Course Overview
The Steel Fabrication & Welding course is an intensive, hands-on training program designed to equip participants with the practical skills required to fabricate, assemble, weld, and install steel structures and metal products used in residential, commercial, industrial, and infrastructure projects. The course covers metal identification, engineering drawing interpretation, material preparation, cutting, shaping, welding, fabrication, finishing, inspection, and quality control using industry-standard equipment and techniques.
Participants will gain practical experience in Shielded Metal Arc Welding (SMAW), Gas Metal Arc Welding (GMAW/MIG), Gas Tungsten Arc Welding (GTAW/TIG), oxy-fuel cutting, grinding, drilling, steel assembly, and structural steel installation. Through workshop exercises and real fabrication projects, learners will develop the competence to manufacture gates, doors, windows, roof trusses, staircases, balustrades, structural frames, tanks, and other fabricated steel components while adhering to workplace safety and industry standards.
Duration: 4 Weeks (20 Training Days)
Tuition: KES 50,000/=
Course Requirements
Participants should have:
- Basic literacy and numeracy skills.
- An interest in metal fabrication, welding, construction, or manufacturing.
- No prior experience in welding or fabrication is required.
- Basic knowledge of engineering tools is an added advantage.
- Appropriate Personal Protective Equipment (PPE), including welding helmet, leather gloves, safety boots, flame-resistant clothing, hearing protection, and safety glasses.
- A notebook, calculator, measuring tape, steel rule, and basic marking tools.
- Willingness to participate in intensive workshop-based practical training.
Course Objectives
By the end of this course, participants will be able to:
- Interpret fabrication drawings, welding symbols, and material specifications.
- Identify steel materials, welding consumables, tools, and fabrication equipment.
- Measure, mark, cut, shape, and prepare steel components accurately.
- Perform SMAW, MIG, and TIG welding on a variety of steel joints.
- Fabricate structural steel components and architectural metal products.
- Install fabricated steel structures safely and accurately.
- Inspect welded joints and fabricated assemblies for quality and compliance.
- Repair defective welds and fabricated components.
- Estimate fabrication materials, labor, and project costs.
- Apply occupational health, safety, environmental, and quality management practices in fabrication and welding operations.
Course Modules
Module 1: Introduction to Steel Fabrication and Welding
- Overview of fabrication and welding
- Types of metals and steel products
- Welding processes and applications
- Fabrication tools and workshop equipment
- Welding terminology
- Occupational health and safety
- Personal Protective Equipment (PPE)
Practical Exercise
Identify fabrication tools, welding machines, consumables, and demonstrate safe workshop practices.
Module 2: Engineering Drawings and Fabrication Layouts
- Reading fabrication drawings
- Welding symbols
- Orthographic views
- Dimensions and tolerances
- Material specifications
- Fabrication planning
- Job sequencing
Practical Exercise
Interpret fabrication drawings and prepare a cutting list for a steel project.
Module 3: Measuring, Marking, and Material Preparation
- Measuring techniques
- Steel marking methods
- Material layout
- Manual cutting
- Mechanical cutting
- Grinding
- Surface preparation
Practical Exercise
Measure, mark, cut, and prepare steel components for fabrication.
Module 4: Oxy-Fuel Cutting and Metal Shaping
- Oxy-acetylene equipment
- Flame adjustment
- Straight-line cutting
- Shape cutting
- Heating and bending
- Metal forming
- Equipment maintenance
Practical Exercise
Perform oxy-fuel cutting and shape steel components to specification.
Module 5: Shielded Metal Arc Welding (SMAW)
- SMAW equipment
- Electrode selection
- Arc striking
- Butt joints
- Lap joints
- Fillet welds
- Weld defects
Practical Exercise
Produce quality welds using SMAW in flat and horizontal positions.
Module 6: MIG and TIG Welding
- MIG welding principles
- TIG welding principles
- Machine setup
- Gas selection
- Wire and filler selection
- Thin material welding
- Weld quality improvement
Practical Exercise
Complete fabrication joints using MIG and TIG welding processes.
Module 7: Welding Positions and Joint Configurations
- Flat position
- Horizontal position
- Vertical position
- Overhead position
- Groove joints
- Fillet joints
- Multi-pass welding
Practical Exercise
Weld steel joints in multiple positions using appropriate techniques.
Module 8: Fabrication of Doors, Windows, and Gates
- Metal doors
- Window frames
- Security doors
- Sliding gates
- Swing gates
- Hinges and locking systems
- Assembly techniques
Practical Exercise
Fabricate and assemble a steel security door or window frame.
Module 9: Structural Steel Fabrication
- Columns
- Beams
- Roof trusses
- Purlins
- Bracing
- Connection plates
- Structural assembly
Practical Exercise
Fabricate and assemble a structural steel roof truss.
Module 10: Staircases, Railings, and Balustrades
- Staircase fabrication
- Handrails
- Balustrades
- Guardrails
- Decorative steelwork
- Site measurements
- Installation methods
Practical Exercise
Fabricate a steel staircase section with handrails.
Module 11: Drilling, Fastening, and Steel Assembly
- Drilling techniques
- Tapping threads
- Bolted connections
- Riveting
- Anchoring systems
- Alignment
- Assembly inspection
Practical Exercise
Assemble fabricated steel members using bolts and fasteners.
Module 12: Surface Finishing and Corrosion Protection
- Grinding and polishing
- Surface preparation
- Priming
- Painting
- Powder coating
- Galvanizing
- Corrosion prevention
Practical Exercise
Prepare and finish fabricated steel products for long-term durability.
Module 13: Welding Inspection and Quality Control
- Visual weld inspection
- Weld defects
- Dimensional inspection
- Non-destructive testing (NDT) basics
- Repair procedures
- Quality documentation
- Acceptance standards
Practical Exercise
Inspect welded joints and repair identified defects.
Module 14: Material Estimation and Project Costing
- Material take-offs
- Steel quantity calculations
- Welding consumables estimation
- Labor costing
- Equipment costing
- Quotations
- Project scheduling
Practical Exercise
Prepare a bill of quantities and project quotation for a fabrication project.
Module 15: Residential Fabrication Project
- Gates
- Burglar proofing
- Window grills
- Balcony railings
- Carports
- Security installations
- Client specifications
Practical Exercise
Fabricate and install steel products for a residential property.
Module 16: Commercial and Industrial Fabrication
- Structural frames
- Warehouse steelwork
- Industrial platforms
- Pipe supports
- Equipment bases
- Steel canopies
- Commercial standards
Practical Exercise
Fabricate structural steel components for a commercial project.
Module 17: Site Installation and Erection
- Site preparation
- Steel lifting
- Structural alignment
- Anchor bolt installation
- Connection methods
- Safety during erection
- Final inspection
Practical Exercise
Install fabricated steel structures on a prepared site.
Module 18: Integrated Steel Fabrication Project
- Project planning
- Material preparation
- Fabrication
- Welding
- Assembly
- Surface finishing
- Documentation
Practical Exercise
Complete a fabrication project from raw material preparation through final installation.
Module 19: Capstone Fabrication Project
- Client requirements analysis
- Drawing interpretation
- Material planning
- Fabrication sequencing
- Quality assurance
- Cost estimation
- Project documentation
Practical Exercise
Design, fabricate, weld, finish, and install a complete steel structure or fabricated product, such as a gate, staircase, roof truss, or structural frame, including quality inspection and project documentation.
Module 20: Final Project Presentation and Assessment
- Project presentation
- Fabrication review
- Weld quality evaluation
- Compliance assessment
- Cost analysis
- Portfolio development
- Career opportunities in steel fabrication and welding
Practical Exercise
Present and demonstrate a completed steel fabrication and welding project, showcasing proficiency in drawing interpretation, material preparation, cutting, welding, fabrication, structural assembly, finishing, quality control, project costing, and compliance with professional fabrication and welding standards.