusing on practical along with necessary required

theoretical knowledge and work ethics.

This curriculum covers the major topics of basic metal work, measuring tools, arc

welding, gas welding, construction fabrication and work ethics.

CURRICULUM SALIENTS:

Name of the course Welder

Entry Level Primary preferable Middle

Duration of Course 6 – Months

800 Hours

40 Hours per week

6 days a week

40 hours per week

07 hours per day

Except Friday 05 hours

Training Methodology Practical 90%

Theory 10%

Medium of Instruction Urdu / English

Welder (6-Months Course)


3

SKILL COMPETENCY DETAILS

On successful completion of this course, the trainee should be able to:

1. Apply Arc Welding by selection of Electrodes.

2. Apply arc welding by selection of current setting.

3. Apply gas welding by selection of electrodes.

4. Make welding on various parts / jobs as per design and drawing.

5. Read the drawing of building metal constructed job / projects.

6. Make the project of construction fabrication as per drawing & designs



4

KNOWLEDGE PROFICIENCY DETAILS

On successful completion of this course, the trainee should be able to:

1. Explain the Measuring.

2. Explain the Marking

3. Define the drilling.

4. Define the cutting tools & Instruments.

5. Explain the usage of tools safely.

6. Explain the arc welding by selection of current setting.

7. Explain the gas welding by selection of gases.

8. Explain the construction fabrication of the construction industry.

9. Explain the drawing of construction fabrication.



5

CCUURRRRIICCUULLUUMM DDEELLIIVVEERRYY SSTTRRUUCCTTUURREE

W E E K

Curriculum Delivery Make up Session

Revision Co-curricula

Activities Final Test

Total

1-20 21-22 23-24 25

26

26

20 2 2 1 1



6

SSCCHHEEMMEE OOFF SSTTUUDDIIEESS WELDER

(6– Months Course)

Sr. No.

Detail of Topics Theory Hours

Practical Hours

1. 1. Safety Precautions 3 -

2. 2. Introduction to Tools 8 -

3. 3. Basic Works 4 80

4. 4. Gas Welding 8 -

5. 5. Straight Beads Flat 6” x 4” x 2 mm - 10

6. 6. Square Butt Joint Flat 1”x1/8”x6” - 20

7. 7. Corner Joint Flat 1”x1/8”x6” - 20

8. 8. Square Butt Joint Vertical Upward 1”x1/8”x6” - 20

9. 9. Square Butt Joint on Pipe Flat 2” x 11/4” SWG12 - 20

10. 10. Electric Welding 8 -

11. 11. Blind Welding 8” x 4” x ¼” - 20

12. 12. Grinding 2 -

13. 13. Electrode 4 -

14. 14. Square Butt Joint (1” x 1/8”) - 20

15. 15. Square Butt Joint (1” x 3/16”) - 20

16. 16. Corner Weld (1” x ¼ “) - 20

17. 17. Fillet Weld 2” x ¼ “ , 1” x ¼ “ - 20

18. 18. Single V Butt Joint (Vertical Upward) 1 ½ “ x 3/8 “ - 20

19. 19. Single V Butt Joint (Horizontal) 1 ½ “ x 3/8 “ - 26

20. 20. T – Joint (Overhead) 2” x ¼ “ , 1” x ¼ “ - 30

21. 21. Single V Butt Joint on Pipe FL/V/oh 4” x 1” ½ SWG 6 - 30

22. 22. Measuring Tools 6 -

23. 23. Grill Welding Pattern (Flat) - 30

24. 24. Grill Pattern Welding (Bar) - 30

25. 25. Measuring Surfaces 6 -

26. 26. Pipe Welding Practice (Box) 1’x’1 - 30

27. 27. Angle Iron Welding Practice - 40

28. Area Calculation 6 -

29. 28. Angle Iron Box Making - 30



7

30. 29. Stool (Square Pipe) - 30

31. 30. Construction Fabrication 5 124

32. 31. Functional English 20 20

33. 32. Work Ethics (Lab. Theory) - 20

Total 80 720



8

DETAIL OF COURSE CONTENTS Welder

(6-Months Course)

Sr. No.

Detail of Topics Theory Hours

Practical Hours

1. 1. Safety Precautions

1.1. Personal

1.2. Tools / Equipments safety

1.3. Job Safety

3 -

2. 2. Introduction to Tools

2.1. Measuring

2.1.1. Steel Foot Rule

2.1.2. Steel Tape

2.1.3. Vernier Caliper

2.2. Cutting

2.2.1. All kinds of files

2.2.2. Hacksaw Blade

2.2.3. Chisel

2.3. Checking

2.3.1. Try Square

2.3.2. Back Try Square

2.3.3. Inside Caliper

2.3.4. Outside Caliper

2.4. Marking Tools

2.4.1. Line Scriber

2.4.2. Centre Punch

8 -

3. 3. Basic Works

3.1. Marking Exercise

3.1.1. Angle and reference Line

3.1.2. Marking

3.1.3. Center Punching

3.2. Sawing Exercise

3.2.1. Notch ends of marking line with

triangular file

4

10

10



9

3.2.2. Sawing of I and II cut

3.2.3. Angle and Size A,B,C

3.3. Drilling Exercise I

3.3.1. Marking

3.3.2. Center Punching

3.3.3. Drilling

3.4. Drilling Exercise II

3.4.1. Internal Thread Cutting by Hand

3.4.2. Reaming

3.4.3. Counter Boring

3.4.4. Counter Sinking

30

30

4. 4. Gas Welding

4.1. Oxygen Cylinder

4.2. Acetylene Cylinder

4.3. Spindle Key

4.4. Gas Regulators

4.5. Back Fire Arrestor

4.6. Rubber Hose Pipes

4.7. Nozzle (Parts)

4.8. Introduction of Flames

4.8.1. Carborizing

4.8.2. Neutral

4.8.3. Oxidizing

4.9. Temperature

4.10. Use in Welding

8 -

5. 5. Straight Beads Flat

5.1. Preparation

5.2. Melting of Base Metal

5.3. Ripple Making

- 10

6. 6. Square Butt Joint Flat

6.1. Preparation

6.2. Tacking

6.3. Bead Forming

- 20



10

7. 7. Corner Joint Flat 1”x1/8”x6”

7.1. Preparation

7.2. Tacking at 90o

7.3. Bead Forming with Equal Ripples

- 20

8. 8. Square Butt Joint Vertical Upward 1”x1/8”x6”

8.1. Preparation

8.2. Tacking at 90 o

8.3. Bead Forming with Equal Ripples

- 20

9. 9. Square Butt Joint on Pipe Flat

9.1. MS Pipe dia 2”

9.2. Cutting of Pipe

9.3. Preparation

9.4. Tacking

9.5. Bead Forming with equal ripples

- 20

10. 10. Electric Welding

10.1. ARC Welding Tools

10.1.1. Welding Machines

10.1.2. Bench Vice

10.1.3. Flat File Rough

10.1.4. Hammer

10.1.5. Steel Foot Rule

10.1.6. Scriber

10.1.7. Centre Punch

10.1.8. Try Square

10.1.9. Divider

10.1.10. Hack Saw

10.1.11. Chisel

10.1.12. Gloves, Welding Screen, Goggle,

Wire brush, Pliers, Chipping Hammer

10.2. Basic Work

10.3. Safety for Tools and use

10.4. Drill

10.4.1. Straight Shank

2

1

-

-



11

10.4.2. Taper Shank

10.4.3. Parts of Body

10.4.4. Shank

10.4.5. Flute

10.4.6. Margins

10.4.7. Cutting Angle

10.4.8. Head

10.4.9. Wedge

10.5. Taps

10.5.1. Plug

10.5.2. Medium

10.5.3. Master (Bottom Type)

10.6. Reamer

10.6.1. Shank / Tapper / Straight

10.6.2. Cutting Edge

10.7. Counter Sink

10.7.1. Angle

10.7.2. Purpose

10.8. Counter Bore

10.8.1. Purpose

10.8.2. Shank

10.8.3. Cutting Edge

10.8.4. Guide

1

2

2

2

-

-

-

-

11. 11. Blind Welding

11.1. Preparation

11.2. Selection of electrode

11.3. Striking/ scratching motion

11.4. Bead Forming

- 20

12. 12. Grinding

12.1. Handling of hand grinder

12.2. Grinding Procedure

12.3. Safety Rules

2 -



12

13. 13. Electrode

13.1. Electrode (size in SWG)(mm)

13.2. Use of welding Electrode

13.3. Care of Electrode (Storing)

4 -

14. 14. Square Butt Joint

14.1. Preparation

14.2. Control of electrode

14.3. Proper Fusion

- 20

15. 15. Square Butt Joint

15.1. Preparation

15.2. Movement of Electrode for Root Pass

15.3. Movement of Electrode for filling pass

15.4. Proper Fusion

- 20

16. 16. Corner Weld

16.1. Preparation

16.2. Tacking

16.3. Angle of Electrode

- 20

17. 17. Fillet Weld

17.1. Preparation

17.2. Tacking of piece 90 o

17.3. Angle of Electrode

17.4. Proper Multi Beeds

- 20

18. 18. Single V Butt Joint (Vertical Upward)

18.1. Preparation of root face

18.2. Root Beed

18.3. Filling Beed

18.4. Capping Beed

- 20

19. 19. Single V Butt Joint (Horizontal)

19.1. Tacking with equal root space

19.2. Root Beed

19.3. Filling Beed

19.4. Capping Multi Beed

- 26



13

20. 20. T – Joint (Overhead)

20.1. Preparation

20.2. Taking at 900

20.3. Control Equal Legs

- 30

21. 21. Single V Butt Joint on Pipe FL/V/oh

21.1. Tacking

21.2. Equal Root Beed

21.3. Equal Capping Beed

- 30

22. 22. Measuring Tools

22.1. Steel Foot Rule

22.2. Steel Tape.

22.3. Addition, Subtraction, Multiplication & Division

of Foot / Inches

6 -

23. 23. Grill Welding Pattern (Flat)

23.1. Preparation

23.2. Tacking

23.3. Straightening / Grinding

- 30

24. 24. Grill Pattern Welding (Bar)

24.1. Preparation

24.2. Tacking

24.3. Straightening / Grinding

- 30

25. 25. Measuring Surfaces

25.1. Square Shape

25.2. Triangular Shape

25.3. Round Shape

6 -

26. 26. Pipe Welding Practice

26.1. Pipe Cutting with machine 90° & 45°

26.2. Tacking

26.3. Welding

-

30

27. 27. Angle Iron Welding Practice

27.1. Angle Iron Cutting with machine at 90°, 45°

27.2. Tacking

27.3. Welding

- 40



14

28. 28. Area Calculation

28.1. Square Shape

28.2. Triangular Shape

28.3. Round Shape

6 -

29. 29. Angle Iron Box Making

29.1. Cutting of Angle Iron

29.2. Cutting of Flat Iron

29.3. Straightening of Pieces

29.4. Tacking of Job.( in length)

- 30

30. 30. Stool (Square Pipe)

30.1. Pipe Cutting according to Drawing

30.2. Tacking of Pipe

30.3. Checking of Size Angle

30.4. Welding of Frame

30.5. Grinding

- 30

31. 31. Construction Fabrication

31.1. Introduction

31.1.1. Window (Z Section 3’ x 4’ )

31.1.2. Cutting of iron according to size

31.1.3. Straightening of pieces

31.1.4. Setting of pieces as per drawing

31.1.5. Tacking

31.1.6. Straightening

31.1.7. Grinding

31.2. Door Frame Angle Iron 7 x 2 ¼’

31.2.1. Preparation


31.2.3. Tacking / Welding

31.2.4. Finishing

31.3. Window Pipe (3’ X 4’)

31.3.1. Preparation

31.3.2. Tacking / Welding

6

20

20

20



15

31.3.3. Movement

31.3.3.1. Finishing

31.4. Drilling

31.4.1. Kinds of drill machine

31.4.2. Function

31.4.2.1. Safety Precaution

31.5. Grill for Windows (Sq bar) 4’ X 4’

31.5.1. Preparation

31.5.2. Tacking

31.5.3. Welding

31.5.3.1. Grinding

31.6. Steel Door 77” X 26”

31.6.1. Preparation

31.6.2. Tacking

31.6.3. Welding

31.6.3.1. Grinding

31.7. Rate Calculation

31.7.1. As per KG

31.7.2. As per foot

31.8. Railing 4’ X 2 ½’

31.8.1. Preparation


31.8.3. Welding

31.8.3.1. Finishing

2

20

20

24

32. 32. Functional English 20 20

33. 33. Work Ethics (Lab. Theory) - 20

Total 80 720



16

LIST OF TOOLS / EQUIPMENT / LAB / WORKSHOP (For A Class Of 25 Students)

Name of Course Welder


Sr. No.

Name of Tools / Equipment Quantity

1 Flat File 300 X 1 25 Nos.

2 Flat File 250 X 1 25 Nos.

3 Half Round File 250x1 25 Nos.

4 Round File 250x1 25 Nos.

5 Try Angular File 250x1 25 Nos.

6 Bench vice (size 5”) 25 Nos.

7 Vernier Caliper 200mm 25 Nos.

8 Steel Foot Rule 300 mm 25 Nos.

9 Flat Chisel 8” 25 Nos.

10 Line Scriber 25 Nos.

11 Try – square 8” / 6” 25 Nos.

12 Center Punch 25 Nos.

13 Hammer 1000 gm / 500 gm 25 each

14 Hand Hacksaw frame (Blade size 12”) 25 Nos.

15 Taps Set 4,5,6,8,10 5 Set each

16 Tap Handle 0 No. , 1 No. 2 Each

17 Counter Sink 90o 2 Nos.

18 Counter Bore 6.4 x 11 8.4 x 14 2 Each

19 Reamer 6H8, 8H8, 10H8 02 Each

20 Machine Vice 1 No.

21 Twist Drill Set (3-13mm) 2 set (set of 20 pieces).

22 Hand Vice 4 Nos.

23 Safety goggle 25 Nos.

24 Welding Face shield 25 Nos.

25 Leather Gloves (Left & Right) 25 Pair

26 Anvil with stand 300 kg. 1 No.



17

27 Straightening Plate 1m x1m x100 mm 1 No.

28 Welding Helmet 12 Nos.

29 Leather Apron 12 Nos.

30 Marking Surface Plate 800x800x30 with ribs 170mm with stand

5 NOS.

31 Oxygen DA Manifold with 8 station 1 No.

32 Oxygen Cylinder New 06 Nos.

33 Acetylene Cylinder New 03 Nos.

34 Gas Welding Goggle 16 Nos.

35 Flush Back Arrestor Acetylene & Oxygen 12 Each

36 Oxygen Regulator 12 Nos

37 Acetylene Regulator 12 No

38 Gas Welding and Cutting Set complete Kit in Box 10 Sets

39 Gas Welding Table with Fire 2’ x 3’ x 2 ¼’ bricks 10 Nos.

40 Cylinder Room 8’x 8’

41 Elect Welding Table 3’ x 2’ x 2 ¼’ top with grill with waste box

10 Nos.

42 Flat Tong 12” 25 Nos.

43 Steel Wire Brush 30 Nos.

Machines:

44 Welding Transformer (50-450amp.) Complete with lead & holders (machine)

8 Nos.

45 Hand Drill Machine (Electric) 01mm to 13mm 2 No.

46 Hand Grinder (Electric) / Angular Grinder. 2 No.

47 Lever Shearing Machine 1 No.

48 Bench Drill Machine 1 No.

49 Twin hose Pipe Length 15 ft each Red and Black 12 Sets

50 Pedestal Grinder with Grinding wheel size 8” (One fine and One Course with 2HP Motor 50Hz 2800 RMP (Machine)

1 No.

51 Portable Transformer Single Phase (Machine) 1 No.

52 Welding Rectifier (Machine Head) 1 No.

53 Welding Generator 1 No.



18

FURNITURE

Sr. No.

Name of Articles Quantity

1. Working bench with vie 5” 10 No’s

2. Instructor table with 3 drawers 01 No.

3. Wooden stool (for students) 25 No’s

4. Chair for teacher 02 No’s

5. White board (3 ½ x 5ft) with stand 01 No.

6. Steel Almirah (4 x 7 ft) 04 No’s



19

LIST OF CONSUMABLE MATERIAL (For A Class Of 25 Students)

Name of Course Welder


Sr. No.

MATERIAL WEIGHT

PER TRAINEE

For 25

TRAINEE Remarks

1. M.S. Flat 2” ½ x 5/8” 0.8 kg 20 kg

2. M.S. Sheet 4” x 1/8 “ 0.4 kg 10 kg

3. M.S. Flat 1” x 1/8” 0.2 kg 5 kg

4. M.S. Pipe 2” x swg 12 120 mm 3 m

5. M.S. Flat 4” x ¼ “ 1 kg 25 kg

6. M.S. Flat 1” x 1/8” 2.2 kg 55 kg

7. M.S. Flat 1” ¼ x 5/32” 0.6 kg 15 kg

8. M.S. Flat 1” x ¼ “ 1.2 kg 30 kg

9. M.S. Flat 1” x ¼ “ 1 kg 25 kg

10. M.S. Flat 1” ½ x 3/8 “ 3.4 kg 85 kg

11. M.S. Pipe 2” x 1/8” 80 mm 2 m

12. M.S. Bay ¼ “ Square 10 kg 10 kg For one grill

13. M.S. Pipe 1” Square 20 ft 40 ft For 6 greep

14. M.S. Angle Iron 1” x 1” x 1/8” 24 ft 10 kgs For 6 greep

15. M.S. Angle iron 1” ½ x 1” ½ x

3”/16

17 ft 15 kgs For one door

frame

16. M.S. Flat 2” 1/8” 17 ft 10 kgs For one door

frame

17. M.S. Z iron 1” x 1” x 1/8” 42 ft 28 kgs For one

window

18. M.S. Pipe 2” ½ x 1” 15 ft 15 ft For one

window

19. M.S. Sheet 7‟x2 ¼‟ x swb 19 7‟ x 2 ¼ „ 7” x 2‟ ½ For one door

20. M. S L shape Pipe 1” 25ft 25 ft For one

window



20

EMPLOYABILITY OF PASS-OUTS: The pass-outs of this course may find job/employment opportunities in the following sectors / areas.

1. Construction Industry

2. Auto mobile industry

3. Repairing Work shop

4. Pakistan Ordinance Factory, Wah Cantt.

5. Heavy Mechanical Complex / Heavy Forge Foundry, Taxila.

6. PECO, Kot Lakhpat.

7. DESCON Engineering.

8. Pakistan Railways Workshops.

9. Tractor manufacturing units Packages.

10. Automobile Industry.



21

REFERENCE BOOKS:

1. ARC WELDING (Basic Fundamentals) by JOHN R.WALKER South Holland, Illions The Good Heart-Will Cox (Company) INC

2. OXYACETYLENE WELDING (Basic Fundamentals) by RONALD J.BAIRD South Holland, Illions The Good Heart-Will Cox (Company) INC

3. MODERN WELDING Althose Turnguist Bowditch South Holland, Illions The Good Heart-Will Cox (Company) INC

4. OXYACETYLENE HAND BOOK by LINDE, Linde Company

5. WELDING SKILLS by JOSEPH W.GIACHINO Pub. American Technical Publisher

6. GAS WELDING AND CUTTING YENSEXER Mosco – Pease Bublisher

Welder (6-Month Course)


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MINIMUM QUALIFICATION OF INSTRUCTOR

DAE in “Metallurgy & Welding Technology” with two years experience in relevant field

OR

Two years certificate of Welder (G-II Level) with 6 years experience in relevant field

Welder 6 MONTHS 800hrs

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