About this module
Level 1 made you safe at the arc and able to make simple products. Level 2 makes you a fabricator who can read a drawing, weld in any position and win paid work.
Who it is for. People who have finished Basic Welding and Fabrication (Level 1), or who can show the same skills. National Proficiency II covers varied work, mostly routine, under limited supervision; it leads to National Certificate I.
CTVET status. CTVET has an approved Welding and Fabrication Technology programme at NP I, NP II and higher levels, but its unit list was not found online. This module is not that curriculum. It follows CTVET's format so it can be put forward later.
Bridge from Level 1: what you already know
- Full PPE, shade 10 at normal currents, cotton not synthetics, screens
- Fume, galvanised, shock, fire-watch and drum rules
- Setting up the machine; reading the E6013 code; storing rods dry
- Grinder safety
- Cutting lists, marking within 2 mm, cutting on the waste side
- Striking an arc; arc length, angle, speed and current
- Flat butt, lap, T and corner joints
- Tacking, checking diagonals, balanced weld order
- A cost sheet with margin and deposit; ORC and Assembly registration
Level 1 did not cover gas cutting, MIG, vertical and overhead positions, or steel prices. Level 2 covers all of these except steel prices, which you collect yourself. Pressure vessels and structures that carry people are still for qualified engineers and coded welders only.
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. About 70% of the time is practical, following CTVET's Oil Palm programme split of about 30% school and 70% workplace.
Unit 1 · Work safely with gas, fume and heavy work
New tools bring new dangers: gas cylinders, more fume, louder grinding and heavier sections.
Competency standard
| Learning outcome | Performance criteria — the trainee… |
|---|---|
| 1.1 Handle gas cylinders | stores, moves and leak-tests oxygen and acetylene cylinders |
| 1.2 Control fume | controls fume on galvanised and coated steel and in enclosed bays |
| 1.3 Protect body and hearing | uses hearing protection and lifts heavy sections safely |
Range. The training workshop. Evidence. Cylinder check record; fume and lifting plan.
Gas cylinders
- Store oxygen at least 6 m from fuel gas, or behind a non-combustible wall about 1.5 m high. Fuel gas cylinders stand valve end up. Keep caps on when not in use. No oil or grease on oxygen fittings. Never use acetylene above 15 psi.
- Acetylene is unstable above about 15 psi. Fit flashback arrestors at the regulators and check valves at the torch. Chain cylinders upright.
- Ghana's National Petroleum Authority warns never to keep gas cylinders indoors and to check hoses and washers. The Fire Service has inspected gas cylinders at Takoradi Market Circle.
Fume
- Welding fume can cause cancer. There is no known safe level; indoors you need extraction at the weld.
- Zinc fume from galvanised steel causes metal fume fever a few hours later, clearing in a day or two. Remove the coating before welding. Drinking milk does not prevent it.
Noise and lifting
- Grinders and generators can damage hearing; wear ear defenders.
- Most informal welders in a Kumasi study reported burns and cuts, and very few wore full PPE. Artisans at Kokompe in Accra suffered back and joint injuries from heavy lifting and poor posture. Lift long sections with two people or a lifting aid.
Safety set-up
- Inspect the gas store: distance, chains, caps, arrestors.
- Leak-test a regulator and hose with soapy water.
- Set up extraction for one bay.
- Plan a two-person lift for a 6 m section.
Workshop check
List three safety improvements for a welding shop you know.
Unit 2 · Read drawings and weld symbols; prepare joints
Paid jobs come with drawings. The weld symbol tells you exactly what the customer wants.
Competency standard
| Learning outcome | Performance criteria — the trainee… |
|---|---|
| 2.1 Read symbols | reads a fabrication drawing and common weld symbols |
| 2.2 Prepare joints | prepares square, single-V and double-V edges |
| 2.3 Mark out from drawings | marks out angles and templates accurately |
Range. Three drawings. Evidence. Symbol worksheet; prepared joints.
Weld symbols
A weld symbol has a reference line, an arrow pointing to the joint, and a symbol: below the line means weld on the arrow side, above means the other side. A triangle means a fillet weld; a circle at the bend means weld all round; sizes sit beside the symbol.
Edge preparation
Square edges suit thin plate up to about 6 mm; single-V up to about 9.5 mm; double-V for thicker plate. Bevels are made by gas cutting, grinding or machining.
Exact gaps and angles. Root gap, root face and bevel angle depend on the procedure and the drawing. Follow the drawing or your trainer's procedure sheet.
Read and prepare
- Read three drawings and list every weld symbol and its meaning.
- Prepare a single-V butt joint on 10 mm plate.
- Mark out a bracket with an angle from a template.
Symbol sheet
Draw and label the weld symbols for a fillet weld all round and a V-butt weld on the other side.
Unit 3 · Cut steel: oxy-acetylene and plasma
Clean cuts make good joints. Bad cuts waste steel and time.
Competency standard
| Learning outcome | Performance criteria — the trainee… |
|---|---|
| 3.1 Use oxy-acetylene | sets up, lights, adjusts and shuts down a cutting set |
| 3.2 Make clean cuts | makes straight and bevel cuts |
| 3.3 Use plasma | cuts thin sheet with a plasma cutter |
Range. Plate and sheet. Evidence. Cut samples; set-up checklist.
Oxy-acetylene cutting
The steel is heated to red, then a jet of oxygen burns through it. It works on mild and medium-carbon steel, not cast iron or stainless steel. Flames are neutral (for general work), carburising (too much acetylene) or oxidising (too much oxygen). Advertised oxy-acetylene torch kits in Greater Accra cost about GH¢2,800–4,000 in October 2026.
Plasma cutting
Plasma cuts any metal that conducts electricity using compressed air or gas, and is good for curves in sheet. Use shade 5–9 and keep others back from sparks. A 40 A plasma cutter was advertised at about GH¢3,600–4,400.
Cutting rules. Light up and shut down in the order your trainer shows you. Use cutting goggles or a shade 5–9 visor. Keep a fire watch for at least 30 minutes after hot work, with an extinguisher and sand at every bay.
Cutting
- Set up an oxy-acetylene set and adjust a neutral flame.
- Cut a straight line and a 30° bevel on 10 mm plate.
- Cut a curved shape from sheet with plasma.
- Shut down correctly and record the checklist.
Gas supplier
Find where to buy and refill oxygen and acetylene in Takoradi.
Unit 4 · Weld in every position with stick
Gates and frames are flat. Machines, trusses and repairs often are not.
Competency standard
| Learning outcome | Performance criteria — the trainee… |
|---|---|
| 4.1 Weld fillets out of position | welds horizontal, vertical-up and overhead fillets |
| 4.2 Weld butts out of position | welds single-V butts in horizontal and vertical positions |
| 4.3 Use the right rod | chooses, dries and stores E6013 and E7018 correctly |
Range. Plate test pieces in each position. Evidence. Test pieces passed by visual inspection.
Electrodes
- E7018 is a low-hydrogen rod for all positions; its coating takes in moisture and must be kept dry.
- Store rods dry and off the floor. Low-hydrogen rods are re-dried in an oven and kept warm; ordinary E6013 rods can be damaged by over-drying. Follow the box.
- Hydrogen cracking needs moisture or dirt, hard steel and stress together. Prevent it with dry low-hydrogen rods, clean steel and less restraint.
- E7018 was advertised in Ghana at about GH¢270–595 a pack.
No rod oven? Many small shops have none. Buy E7018 in small sealed tins and use them fresh. Damp E7018 can crack welds.
Technique
Hold the rod about 45° into the joint with a slight drag. For vertical-up, weave slightly and pause at the edges; for overhead, use lower current and a short arc. Your trainer will demonstrate each position.
Overhead work. Wear full leathers, a cap and a buttoned collar against falling spatter. Secure the work before welding.
Position tests
- Weld fillets horizontally, vertically up and overhead.
- Weld a single-V butt horizontally and vertically.
- Inspect each and repeat until passed.
Rod store
Design a dry rod store for a small workshop.
Unit 5 · MIG and thin or galvanised sheet
MIG is fast and clean on thin sheet, used for kiosks, containers, cages and car bodies.
Competency standard
| Learning outcome | Performance criteria — the trainee… |
|---|---|
| 5.1 Set up MIG | sets wire, gas and polarity, or uses gasless wire |
| 5.2 Weld thin sheet | welds sheet without burning through |
| 5.3 Weld galvanised steel | welds galvanised steel safely and restores the coating |
Range. 1–3 mm sheet; galvanised sections. Evidence. Sheet welds; galvanised sample.
MIG basics
MIG uses DC with the wire positive. Short-circuit transfer suits thin sheet with low heat. For steel use CO2 or argon-CO2 mixes. Wind blows shielding gas away outdoors; gasless flux-cored wire works outside but leaves slag. Small MIG machines were advertised in Ghana at about GH¢5,400–5,500.
Galvanised steel
Grind off the zinc where you weld, use extraction or a respirator, then repaint the welded area with zinc-rich paint (see Unit 1 for metal fume fever).
Sheet work
- Set up a MIG machine and weld 1.5 mm sheet without burn-through.
- Weld a galvanised section safely and repaint it.
- Compare gas and gasless welds outdoors.
Product idea
Name a product you could make with MIG and sheet, and who would buy it.
Unit 6 · Inspect, control distortion and fabricate
Check your own work before the customer does.
Competency standard
| Learning outcome | Performance criteria — the trainee… |
|---|---|
| 6.1 Inspect welds | inspects welds and names the causes of defects |
| 6.2 Control distortion | uses jigs, tacks and weld order on large work |
| 6.3 Build to drawing | builds a gate, truss, solar frame or machine frame, then primes and paints it |
Range. One finished product. Evidence. Inspection sheet; finished product.
Defects and causes
| Defect | Common cause |
|---|---|
| Porosity | Damp rods, wrong settings |
| Slag inclusion | Not cleaning between runs |
| Undercut | Current too high, poor angle |
| Lack of fusion | Procedure not followed |
| Cold cracks | Hydrogen; may appear up to a day later |
Distortion
Use tacks, a balanced welding order and the smallest weld that does the job. Clamp work in a jig for repeated products.
Products that sell
Advertised prices in Ghana (October 2026) show the market:
- Cassava graters GH¢1,300–6,800
- Corn mills with motor GH¢2,800–27,000
- Burglar-proof bars and gates
Build a product
- Build a gate, truss, solar frame or cassava grater stand from a drawing.
- Use a jig and a written weld order.
- Inspect every weld and record any defects.
- Prime and paint.
Cost the product
Cost the materials of your product and compare with the advertised price.
Unit 7 · Cost, quote, contract and grow
A good quote wins the job. A good contract makes sure you get paid.
Competency standard
| Learning outcome | Performance criteria — the trainee… |
|---|---|
| 7.1 Price a job | prices a multi-part job from a material list |
| 7.2 Quote and contract | writes a quote and simple contract with deposit and stages |
| 7.3 Plan to grow | plans location, niche, partners and certification route |
Range. Two real or sample jobs. Evidence. Quotes; contracts; growth plan.
Pricing
Job price = steel (with waste) + rods, wire and gas + paint + labour + power or fuel + transport + margin
Collect steel prices from Takoradi dealers each time; they change often. Electricity tariffs changed in April and July 2026. If you use a generator, keep it outside: generator exhaust can kill.
Quote a gate
Steel GH¢1,800 plus 10% waste, rods GH¢150, paint GH¢200, labour 3 days at GH¢150, power GH¢120, transport GH¢100. Add 25% margin. What is the price? Ask a 50% deposit: how much?
Contract basics
- Drawing or photo of what will be made
- Materials and finish
- Price, deposit and payment stages
- Delivery date
- Who installs and who pays transport
- Signatures of both sides
The oil and gas route
- The Ghana Welding Bureau is Ghana's professional welding institute and member of the International Institute of Welding. It certifies welders and trains in the formal and informal sectors.
- The Petroleum Commission promotes local content and requires permits for service providers.
- The Ghana Local Content Conference runs 10–13 November 2026 in Takoradi, with meetings linking local firms to international service providers.
- The Jubilee oil field lies about 60 km off the Western Region coast.
Coded welding for oil and gas needs certified tests beyond this module. Ask the Ghana Welding Bureau about the route.
Location settings that give good returns
- On a busy road in Takoradi, Tarkwa or a district capital, visible to buyers
- Near building sites and new estates (gates, burglar proof, trusses)
- Near farming areas (graters, mills, cages, solar frames)
- Near a metal dealer and gas refill point
- With mains power or a safe generator area
Suame Magazine in Kumasi shows how clusters work: about 200,000 people work in metal and vehicle trades there.
Business ideas and ingenuity
- Agro-processing machines: graters, presses, mill stands, dryers
- Solar panel frames and stands for installers
- Poultry and rabbit cages
- Kiosks and container shops
- Maintenance contracts with farms and factories
- Export machines across Africa with a rules-of-origin certificate
Market yourself
- Photos of every finished job on WhatsApp Business and Facebook.
- A sign and your Assembly permit displayed.
- Written quotes and on-time delivery.
Accessibility
Ghana's Disability Act requires accessible public places and bans job discrimination. The Assemblies' disability fund rose to 5% in 2026, aimed at skills, devices and capital, and the Sekondi-Takoradi Assembly has given equipment to persons with disabilities. Workshops can add flashing alarms, tactile marks, seated benches and good task lighting. Deaf welders need agreed hand signals, picture instructions and a buddy for grinding, and deaf youth name a lack of skills as a barrier to work. Seated bench welding of flat and horizontal work suits many wheelchair users.
Quote and grow
- Write a quote and contract for two jobs.
- Write a one-page growth plan: location, niche, partners, certification.
GWB
Contact the Ghana Welding Bureau and ask how a welder becomes certified.
Glossary
| Term | Meaning |
|---|---|
| Bevel | An angled edge prepared for welding |
| Distortion | Bending of metal caused by welding heat |
| Flashback arrestor | A device that stops a flame going back into the hose |
| Hydrogen cracking | Cracks caused by moisture in the weld |
| Low-hydrogen rod | A rod (such as E7018) that must be kept dry |
| MIG | Welding with a wire fed through a gun, shielded by gas |
| Weld symbol | A drawing sign that shows the weld needed |
Logbook
- Unit 1: cylinder check; leak test; lifting plan
- Unit 2: symbol worksheet; prepared joints
- Unit 3: cut samples; set-up checklist
- Unit 4: position test pieces
- Unit 5: sheet and galvanised samples
- Unit 6: inspection sheet; finished product
- Unit 7: quotes; contracts; growth plan
- Every homework, dated
Self-check quiz
- How far apart must oxygen and fuel gas be stored?
- Why must oxygen fittings be free of oil?
- What does a weld symbol below the reference line mean?
- Which metals can oxy-acetylene not cut?
- Why must E7018 be kept dry?
- What causes porosity?
- What prevents metal fume fever?
- Why use a jig?
- Name five items in a job price.
- Who certifies welders in Ghana?
Further reading and sources
Best next reads: your Level 1 manual; TWI job knowledge articles; the Ghana Welding Bureau; the Hub's Money Skills manual.
What this module does not cover: TIG welding, pipe welding to code, pressure vessels, structures that carry people, and coded welder certification tests.
Every source used in this manual is listed, with links, in the Teacher Copy.