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
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)
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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
Welder (6-Months Course)
Developed by Curr icu lum Sect ion, Academics Department TEVTA.
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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.
Welder (6-Months Course)
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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
Welder (6-Months Course)
Developed by Curr icu lum Sect ion, Academics Department TEVTA.
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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
Welder (6-Months Course)
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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
Welder (6-Months Course)
Developed by Curr icu lum Sect ion, Academics Department TEVTA.
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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
Welder (6-Months Course)
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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
Welder (6-Months Course)
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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
-
-
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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 -
Welder (6-Months Course)
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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
Welder (6-Months Course)
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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
Welder (6-Months Course)
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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
31.2.2. Straightening
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
Welder (6-Months Course)
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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
31.8.2. Straightening
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
Welder (6-Months Course)
Developed by Curr icu lum Sect ion, Academics Department TEVTA.
16
LIST OF TOOLS / EQUIPMENT / LAB / WORKSHOP (For A Class Of 25 Students)
Name of Course Welder
Duration of Course 6 – Months
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.
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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.
Welder (6-Months Course)
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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
Welder (6-Months Course)
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LIST OF CONSUMABLE MATERIAL (For A Class Of 25 Students)
Name of Course Welder
Duration of Course 6 – Months
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
Welder (6-Months Course)
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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.
Welder (6-Months Course)
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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