1、Guide for the Design of a Welder Training Facility STD-AWS GWF-ENGL 1998 O784265 0514341 510 Guide for Setting Up a Welder Training Facility STD-AWS GWF-ENGL 1998 07842b5 0514342 457 Guide for Setting Up a Welder Training Facility Prepared by the Technical Education Committee Under the Direction of
2、the Educa ti on Committee For the American Welding Society STD-AWS GWF-ENGL L998 I 07842b5 0524343 393 Disclaimer for AWS Education Materials - Note: The primary purpose of AWS is to serve and benefit its members. To this end, AWS provides a forum for the exchange, consideration, and discussion of i
3、deas and proposals that are relevant to welding education and industry, the consensus of which forms the basis for this guide. By providing such a forum, AWS does not assume any duties to which a user of these materials may be required to adhere. By publishing this guide, the American Welding Societ
4、y does not insure anyone using the information it contains against any liability arising from that use. Publication of education material by the American Welding Society does not carry with it any right to make, use, or sell any patented items. Users of the information in this guide should make any
5、independent investigation of the validity of that information for their particular use and the patent status of any referred to herein. International Standard Book Number: 0-87 17 1-584-8 American Welding Society 550 N.W. LeJeune Rd., Miami, Florida 33126 1998 by American Welding Society. All rights
6、 reserved Printed in the United States of America Forward The American Welding Society (AWS), recognizing the need for competent welding specialists, through the Education Committee (EC) assigned the Technical Education Committee the task of preparing this guide. Welding has become a very sophistica
7、ted and technical science, requiring not only hands-on abilities but also mental application. The future need for competent welding specialists should prompt the establishment of a greater number of education programs. Thus, it becomes imperative that the education given be of a quality and quantity
8、 that adequately prepares the graduating students for industrial assignments well into the next century. As the name implies, it is the intent of this document to serve as a GUIDE for those wishing to establish, expand, or enhance a private or public education program for welding specialists. The ba
9、sic requirements contained in this document are the result of the joint efforts of individuals from industry and academia to standardize the instruction and evaluation of welding specialists throughout the United States of America and the world. Members of the AWS community and the Education Committ
10、ee have a growing interest in positively promoting Welding Specialist education and providing minimum standards for its delivery. The Education Committee welcomes comments on this publication, and communications should be addressed to: The American Welding Society, Attention: Director of Education,
11、550 N.W. LeJeune Road, Miami, Florida, 33126 STDeAWS GWF-ENGL 1998 07842b5 0514345 Lbb W TABLE OF CONTENTS 1. Scope and Purpose 2. Facility and Services 2.1 School Facilities 2.1.1 Primary Structures(s) 2.1.2 Classrooms(s) 2.1.3 Laboratory 2.1.4 Off ice) 2.1.5 Storage 2.1.6 Personal Services 2.1.7 B
12、udget 2.2 Facility Support 2.2.1 Lighting 2.2.2 Electricity 2.2.3 Ventilation 2.2.4 Heating 2.2.5 Water 2.2.6 Safety 1 1 1 1 2 2 3 4 4 4 5 iii 3. Equipment and Supplies 3.1 Instructional Equipment 3.1.1. Welding/Cutting 3.1.2 Stationary Power 3.1.3 Portable Power 3.1.4 Individual 3.1.5 Testing 3.2 T
13、raining Materials 3.2.1 Instructional Materials 3.2.2 Base Metals for Welding Practice 3.2.3 Filler Materials and Fluxes 3.2.4 Gases APPENDIX A - CONTACT ORGANIZATIONS FOR FURTHER INFORMATION APPENDIX B - LITERATURE AND SOURCE LIST 6 6 6 7 8 8 9 10 10 10 10 10 11 11 iv - STDmAWS GWF-ENGL 1998 O78426
14、5 05L11347 T39 1. G ENERAL 1, Scope This manual defines the physical requirements of a welding instruction facility. It is intended to give guidance to institutions that desire to build or convert facilities to train welders to produce welds using the manual and semi automatic welding processes comm
15、only found in industry. In addition, this guideline provides a list of equipment and supplies that are normally needed to facilitate training and the welding operations themselves. This guideline does not purport to be all-inclusive. Modifications should be made to this guideline to best accommodate
16、 the facilities and budget of the institution that is implementing a welding instruction program, 1,2 Objectives A) To provide guidance to facility planners in the provision of safe and efficient facilities for the B) To assure that needed electrical service, lighting, ventilation and other environm
17、ental concerns C) To maximize the quality of the educational experience of the welding student while in the D) To provide basic guidance in responding to fire, life safety and environmental regulations as they teaching of welding skills. are addressed in the facility planning stage. facility. pertai
18、n to welding instructional facilities and equipment. 1 STD-AWS GWF-ENGL 1998 07842b5 0514348 975 2. Facilitv and Services 2,1 School Facilities 2.1 .i Primary Structure(s) The building should be fireproof and well designed. Welding instructional facilities will function best if located on the ground
19、 floor, preferably in a one-story wing of the main building or in a separate building with covered access ways. Instructional areas in which noisy activities are conducted are best placed farthest from other academic areas of the school or production areas in an industrial facility. Walls should be
20、smooth, with no ledges to collect dust. Floors must be fire resistant, waterproof, and contain adequate floor drains. A minimum light level of 100-foot candles (100 candela) 30 inches (762 millimeters) from the floor is recommended. To enhance motivation and morale, adequate natural light from windo
21、ws and skylights should be available. Walls should be prepared with a low reflective paint to reduce ultraviolet radiation. “Cool“ colors-blues or greens are recommended. The various workstations in a laboratory should meet the foilowing objectives: (A) Provide suitable facilities where the instruct
22、or may demonstrate the skills and techniques (B) Provide a place at which the welding students may develop such competencies (C) Provide an area in which power sources, equipment and projects may be secured and serviced (D) For specific industry welding training facilities, provide special fixturing
23、 and production work mock-ups to adequately demonstrate the production work to be expected in order to allow students to experience typical job related welding positions, conditions, and interferences. necessary to develop welding competencies A modular system of layout should be considered so that
24、flexibility and expandability can be achieved. The former is accomplished by allowing the maximum possible interchange of workstations and other facilities. Future expansion is planned in terms of multiples of specific workstations needed rather than in terms of the general area to be added. These f
25、eatures would simplify the work of the architect, increase the usable life of the laboratory, and provide the instructor with more possibilities to offer curriculum changes. The flexibility and expandability of laboratories should be greatly enhanced if architectural design permits use of non-load b
26、earing partitions between adjoining areas. Good planning includes the provision of doors large enough to permit easy entry of the largest piece of equipment into each shop. In addition, placement of such doors to permit the maximum degree of future flexibility with changes in partition locations sho
27、uld be considered. 2 STDmAWS GWF-ENGL 3998 07842b5 0534349 BOL W If facilities are to be used for evening classes, easily accessible outside entrances which eliminate the necessity of opening or lighting other parts of the building offer important savings in operating and maintenance costs. 2.1.2 Cl
28、assroom(s) Ideally, a room for instruction should be about 20 feet (6.1 meters) x 24 feet (7.3 meters) and adjacent to the laboratory. Classrooms should provide a clear but protected view of the laboratory area. The minimum ceiling height should be 12 feet (3.7 meters) or higher. Classrooms must be
29、acoustically insulated from laboratory noise. This space should have chalk and tack boards, a demonstration table, adequate seating facilities and provision for darkening (for use with visual aids). At least one bulletin board should be near the main entrance. Instructors and welding personnel must
30、have nominal access to the classroom. Storage for audio-visual equipment, charts, models, samples, reference texts, etc., need to be provided. Exhibit cases have strong appeal to parents and observers, especially when located to permit viewing from the outside corridor. 2.1.3 Laboratory A minimum of
31、 100 square feet (9.3 square meters) of laboratory floor space per individual is considered a good general planning figure, exclusive of washroom, storage, office space and the classroom. At the outset the architect and laboratory planner must take into account state recommendations as to minimum sq
32、uare footage per individual. While they vary from state to state, factors of 75 square feet (7.0 square meters) to 150 square feet (13.9 square meters) of work space per individual and a minimum of 400 square feet (37.2 square meters) to 800 square feet (74.3 square meters) for material storage are
33、generally accepted requirements for this particular size area and the subjects to be taught. Floor dimensions of 40 feet (12.2 meters) x 85 feet (25.9 meters) are reasonably close to the normally accepted length to width proportions of 2 to 1. The minimum ceiling (clearance) height should be no less
34、 than 14 feet (4.3 meters). At least one entrance must be large enough 14 feet (4.3 meters) x 14 feet (4.3 meters) to accommodate bulky materials, equipment and projects. Future expansion should always be considered. This should permit additional enrollment, new equipment, or extra shop subjects to
35、be reasonably accommodated without going below space-per-individual minimums. Where a hazard exists around machines, the power equipment should be so placed that welding personnel are not in the line of danger. Added protection is given by enclosing this equipment in a safety zone painted on the flo
36、or. Wide aisles of travel should be provided between benches, machines, and in areas in front of tool cabinets and storage lockers. These aisles should be a minimum of 3 feet (.9 meters) in width. Aisles of travel may be designated by painted lines similar to those used in industry. Non-skid surface
37、s such as sand on shellac should be applied to the floor in the area around machines to minimize danger of slipping. An area 6 feet (1.8 meters) x 6 feet (1.8 meters) area should be planned for process booths and ought not to contain a power source. Welding booths must be constructed of fire resista
38、nt material, with the walls open at least 12 inches (305 millimeters) at the bottom to permit air circulation. AU four 3 sides of the welding booth shall provide complete protection to the welding personnel and others in the area from harmful rays and hot sparks. A minimum of one 10 feet (3.1 meters
39、) x 10 feet (3.1 meters) demonstration area should be available for every 20 welding personnel. Positioning jigs, independent of other activities to prevent congestion, should be provided. Tools and supplies should be located as near to work areas as practical to reduce travel and interferences. Mac
40、hines should be placed to allow for ease of cleaning around the base. Cabinets should fit flush to walls or be trimmed to fit flush for the same reason. Bases for cabinets and benches should provide toe space for comfort and safety of workers. 2.1.4 Office(s) The entrance to the instructors office s
41、hould be easily accessible from the classroom, laboratory and facility corridor. Activities in the classroom and laboratory must be visible from the office. The office window space should be designed to provide maximum vision to all areas along with proper ultra violet light protection. The office o
42、ught to provide at least 120 square feet (1 1.2 square meters) of floor space per instructor size 10 feet (3.1 meters) x 12 feet (3.7 meters). The office needs to be planned with at least one 3 foot (.9 meters) wide door, tile or carpet flooring cover, and an acoustical ceiling with fluorescent ligh
43、ting. For instructional use and laboratory safety the office should have a telephone. It should also have room for file cabinets, desk, bench with storage underneath for weld supplies, a shelf for boots, and room for two chairs for counseling welding personnel. 2.1.5 Storage Decentralized storage sh
44、ould help conserve space and increase efficiency by reducing individual traffic. A storage area for bar stock should be at least 25 feet long (7.6 meters) and 7 feet wide (2.1 meters), with a door centered at both ends. This permits both economical purchase of steel in long lengths and wall storage
45、within the room. Use of horizontal or vertical racks depends on space limitations and personal preference. Storage of bulk supplies (adequately secured) should be located adjacent to an outside service door for convenient delivery. Adequate filler metal storage should be considered and should be con
46、trolled. Rod, wire, and fluxes, depending on their nature, must be maintained under certain storage conditions. The materials of higher value or requiring temperature control shall require tighter controls to ensure that product quality is retained. Acquisition of an electrode storage oven is highly
47、 recommended. Open tool cabinets in each process area should conserve, personnel time and travel while helping them associate proper tool selection and application with a particular activity. This also provides for easy checking of tools. Space underneath benches and tables is excellent for storage
48、of hardware, small amounts of raw stock or even small projects. Storage for projects of welding personnel and personal belongings is always a problem and should be well thought out. Cylinder storage should be located near the laboratory but accessible to truck traffic. All volatile material) should
49、be stored outside in an identified, isolated area to minimize the potential hazards 4 STD-AWS GWF-ENGL L998 0784265 05L435L 4bT M involved. Cylinder storage shall follow the guidelines set forth in ANSYASC Z49.1. Safety, Cutting and Allied Processes, Part II Specific Processes, 10.8.2 Cylinder Storage. One door should open directly to the outside from this room so that stock may be loaded into the room with no interference to shop activities. Scrap storage could be located near this entrance. Thus, material storage areas or rooms should be located conveniently for
