About this module
Welding is one of the most useful trades for a young person with little money and little schooling. With a small machine, a grinder and hand tools you can make and repair things that every house, shop and farm needs. This module teaches you to do it safely and well, and to earn from it.
Who it is for. People with no formal certificate, aged 18 or over. National Proficiency I is a bridging level for people with little or no formal education; holders do routine tasks under supervision. In Ghana, nobody under 18 may do hazardous work.
Why welding
- Apprenticeship pays off most for people with the least schooling: one study in urban Ghana found it raised earnings by about 41% for them.
- When Ghana's National Apprenticeship Program paid apprentices' fees, the firms that took them in, welding shops among them, grew their profits and staff.
- The Ghana Enterprises Agency and the Mastercard Foundation have given start-up kits, including small welding machines, to artisans who finished an apprenticeship.
CTVET has welding and fabrication training. CTVET agreed with the Ghana Atomic Energy Commission to deliver competency-based welding and fabrication training at NP I and NP II, and GAEC runs a one-year welding apprenticeship. The official unit list was not found online, so this module is not that curriculum. Ask CTVET or the regional Ghana TVET Service office for the Welding and Fabrication standard and match this module to it.
Welding in Takoradi
The Sekondi-Takoradi Metropolitan Assembly (STMA) says master artisans must register all their trainees, and planned to check artisans' operating licences from January 2025. Under a GIZ-funded project, the Ghana Institution of Engineers licensed 118 artisans in Takoradi.
How the module works
Each unit has learning outcomes, performance criteria, the range and the evidence your assessor needs. You are judged Competent or Not Yet Competent by being watched at work, by your welds and products, by answering questions, and by your logbook. About 70% of the time is practical, following CTVET's Oil Palm programme, which uses about 30% in school and 70% at the workplace.
Unit 1 · Weld safely
The arc is brighter than the sun, hotter than a cooking fire, and carries electricity. The fumes can cause cancer. Every rule in this unit protects your eyes, your lungs, your skin and your life.
Competency standard
| Learning outcome | Performance criteria — the trainee… |
|---|---|
| 1.1 Wear the right PPE | wears helmet with the right shade, leather gloves, apron, boots, cotton clothes |
| 1.2 Control fumes | welds only with ventilation or extraction; never welds galvanised steel without removing the coating |
| 1.3 Prevent shock | uses dry gloves; checks cables; never welds in wet conditions |
| 1.4 Prevent fire | clears flammables; keeps an extinguisher; watches for 30 minutes after |
| 1.5 Never weld containers | refuses to cut or weld drums or tanks that held fuel |
Range. All workshop work. Evidence. Observation every session; oral questions.
Your eyes and skin
- The arc gives off ultraviolet (UV) light that causes arc eye: pain, tears, redness, a feeling of sand in the eye and pain from light. A few seconds is enough, and it may only start hurting hours later.
- The arc also burns bare skin like sunburn, and reflected arc light is a hazard too.
- Never look at the arc without a helmet, and never weld where others can see the arc without a screen.
The right filter shade
| Electrode size | Current | Minimum shade (OSHA) | Comfort shade (ANSI/AWS) |
|---|---|---|---|
| under 2.4 mm | under 60 A | 7 | (none given) |
| 2.4–4.0 mm | 60–160 A | 8 | 10 |
| 4.0–6.4 mm | 160–250 A | 10 | 12 |
Start with a shade too dark to see the weld, then go lighter until you can see well, but never below the minimum.
Shade 8 or shade 10? For beginner work at 60–160 A, OSHA's minimum is shade 8, but ANSI/AWS recommend shade 10. Use shade 10 for 2.5 mm and 3.2 mm electrodes. A darker shade is always safe; a lighter one is not.
Fumes
- Welding fume and welding UV are classified as "carcinogenic to humans" (Group 1). Fume causes lung cancer; UV causes eye cancer.
- The UK safety regulator says there is no known safe level of welding fume, and that general ventilation is not enough indoors: use extraction near the weld, and a fume mask where extraction is not enough, including outdoors.
- Keep your head out of the smoke. Weld outdoors or in an open bay where the wind blows fume away from you.
Galvanised (zinc-coated) steel
Welding or cutting galvanised steel gives off zinc fume, which causes metal fume fever: fever, chills, cough, a metal taste and aching muscles, starting about 8–12 hours later. Grind the coating off first and use extraction.
Electric shock
- The welding voltage is 20–100 volts; even 50 volts or less can injure or kill.
- Wear dry gloves with no holes; never change an electrode with a bare or wet hand.
- In wet or very humid conditions, extra protection against shock is required. Do not weld in the rain or standing in water.
- Take the electrode out of the holder during breaks.
- Check that cables and clamps are in good condition and the work clamp is tight.
Fire
Sweep away anything that can burn within about 10 metres. If flammables are closer, someone must watch for fire, and keep watching for at least 30 minutes after welding stops. Keep a fire extinguisher and a bucket of sand by the bench.
Never weld or cut a drum
Drums kill welders. A drum that looks empty can still hold fuel in its seams and explode when heated. Two workers died cutting drums. Never weld or cut a drum or tank until it has been cleaned so that nothing flammable is left. Cut drums cold (with a chisel or shears), use a new drum, or have it made safe by specialists. At this level, do not hot-cut or weld any drum. Make coal pots from new sheet.
Clothing
Wear leather gauntlet gloves, flame-resistant boots that also protect against shock, and tightly woven long sleeves and trousers, plus safety glasses under the helmet. Cotton, not nylon or polyester: synthetics melt onto the skin.
Generators
Never run a generator indoors or in a closed space: open windows do not stop carbon monoxide building up. Keep it away from doors and windows.
Safe or unsafe?
Your trainer describes eight scenes. For each, say safe or unsafe and why.
Safety set-up
- Dress in full PPE; your partner checks you.
- Choose the right shade for 2.5 mm and 3.2 mm electrodes.
- Check the welding machine cables, holder and work clamp for damage, with the machine off.
- Clear the bay of flammables; place the extinguisher and sand bucket.
- Set up screens so arc light cannot reach others.
- Record the checks in your logbook.
Look around
Visit a welding shop near you (from a safe distance). Note three safe things and three unsafe things you see. Do not look at the arc.
Unit 2 · Know your tools and machine
You can start a welding business with a small machine, a grinder and a bag of hand tools. Know each one and look after it.
Competency standard
| Learning outcome | Performance criteria — the trainee… |
|---|---|
| 2.1 Name the tools | names and uses the basic hand tools |
| 2.2 Set up the machine | connects holder and work clamp; sets the current |
| 2.3 Use the grinder safely | fits the right disc with the guard; holds with two hands |
| 2.4 Choose and store electrodes | reads the electrode code; stores electrodes dry |
Range. Inverter or transformer machine; angle grinder; E6013 electrodes. Evidence. Observation; oral questions.
The machine
Stick welding (also called manual metal arc, MMA, or SMAW) uses a machine that supplies a steady current to melt the electrode. There are two main kinds:
| Machine | What it is | Good for |
|---|---|---|
| Transformer | Simple, heavy, gives AC | Strong, cheap to repair |
| Inverter | Light and compact | Easy to carry to customers' sites |
There are two cables: the electrode lead to the holder, and the work (return) clamp fixed to the job.
| Item (Greater Accra listings, October 2026) | Price |
|---|---|
| 130–160 A inverter welding machine | GH¢1,250–1,645 |
| 200 A inverter | GH¢2,200 |
| E6013 electrodes, 2.5 mm, 5 kg box | GH¢180–195 |
| Electrode holder | GH¢44 |
These are advertised prices on a classifieds site, not a market survey; check your local shops.
Electrodes
The code on the box tells you what the rod does. "E" means electrode; the first two numbers give the strength (60 = 60,000 psi); the third number 1 means it works in all positions; the last number gives the coating and current.
- E6013: soft arc, little spatter, slag that comes off easily. Easy to use, all positions, AC or DC, and tolerant of a little rust. This is the beginner's rod.
- E7018: low-hydrogen, for thicker structural steel; must be kept very dry.
| E6013 diameter | Current (ESAB) |
|---|---|
| 2.5 mm | 60–100 A |
| 3.2 mm | 80–150 A |
| 4.0 mm | 100–230 A |
What current for a 3.2 mm rod? ESAB gives 80–150 A; Lincoln gives 110–140 A on AC. Brands differ. Always start from the range printed on your electrode box, then adjust.
Storage. Keep electrodes dry, off the floor on racks; E6013-type rods do not need oven drying, but basic (E7018-type) rods do. Damp rods cause holes in the weld. In Takoradi's damp air, keep rods in a sealed box or bucket with a lid.
The angle grinder
- Always use the guard.
- The speed marked on the disc must be equal to or higher than the grinder's maximum speed.
- Wear safety glasses and a face shield.
- Hold with both hands, with firm footing; stand aside when starting.
- Let the disc stop fully before putting the grinder down or changing the disc; do not over-tighten the nut.
Kickback can throw the grinder at you: never stand in line with the disc as it speeds up.
Tool tour and set-up
- Name and show the use of: tape, square, scriber, centre punch, hacksaw, file, vice, clamps, chipping hammer, wire brush.
- With the machine off, connect the holder and work clamp. Set the current for a 2.5 mm E6013 rod using the box.
- With the instructor, check the grinder: guard on, disc speed rating, disc condition. Fit a new disc.
- Read three electrode boxes and explain the codes.
Price the kit
Visit a hardware or welding supply shop. Write the prices of a welding machine, a grinder, a helmet, a box of E6013 rods and cutting discs.
Unit 3 · Measure, mark and cut
Measure twice, cut once. A good weld cannot save a part cut to the wrong size.
Competency standard
| Learning outcome | Performance criteria — the trainee… |
|---|---|
| 3.1 Read a simple drawing | reads lengths and angles from a sketch |
| 3.2 Measure and mark | marks lengths within 2 mm and corners square |
| 3.3 Cut and clean | cuts with hacksaw or grinder; files off sharp edges |
Range. Flat bar, angle iron, square pipe, round rod. Evidence. Cut parts checked by the assessor.
How to do it
- Read the sketch. Write a cutting list: each part, its length, how many.
- Measure from a square end. Mark with a scriber and a square.
- Cut on the waste side of the line.
- File or grind off sharp edges (burrs).
- Check each part against the list.
Cutting list
A window burglar proof is 1,200 mm high and 900 mm wide, with a square-pipe frame and 5 upright bars. Write the cutting list.
Cut a frame kit
- From a sketch, write a cutting list for a 400 × 400 mm square frame.
- Mark and cut four pieces of square pipe or angle iron.
- Clean the edges.
- The assessor checks lengths (within 2 mm) and square ends.
Measure at home
Measure a window at home. Sketch a burglar proof for it, with sizes.
Unit 4 · Strike an arc and run a bead
This is the heart of welding. Expect many failed tries; every welder started the same way.
Competency standard
| Learning outcome | Performance criteria — the trainee… |
|---|---|
| 4.1 Strike the arc | strikes and holds an arc without sticking |
| 4.2 Run a bead | runs a straight, even bead on flat plate |
| 4.3 Clean and check | removes slag; names common defects and their causes |
Range. Flat position; E6013 2.5 mm and 3.2 mm; mild steel plate. Evidence. Beads checked by the assessor.
Striking the arc
Strike the rod slightly across the plate like a match (scratch), or tap it, then lift it just above the plate.
The four things to control
| Control | Right | Signs it is wrong |
|---|---|---|
| Arc length | About the rod's diameter (3 mm for a 3.2 mm rod) | Too long: crackling, spatter, wide bead. Too short: buzzing, rod sticks |
| Angle | Tilt 5–15° towards travel (drag) | Poor shape, slag trapped |
| Speed | Steady | Too slow: heaped metal. Too fast: thin bead, poor penetration |
| Current | From the box, then adjust | Too high: undercut, spatter. Too low: rod sticks, poor fusion |
Common faults
- Porosity (holes): damp rods, oil or grease, or a long arc.
- Undercut (a groove beside the weld): speed or current too high, or wrong angle.
- Slag inclusion: slag not removed between runs; clean by chipping, brushing or grinding.
Bead plate
- Clean a plate with the wire brush or grinder.
- Strike and hold the arc 20 times without sticking.
- Run 10 straight beads, 100 mm long, side by side.
- Chip and brush the slag off each bead (wear glasses: slag flies).
- Mark your best and worst bead and say what caused the difference.
- Record the current, rod size and number of rods used.
Fault diary
For each bead plate, write one fault you saw and what you will change next time.
Unit 5 · Join steel: tacks, joints and frames
Joining pieces is where welding becomes making.
Competency standard
| Learning outcome | Performance criteria — the trainee… |
|---|---|
| 5.1 Tack | holds parts with tack welds; checks square before full welding |
| 5.2 Weld basic joints | welds butt, lap, T (fillet) and corner joints in flat position |
| 5.3 Control distortion | uses a welding sequence to keep frames square |
Range. Flat bar, angle iron, square pipe; flat position. Evidence. Joints and a square frame.
Tack, check, weld
Tack welds hold the parts and set the gap. Tack all corners, check square (measure both diagonals: they must be equal), adjust, then weld fully. Weld in a balanced order, for example opposite corners in turn, and don't put on more weld metal than needed, to stop the frame pulling out of shape.
Joints
| Joint | What it is | Used in |
|---|---|---|
| Butt | Two ends meeting in line | Joining lengths of bar |
| Lap | One piece over another | Brackets, straps |
| T (fillet) | One piece standing on another | Bars on a frame |
| Corner | Two ends meeting at a corner | Frames, boxes |
For lap and T joints, point the rod about 45° into the joint and tilt it 10–15° towards travel.
Square frame
- Weld one of each joint on scrap; chip and inspect.
- Using your frame kit from Unit 3, tack the four corners.
- Measure both diagonals; adjust until equal.
- Weld fully in a balanced order; re-check the diagonals.
- Grind the joints neat.
Spot the joints
Find five welded joints at home or in town (gates, chairs, kiosks). Sketch each and name the joint.
Unit 6 · Make products that sell
Customers pay for things that are strong, square, neat and painted.
Competency standard
| Learning outcome | Performance criteria — the trainee… |
|---|---|
| 6.1 Make a product | makes a product to a sketch and size |
| 6.2 Finish | grinds welds, removes slag and paints with primer |
| 6.3 Check quality | checks size, square, strength and finish |
Range. Burglar proof panel, small gate, coal pot (from new sheet), stool or poultry cage frame. Evidence. Finished product; quality checklist.
Products
Advertised prices in Greater Accra include burglar-proof work at about GH¢3,500 and gates at about GH¢1,800. Prices vary a lot with size, material and place. Other common jobs: coal pots, poultry cages, kiosk frames, chairs and tables, and repairs.
- Size. Matches the sketch within a few millimetres.
- Square. Diagonals equal; sits flat.
- Strong. Every joint welded, no cracks, no missed bars.
- Smooth. No sharp edges or spatter where hands touch.
- Painted. Slag and rust cleaned off; primer, then top coat.
Your first product
- Choose a product with your instructor: a small burglar-proof panel, a stool or a coal pot from new sheet.
- Sketch it, write the cutting list, and list materials and costs.
- Cut, tack, check square, weld, grind and paint.
- Check it against the quality checklist.
- Photograph it for your portfolio.
Market walk
Visit two welding shops or furniture sellers. Write what they sell most and their prices.
Unit 7 · Price your work and start a workshop
A good welder who prices badly stays poor. Count every cost, add a fair profit, and keep records.
Competency standard
| Learning outcome | Performance criteria — the trainee… |
|---|---|
| 7.1 Cost a job | lists all costs and sets a price with profit |
| 7.2 Keep records | records each job: customer, materials, price, paid |
| 7.3 Plan a workshop | names start-up tools, costs, registration and permits |
Range. Small jobs for local customers. Evidence. Costed quotes; job records; business plan.
Costing a job
Add up: materials (steel, paint) + electrodes + discs + power (electricity or fuel) + your labour, then add profit. Electricity for non-residential users from April 2026 cost about GH¢1.78 per unit (kWh) for the first 300 units a month, and tariffs rose 3.49% from July 2026.
Price a burglar proof
Example prices: steel GH¢900, electrodes GH¢80, discs GH¢40, primer and paint GH¢150, power GH¢30, your labour 2 days at GH¢150 a day. (1) Total cost? (2) Price for a 25% margin? (3) If the customer pays 60% deposit, how much is that?
Registering and permits
- Register your business name at the Office of the Registrar of Companies: GH¢130, then GH¢70 a year to renew (2026 fees). Your Ghana Card number is your tax number (TIN).
- STMA's 2025 business operating permit fees included GH¢200 a year for metal fabricators and GH¢550 for auto arc welders.
Start-up kit
A small inverter machine, grinder, helmet, gloves, apron, hand tools and a first box of rods is a realistic start; use the prices you collected in Unit 2. Many welders start by doing site jobs with a portable machine before renting a workshop space.
Quote and plan
- For your Unit 6 product, write a full cost sheet and a price.
- Write a one-page workshop plan: tools and their cost, where you will work, three products, prices, first customers, registration and permit.
- Present your plan to the class.
- Keep a job record book from today.
Talk to a master
Ask an experienced welder how they price jobs, how they find customers, and what they wish they had known when starting. Write it down.
Glossary
| Term | Meaning |
|---|---|
| Arc | The bright electric spark that melts the metal |
| Arc eye | Painful eye burn from looking at the arc |
| Bead | A line of weld metal |
| Competent / Not Yet Competent | The two possible results of a CBT assessment |
| Electrode (rod) | The coated stick that melts to make the weld |
| Fillet weld | Weld in the corner of a T or lap joint |
| Galvanised | Steel coated with zinc |
| Inverter | A light, compact welding machine |
| Slag | The crust on top of a weld; chip it off |
| Spatter | Small drops of metal thrown out while welding |
| Tack weld | A short weld that holds parts in place |
| Undercut | A groove melted beside the weld |
Logbook
Copy these pages into an exercise book. Your logbook is part of your assessment evidence.
- Unit 1: safety set-up checks; shade chosen
- Unit 2: tool list; electrode codes; kit prices
- Unit 3: cutting lists; frame kit checked
- Unit 4: bead plates; current and rod used; fault diary
- Unit 5: joints; frame diagonals before and after
- Unit 6: product sketch, cost sheet, quality check, photo
- Unit 7: quotes; job record book; workshop plan
- Every homework, dated
Self-check quiz
- What causes arc eye?
- What filter shade should you use for a 3.2 mm rod?
- Why must you never weld or cut an old fuel drum?
- What should you do before welding galvanised steel?
- Why wear cotton and not nylon?
- What does the "1" in E6013 tell you?
- How long should the arc be?
- Name two causes of holes (porosity) in a weld.
- How do you check a frame is square?
- What should the speed rating on a grinder disc be?
- Name five costs in a welding job.
- Where do you register a business name?
Further reading and sources
Best next reads: TWI's free "Job Knowledge" articles on stick welding; the box and leaflet of your electrodes; your machine's manual.
What this module does not cover: gas welding and cutting, MIG and TIG welding, vertical and overhead positions, welding on pressure vessels or structures that carry people, and Ghana steel prices (not found reliably; ask local dealers).
Every source used in this manual is listed, with links, in the Teacher Copy.