MIVA STUDY PACK — Welder & Metal Fabricator (English) Downloaded 2026-09-29. Free to pass on. Welder & Metal Fabricator — Lesson 1: The welding trade and where the jobs are 7 minutes read WHAT IS METAL FABRICATION? Welding is the skill of joining two pieces of metal together using heat. Metal fabrication is the bigger job. It means taking raw steel bars, pipes, and sheets, then measuring, cutting, bending, and welding them to build something useful. Look around your town or city. You will see metal everywhere. Houses need secure doors and window bars. Shops need rolling shutters. Water tanks need strong steel stands. Transport operators need repairs on tipper trucks, keke frames, and tro-tro bodies. All these items are created by metal fabricators. WHERE FABRICATORS WORK As a welder, you can work in different settings depending on your interest and local demand. Most fabricators start in small roadside workshops, but there are several paths you can take. - Neighborhood workshops: These small shops make everyday items like security gates, window grills, and generator cages for local residents. - Construction sites: Large building projects hire welders to build roof trusses, structural columns, staircases, and balcony railings. - Industrial plants and factories: Processing plants need fabricators to repair heavy machinery, conveyor belts, and storage tanks. - Transport yards: Auto-welders specialize in repairing vehicle chassis, truck beds, and trailer frames. EVERYDAY PRODUCTS YOU WILL LEARN TO BUILD A general welder in West Africa receives requests for many practical products. Building these requires knowing how to read measurements, cut straight angles, and lay strong weld beads. - Burglar-proof window bars and door grilles - Sliding and swinging gate frames using square pipes - Elevated steel stands for 1,000-liter water tanks - Roof trusses for homes, churches, and event halls - Shop display racks, school desks, and metal doors [Try this today] Take a walk down your street or market area. Find three different items made of welded steel. Look closely at where the pieces join together. Notice if the joints look smooth and straight, or rough and uneven. HOW WELDERS RUN THEIR BUSINESS Welding is a trade where many skilled artisans run their own small business. When a customer wants a gate, you calculate the material cost first. This includes steel pipes, cutting discs, welding electrodes, primer, and paint. You add your labor charge and transport fees to the material cost to give the customer a total price. For example, if materials cost 50,000 Naira or 400 Cedis, you estimate your labor based on the time and skill needed to finish the job. To win consistent work, you need more than technical welding skill. You must deliver jobs on time, use the correct metal thickness requested, and treat customers with respect. Word of mouth and sharing photos of finished jobs on WhatsApp are the primary ways fabricators get new clients. PRACTICE QUESTIONS 1. What is the main difference between basic welding and metal fabrication? A) Welding uses paint, while fabrication uses heat. B) Welding joins metal, while fabrication involves measuring, cutting, shaping, and building complete structures. C) Welding is only done in factories, while fabrication is done at home. D) Fabrication only uses plastic materials instead of steel. Answer: B — Welding is specifically the act of joining metal pieces with heat. Fabrication is the full process of measuring, cutting, bending, and assembling metal into finished products like gates or roof frames. 2. How do independent welders usually find new customers? A) By putting advertisements on national television B) By relying only on government job assignments C) Through word of mouth and sharing photos of completed work with contacts D) By waiting for customers to bring raw steel to their house Answer: C — Most small welding workshop owners get new jobs through happy customers recommending them to others, and by showing photos of their finished gates, bars, or railings on mobile apps like WhatsApp. ---------------------------------------- Welder & Metal Fabricator — Lesson 2: Protecting your eyes, skin and lungs 8 minutes read WHY WELDING SAFETY COMES FIRST Welding is a dangerous trade if you do not respect the equipment. An electric arc reaches temperatures over 3,000 degrees Celsius. It produces bright light, intense invisible rays, hot sparks, and dangerous fumes. A good welder protects their body every single time they light an arc. Skipping protective gear to save a few minutes can cause long-term injuries to your eyes, skin, and lungs. [Safety Warning: Arc Eye Hazard] Never look directly at a welding arc with your bare eyes. The ultraviolet (UV) light causes a painful condition called 'arc eye' or 'welder's flash.' It feels like grit or hot sand trapped inside your eye and can permanently damage your vision. ESSENTIAL GEAR FOR YOUR EYES AND FACE Your eyes and face are most at risk during welding and grinding operations. You must use the correct protective helmet and eye wear for each task. - Welding helmet with shade filter: Standard dark glass shades (shade 10 or 11) or auto-darkening helmets protect your eyes from UV light and infrared heat. - Grinding safety glasses: Clear plastic safety glasses protect your eyes from flying metal chips and sparks when using an angle grinder. Never use a welding mask for grinding, and never grind without eye protection. PROTECTING YOUR SKIN AND BODY Hot metal sparks fly several meters away from the arc. UV rays from the arc will also burn unprotected skin just like severe sunlight. - Heavy leather welding gloves: Protect your hands from severe burns, hot metal, and electric shock. - Long-sleeve cotton or leather clothes: Synthetic fabrics like nylon or polyester melt when hit by sparks and stick to your skin. Always wear heavy cotton, denim, or leather. - Safety boots: Steel-toe boots with leather uppers protect your feet from dropped steel bars and falling hot slag. PROTECTING YOUR LUNGS FROM DANGEROUS FUMES When metal melts, it releases smoke and fine particles into the air. Burning paint, oil, or zinc coatings on galvanized pipes creates toxic fumes. Inhaling zinc fumes causes 'metal fume fever,' which makes you feel violently sick with fever, chills, and headache. Always weld in an open area with good airflow. Use an N95 dust mask or specialized fume respirator when working on coated metals or inside closed spaces. [Try this today] Check the clothing you are wearing right now. Look at the tag inside your shirt or trousers to see what material it is made from. Identify if you have heavy cotton clothing suitable for workshop practice. DAILY WORKSHOP SAFETY ROUTINE Before striking your first arc of the day, do a quick safety check around your workspace. - Keep flammable materials like petrol, foam, thinners, and dry wood away from your welding area. - Check that your electric cables have no exposed wires or broken insulation. - Ensure your workspace floor is dry to prevent dangerous electric shock. - Make sure clear safety goggles and a fire bucket filled with sand or water are within reach. PRACTICE QUESTIONS 1. What causes the painful condition known as 'arc eye'? A) Bright sunlight in the workshop B) Ultraviolet (UV) radiation from looking directly at a welding arc C) Dust particles floating in from the road D) Cold water splashed on hot metal Answer: B — Arc eye is a painful burn on the surface of the eye caused by exposure to ultraviolet (UV) light emitted by the electric welding arc. 2. Why should you never wear nylon or polyester clothes while welding? A) Synthetic fabrics melt from hot sparks and stick severely to your skin. B) They reflect light into the eyes of other workers. C) They make you feel too cold in the workshop. D) They slow down the electric current from the welder. Answer: A — Synthetic materials like nylon and polyester melt when hit by hot sparks or molten slag, causing deep, painful skin burns. Heavy cotton or leather should always be worn. ---------------------------------------- Welder & Metal Fabricator — Lesson 3: Tools, machines and metals 8 minutes read THE CORE EQUIPMENT OF A FABRICATOR To build gates, window frames, tank stands, or trailer bodies, you need the right tools and materials. In a modern metal shop, electrical machines supply heat, hand tools shape and hold pieces, and standardized raw metal profiles form the structure. Understanding your equipment helps you work faster, save money, and produce neat, strong welds. WELDING MACHINES: STICK, MIG, AND TIG The most common welding machine in West Africa and small North American shops is the Stick welder, formally known as Shielded Metal Arc Welding (SMAW) or MMA. Today, most fabricators use compact inverter stick machines instead of old heavy transformers. These small electronic boxes plug into standard electricity outlets or portable generators. They are lightweight enough to carry to site installations in a taxi or tro-tro. MIG welders (Metal Inert Gas) feed a continuous wire spool through a handheld gun. They are very fast for workshop production where many identical frames are made, but they require shielding gas cylinders (like argon or CO2 mix) and clean workspace. TIG welders (Tungsten Inert Gas) make clean, precise welds on stainless steel handrails or aluminum, but require higher manual skill and steady hands. - Stick Inverter Machine: Lightweight, affordable, great for outdoor site work and general mild steel fabrication. - MIG Machine: Fast, clean welds for workshop assembly using continuous wire and shielding gas. - TIG Machine: High precision welder for thin metals, decorative stainless steel, and aluminum. ESSENTIAL HANDHELD FABRICATION TOOLS Besides the welding power source, a fabricator relies on hand tools to clean metal, clamp joints, and remove welding slag: - Angle Grinder (4.5 inch or 5 inch): The workhorse tool for grinding down weld beads, removing mill scale rust, and cutting metal. - Clamps (G-clamps and F-clamps): Essential for holding joint pieces tight against a flat table before tack welding so parts do not pull out of square. - Chipping Hammer and Wire Brush: Used immediately after stick welding to knock off baked slag coating and scrub the joint clean. - Bench Vise: Holds metal bars securely on your worktable while cutting, filing, or bending. UNDERSTANDING COMMON WORKSHOP METALS Mild steel (carbon steel) is the main material for metal fabrication in Nigeria, Ghana, Togo, and across global metal shops. It is strong, easy to cut and weld, and widely available at local steel yards in distinct shapes: - Square and Rectangular Hollow Sections: Hollow steel tubes used for gate frames, door frames, and table legs. Common sizes include 1-inch, 1.5-inch, and 2-inch tubes. - Angle Iron (L-shape): Tough structural steel used for bed frames, water tank stands, and protective borders. - Flat Bar: Solid flat metal strips used for bracket straps, door latches, hinges, and decorative scrolls. - Round Rod and Rebar: Solid round steel used for window burglar-proofing and structural reinforcement. - Sheet Metal and Steel Plate: Flat metal panels used to cover security gates or build water tanks and truck beds. [Safety First: Electrical and Machine Setup] Always check your welding machine power cables, earth clamp, and electrode holder for bare copper or cracked insulation before plugging in. Connect the earth clamp directly to clean, rust-free metal on your workpiece. A loose or damaged earth connection causes weak arcs, overheated cables, and severe shock risks, especially when working on damp workshop floors. [Try This Today: Identify Metal Stock] Visit a nearby steel supplier or welding shop in your market. Look at the stock rack and identify three common profiles: square hollow section, angle iron, and flat bar. Touch the surface to feel the difference between dark mill scale steel and bright clean steel. Ask the welder or vendor what metal thickness (gauge) they use most for home security gates. PRACTICE QUESTIONS 1. Which material profile is most commonly used for constructing lightweight doors, gate frames, and window frames? A) Thick solid copper bar B) Square hollow section (pipe) C) Cast iron engine block D) Aluminum foil sheet Answer: B — Square hollow sections (pipes) provide high structural strength with low weight, making them the standard choice for gate and window frames. 2. Why are modern inverter stick welding machines preferred over old heavy transformer machines for site work? A) They do not need an earth clamp connected B) They are lightweight, portable, and consume less power C) They can only weld thin plastic materials D) They rely on gas cylinders instead of electricity Answer: B — Inverter machines convert power electronically, making them small, light, and easy to run on small generators or standard building power. ---------------------------------------- Welder & Metal Fabricator — Lesson 4: Measuring, marking and cutting 8 minutes read ACCURACY STARTS BEFORE THE FLAME A successful fabricator measures twice and cuts once. Steel is expensive in naira, cedis, or CFA. If you cut a square pipe 5 millimeters too short, you cannot stretch it back. You end up wasting raw material or spending extra hours filling wide gaps with expensive welding electrodes, which weakens the finished frame. MEASURING TOOLS YOU MUST MASTER Precision begins with using the correct tool for metalwork. Flexible cloth tailor tapes stretch out over time and cause incorrect measurements. Always use rigid steel measuring tools. - Steel Tape Measure: A 5-meter or 8-meter tape with a sliding metal end hook. The hook moves slightly to account for its own thickness during inside and outside measurements. - Try Square (90-Degree Square): A heavy metal square used to draw straight 90-degree lines across square pipes and angle iron, and to check frame corners. - Combination Square: A sliding ruler head with 90-degree and 45-degree faces, a built-in spirit level, and a scriber needle. - Long Steel Ruler: Useful for quick straight-edge checks and layout work on flat sheet metal panels. TOOLS FOR MARKING CLEAR LINES ON METAL Standard pencil lines rub off easily on rough steel and disappear when heated by cutting torches or grinders. Professional fabricators use dedicated marking tools: - Soapstone (French Chalk): A natural white talc stick that leaves bright white lines on dark steel. Soapstone resists high heat and won't burn off during tack welding. - Metal Scriber: A hardened steel tool with a sharp needle point that scratches fine, precise lines directly into the metal surface. - Center Punch: A pointed steel punch hit with a hammer to make a small dimple in steel. This dimple stops drill bits from sliding away when starting a hole. - Permanent Marker: Good for writing sizes, piece numbers, and quick layout notes directly on metal tubes. TOOLS AND METHODS FOR CUTTING STEEL Once your cut line is marked clearly around all sides of the metal bar, choose the right cutting tool based on metal thickness and required accuracy: - Angle Grinder with Thin Cut-Off Disc (1.0mm to 1.6mm thickness): The fastest, most common tool for cutting square pipes, flat bars, and angle iron. - Cut-Off Saw (Chop Saw): A heavy bench-mounted machine with a 14-inch cut-off wheel. It makes clean, straight 90-degree and 45-degree miter cuts quickly. - Hacksaw: A manual hand frame saw with a fine-toothed blade (24 teeth per inch). Best for small, precise cuts when electrical power is unavailable. - Oxy-Acetylene or Plasma Torch: Used to cut thick steel plate (above 6mm thickness) or cut complex curved shapes. [Safety First: Angle Grinder Cutting Hazard] Thin cut-off discs spin at over 10,000 RPM and can burst violently if twisted or pinched inside a cut. Always wear a full-face shield over safety glasses. Never force a cutter sideways, never use a thin cutting disc for grinding weld beads, and always keep the guard positioned between the spinning wheel and your body. [Try This Today: Mark a Square Cut Line] Take a scrap piece of square pipe or angle iron. Clean off dust and oil with a rag. Press a try square firmly against one side, and draw a thin line with soapstone or a scriber. Move the try square to the next side and extend the line all the way around all four faces. If the end of your line meets the exact starting point, your line is square and ready for cutting! PRACTICE QUESTIONS 1. Why is soapstone (French chalk) widely used instead of a standard pencil for marking cut lines on steel? A) It permanently glues metal pieces together before welding B) It leaves visible white lines that resist heat and do not burn off easily C) It cuts directly through steel without using power tools D) It coats steel to stop all rust permanently Answer: B — Soapstone leaves a clear white line on dark metal that remains visible even when heat from cutting or welding touches the area. 2. What is the main safety hazard when using a thin cut-off disc on an angle grinder? A) The disc can shatter if twisted in the cut or used for side grinding B) The disc causes the metal pipe to freeze instantly C) The disc uses too much water during operation D) The disc turns mild steel into aluminum Answer: A — Thin cut-off wheels are designed only for straight line cutting. Bending the wheel or grinding sideways can shatter the disc at high speed. ---------------------------------------- Welder & Metal Fabricator — Lesson 5: Arc welding: your first beads 8 minutes read WHAT IS ARC WELDING? Arc welding uses high electric current to create intense heat. This heat melts your steel workpiece and a metal filler rod at the same time. As the melted metal cools down, it fuses the pieces into one strong unit. In West Africa, most small fabrication shops in places like Lagos, Accra, and Lome use stick welding, which is officially called Shielded Metal Arc Welding (SMAW). Stick welding is very popular because the equipment is durable and simple. You can pack an inverter welding machine into a bag, load it onto a motor tricycle or taxi, and carry out repairs right on a customer's building site. [Protect your eyes and skin] Never look directly at the arc bright light without a shaded welding helmet. The intense ultraviolet light causes welder's flash, an extremely painful burn on your eyeballs that feels like hot sand in your eyes. Always wear a shade 10 or 11 helmet, long sleeves, and leather gloves to shield yourself from sparks and radiation. SETTING UP YOUR WELDING MACHINE Your arc welder has two thick output cables. One cable attaches to the earth clamp. You must clip this earth clamp firmly onto clean, shiny metal on your workpiece. If you clip it over thick rust or paint, current cannot flow smoothly. The second cable connects to the electrode holder, often called the stinger. For general gate building and structural work with mild steel box pipes, standard gauge E6013 electrode rods are most common. The current setting depends on the thickness of your rod: - 2.5 mm rod: Set your current between 70 and 90 amps. - 3.2 mm rod: Set your current between 90 and 130 amps. - 4.0 mm rod: Set your current between 140 and 180 amps for thick steel plates. If your current is set too low, the rod will stick to the metal constantly. If your current is set too high, the rod will burn right through thin metal pipes and leave large holes. STRIKING AN ARC AND MOVING THE ROD Striking an arc is similar to striking a match on a box. Lightly scratch the tip of your rod along the clean steel surface. The moment sparks fly, lift the tip about 2 to 3 millimeters off the metal. This gap sustains a glowing electrical arc with a loud, crackling sound like frying food. To run a clean line of weld (a bead), keep four main factors in mind: - Angle: Tilt the rod about 15 to 20 degrees in the direction you are travelling. - Arc length: Maintain a tiny distance between the tip of the rod and the metal pool, equal to the rod's steel wire core width. - Speed: Move forward at a steady pace. Moving too fast makes a thin, weak bead. Moving too slow leaves a large, sloppy lump of steel. - Current: Keep your machine amps dialed in for your specific material depth. CLEANING AND INSPECTING YOUR WELD BEAD As you weld, the chemical coating on the electrode melts into a protective glass layer over the hot metal called slag. Wait a few seconds for the metal to cool from red heat. Put on clear safety glasses, then tap the slag off using a chipping hammer and brush the joint clean with a wire brush. A good weld bead looks like a series of smooth, overlapping coins. The edges of the weld should blend flat into the base metal without deep cut marks or trapped black slag pockets. [Try this today] Get a scrap piece of mild steel plate from a workshop floor. Clean off the rust with a wire brush. Practice striking an arc 10 times without freezing the rod to the plate. Once you master striking, run a straight 5-centimeter bead. PRACTICE QUESTIONS 1. What is the main cause of an electrode rod constantly sticking to the metal plate when you try to weld? A) The current (amperage) set on the machine is too low. B) The earth clamp is attached too tightly. C) The electrode rod is too dry. D) The work table is made of thick steel. Answer: A — When amperage is too low, there is not enough heat to instantly melt the rod tip as it touches the steel, causing it to freeze or stick. 2. Why must you chip off the slag layer after completing a weld bead? A) To make the metal weigh less before selling it. B) To inspect the quality of the solid metal weld underneath. C) To cool the steel down with cold air. D) To change the color of the electrode wire. Answer: B — Slag covers the solid steel joint. You must chip and brush it away to check if the weld is solid, smooth, and fully melted into the metal. ---------------------------------------- Welder & Metal Fabricator — Lesson 6: Building a gate or frame step by step 9 minutes read PLANNING YOUR FABRICATION WORK Making a basic steel gate or burglar-proof frame for a window is core work for any metal workshop. A good fabricator plans carefully before striking the first arc. A mistake of just 5 millimeters can prevent a door from swinging shut or leave an open gap that lets rain in. First, measure the opening at the building site using a metal tape measure. Measure the width at the top, middle, and bottom, then measure the height on both sides. Use the smallest measurements, then subtract about 10 millimeters from both overall width and height. This clearance gap ensures the completed frame fits inside the masonry wall easily. STEP 1: CUTTING YOUR FRAME MEMBERS Most standard residential frames use hollow structural steel (square or rectangular box pipe) or steel angle iron. Mark your cuts with a steel scriber or chalk line. Use an angle grinder with a thin cutting disc or a cut-off chop saw to make clean cuts. For neat 90-degree frame corners, cut the pipe ends at 45-degree angles (miter cuts). Alternatively, use straight butt joints where horizontal rails butt up against vertical posts. Grind away metal burrs from the cut edges so pieces fit flush together. STEP 2: CHECKING FOR SQUARENESS Lay your cut frame pieces flat on a clean, level concrete floor or a steel fabrication table. Push the corner joints together tightly. Place a steel try-square against each inner corner to check the right angles. Next, use a tape measure to check the frame's diagonals. Measure from the top-left corner to the bottom-right corner, then measure from the top-right corner to the bottom-left corner. If both diagonal distances are identical, your frame is perfectly square. [Try this today] Take a steel tape measure and check any finished door frame, window, or square table near you. Measure corner to corner diagonally in an 'X' shape. Compare the two numbers to see if the structure is square. STEP 3: TACK WELDING THE CORNERS Never full-weld a frame right away. Heavy welding heat causes steel to expand and pull tightly toward the weld. If you make a full weld on one side, your frame will warp out of shape immediately. Instead, apply short tack welds—small dots of weld about 5 millimeters long—at each corner joint. Once all corners are tack welded, measure the corner-to-corner diagonals again. If the frame moved during tacking, tap the longer diagonal corner with a hand hammer until both diagonal measurements match. STEP 4: FULL WELDING AND FITTING INTERNAL BARS With the frame confirmed square, finish welding all joints completely. Alternate your welding spots: weld one top corner, then move to the opposite bottom corner. This balances the heat and stops warping. Next, cut and place vertical security bars or decorative scrolls inside the frame. For standard security windows, keep space between internal bars to 10 or 12 centimeters maximum so small hands or items cannot pass through. Tack weld each bar into place, re-check straightness, then make final welds. STEP 5: HINGES, LOCKS, AND SURFACE PREPARATION Weld heavy-duty barrel hinges (bullet hinges) to the frame side post and door frame. Ensure the hinge pins align straight so the door swings without binding. Weld a metal lock box or heavy padlocking ears onto the opening side. [Protect yourself during grinding] When using an angle grinder fitted with a grinding disc to smooth down rough weld beads, wear full eye goggles, a face shield, and ear protection. Hot metal sparks can travel several meters and cause serious eye injury or ignite rags and fuel nearby. PRACTICE QUESTIONS 1. Why must a fabricator measure diagonal lines corner-to-corner before full welding a rectangular frame? A) To determine how much paint is needed for the gate. B) To confirm that all four corners of the frame are perfectly square. C) To check if the metal is strong enough for heavy weight. D) To calculate how many welding rods will be consumed. Answer: B — If both diagonal measurements of a rectangle are equal, all four corners are true 90-degree right angles. 2. What is the main purpose of putting small tack welds on a frame before running continuous welds? A) To test if the welding machine has enough electricity. B) To make the frame lighter to carry around the shop. C) To hold parts in place while checking squareness and preventing heat distortion. D) To save money on electrode rods. Answer: C — Tack welds hold the structure together lightly. This allows you to check dimensions and correct any heat pull before committing to full, permanent welds. ---------------------------------------- Welder & Metal Fabricator — Lesson 7: Finishing, painting and rust protection 7 minutes read WHY FINISHING MATTERS Even a strong, straight weld will look unprofessional if it is covered in black slag, metal spatter, or rough edges. Customers pay for work that looks neat and stays strong over time. In warm and humid places like Lagos, Accra, or Lomé, bare iron starts to rust within days. Rain and salt air from the coast will eat through cheap or unprotected steel very quickly. Finishing is the process of cleaning, smoothing, and sealing your metalwork. A good finish protects your work from moisture and makes your customer proud to install your gate or window grid on their building. STEP 1: REMOVING SLAG AND METAL SPATTER After arc welding, your weld bead is covered in a hard crust called slag. You must remove all slag before inspecting or painting the joint. - Use your chipping hammer to lightly tap along the weld line until the slag cracks off. Always look away or wear safety glasses, as hot slag can fly into your eyes. - Use a stiff wire brush to scrub away remaining crust and loose dust. - Use a flat chisel or an angle grinder with a grinding disc to knock off tiny metal droplets (spatter) stuck to the metal surface near the weld. STEP 2: GRINDING AND SMOOTHING JOINTS For visible areas like gate corners or door frames, customers want smooth joints where two pipes meet. Use an angle grinder to make the joint flush. - Grinding disc: Use a thick grinding disc to remove high spots and heavy weld humps. Hold the grinder at a 15 to 30 degree angle to the metal. - Flap disc: Switch to a flap disc (sanding disc) to smooth out scratches and blend the weld smoothly into the surrounding metal. - Do not grind away too much metal. If you grind the weld down completely flat, you may weaken the joint. [Safety Alert: Grinding hazards] Angle grinders throw sharp metal dust and hot sparks at high speed. Always wear clear safety goggles, leather gloves, and a dust mask. Never use a grinding disc that is cracked or chipped. STEP 3: CLEANING AND DEGREASING New steel pipes come from the market covered in heavy industrial oil and grease. Paint cannot stick to oil. If you paint over grease, the paint will peel off in sheets after a few weeks. Wipe down the entire structure using a clean rag soaked in paint thinner, red oxide thinner, or kerosene. Let the metal dry completely. The surface should feel dry and clean to your bare touch. STEP 4: APPLYING ANTI-RUST PRIMER AND TOPCOAT Never apply final gloss paint directly onto raw steel. You must apply primer first to seal the metal against moisture. - Red oxide or zinc chromate primer: Brush or spray one thorough coat over all metal surfaces. Pay close attention to corners, joints, and hidden edges where water collects. Let it dry for 2 to 4 hours. - Filling small gaps: If water can get inside hollow square pipes, seal small gaps with body filler (putty) or silicone before painting. - Topcoat paint: Apply two thin coats of oil-based gloss paint (such as black, silver, or green). Thin coats dry faster and stick better than one thick, dripping coat. [Try this today] Take a scrap piece of metal that has rust or oil on it. Clean one half with a wire brush and paint thinner, leaving the other half untouched. Apply primer to both halves. Notice how smoothly the paint sticks to the clean side compared to the oily side. PRACTICE QUESTIONS 1. Why must you clean oil and grease off steel before painting? A) Oil makes the paint dry too fast B) Paint cannot stick to oily metal and will peel off later C) Grease makes the steel turn soft under the paint D) Oil changes the color of red oxide primer Answer: B — Paint needs a clean, dry surface to bond with steel. Oil forms a barrier that prevents paint from sticking, causing it to peel off over time. 2. What tool is best for smoothing out grinding scratches on a gate corner? A) A metal chipping hammer B) A flap disc attached to an angle grinder C) A stiff steel wire brush D) A heavy cutting disc Answer: B — A flap disc contains layered sandpaper strips that smooth out rough grind marks and blend metal joints cleanly. ---------------------------------------- Welder & Metal Fabricator — Lesson 8: Pricing work and winning customers 8 minutes read UNDERSTANDING THE BUSINESS OF WELDING Being a great welder is only half of running a successful shop. To stay in business, you must calculate your costs correctly so you make a profit on every job. If you undercharge, you will spend your own money to complete a customer's gate. Customers look for three main things: fair prices, neat work, and delivery on time. Clear communication helps you build trust and win repeat business. STEP 1: CALCULATING YOUR MATERIAL COSTS Before you tell a customer a price, write down a full bill of materials. Go to your local steel market or call a dealer to confirm current prices for metal and supplies. - Raw steel: Count how many full lengths (usually 6 meters long) of square pipe, angle iron, or flat bar you need. Always add 10% extra for cutting waste. - Consumables: Include the cost of welding electrodes (gauge 10 or 12), cutting discs, grinding discs, and hack-saw blades. - Finishing materials: Include paint thinner, red oxide primer, topcoat paint, and paint brushes. - Accessories: Include hinges, locks, door handles, or wheels if you are making a rolling gate. STEP 2: ADDING OPERATIONAL EXPENSES AND LABOR Materials are not your only cost. Every job uses your shop's power, time, and tools. - Power and fuel: If power cuts happen and you use a petrol or diesel generator, add the cost of generator fuel into your quote. - Transport: Include tro-tro, taxi, or tricycle transport costs for buying materials and moving the finished job to the customer's site. - Labor and profit: Decide on a fair daily rate for your time and your assistant's pay. Then add 15% to 20% extra as business profit to help you buy new tools or expand your workshop. [Business Rule: Protect your cash flow] Never buy materials with your own money. Always ask for an upfront deposit (usually 50% to 60% of the total price) before buying steel or starting work. Collect the remaining balance immediately upon installation. STEP 3: WRITING A CLEAR QUOTATION Do not give price estimates by word of mouth alone. Write down a simple quotation on paper or send it as a neat WhatsApp message to your client. Your quotation should show the description of the item (for example, '4ft x 5ft burglar-proof window grid with 20mm square pipe'), the total cost in your local currency (Naira, Cedis, or CFA), the deposit required, and how many days it will take to finish. STEP 4: WINNING CUSTOMERS WITH A DIGITAL PORTFOLIO Most new clients want to see work you have already completed before they trust you with their money. - Take clean photos: Wipe dust off your finished work and take clear pictures in good daylight. - Show details: Take photos of smooth corner joints, neat paintwork, and strong hinges, not just distant shots of whole gates. - Use WhatsApp status: Post your finished jobs on your WhatsApp status and social media pages regularly. Many homeowners and builders look for artisans through personal contacts. [Try this today] Calculate the material cost for a basic 3ft by 4ft window burglar-proof grid. List the number of square pipe lengths, welding rods, cutting discs, and primer paint needed. Add local transport and fuel costs to see your true total expense. PRACTICE QUESTIONS 1. Why should you add 10% extra steel to your material list? A) Because steel shrinks when welded B) To cover waste from cutting and small measurement errors C) To give free extra metal to the client D) Because steel dealers charge a 10% tax Answer: B — When cutting pipes and angle iron, some material is lost in offcuts and saw kerfs. Adding 10% ensures you do not run short of metal. 2. What is the standard upfront deposit you should collect before starting a job? A) 10% to 20% B) 50% to 60% C) 100% full payment upfront D) 0% until the job is fully completed Answer: B — A deposit of 50% to 60% covers the cost of buying raw materials and supplies so you do not use your own personal cash to complete the work. ---------------------------------------- Welder & Metal Fabricator — Lesson 9: Build Your Professional Profile 10 min read OBJECTIVE: Set up a simple, honest professional presence online so employers and customers can find and trust you. Before someone hires you or buys from you, they often look you up. A professional profile is simply a clean, honest page that answers three questions: who are you, what can you do, and how can someone reach you? You do not need to be famous or have a computer. A phone and one good photo are enough to start. START WITH WHAT IS FREE - WhatsApp Business — free app. Add your trade, working hours, location and a short catalogue of your work or services. Many customers in West Africa will find you here first. - Google Business Profile — free. If you have a shop, workshop or stall, this puts you on Google Maps so people nearby can find you. - LinkedIn (free Basic account) — useful if you want office, NGO or company work. Add a clear photo, your trade or skill, and two or three lines about what you have done. - Local job and trade groups — Facebook and WhatsApp groups for your town or trade are where many real opportunities are shared first. You do not need all four on day one. Pick the one where your customers or employers actually are. A tailor or caterer may get more from WhatsApp Business and local groups; an IT support learner may need LinkedIn first. Add the others over time. WHAT MAKES A PROFILE TRUSTWORTHY - A real photo of you — face visible, plain background, neat clothing. No sunglasses, no filters. - Your real name, written the same way everywhere. - One honest sentence about what you do: 'I install and repair solar home systems in Hohoe.' - Proof: photos of finished work, a certificate, or a short quote from a happy customer. - A phone number or WhatsApp link that actually works. [Protect yourself] Never pay anyone who promises to 'verify' your profile or guarantee you a job for a fee. Real platforms like LinkedIn, WhatsApp Business and Google Business Profile are free to set up. Anyone asking for money to list you is likely a scammer. [Try this today] Write your one honest sentence — who you are and what you do — and save it in your notes. You will reuse it in every profile, CV and introduction from now on. PRACTICE QUESTIONS 1. Which of these is free to set up and puts your workshop on Google Maps? A) A paid business directory B) Google Business Profile C) A printed flyer D) A website you pay a developer for Answer: B — Google Business Profile is free and places your business on Google Maps and Search, so people nearby can find you. You only need a phone and your business details. 2. What is the most important quality of a professional profile photo? A) It was taken by a professional photographer B) It uses an attractive filter C) Your face is clearly visible and you look neat D) It shows you with expensive items Answer: C — Employers and customers want to see a real, trustworthy person. A clear, neat photo with a plain background builds more trust than any filter or expensive backdrop. ---------------------------------------- Welder & Metal Fabricator — Lesson 10: Write Your Goals and Plan for Obstacles 10 min read OBJECTIVE: Turn a wish into a written goal, review it weekly, and use if-then plans to handle the obstacles that usually stop you. A goal that stays in your head is a wish. A goal written down, with a date and a next step, is a plan. Research on how people actually change their behaviour keeps finding the same thing: people who write their goals down, check them regularly, and decide in advance what to do when things go wrong are far more likely to finish what they start. WRITE IT DOWN, THE PRACTICAL WAY - One goal at a time. 'Finish the solar course by 30 November' beats five vague wishes. - Make it checkable. You should be able to say 'done' or 'not done' — not 'I tried my best'. - Give it a date. A goal without a date quietly becomes 'someday'. - Write the very next small step. Not 'get a job' but 'message two hardware shops on Saturday morning'. - Keep it where you will see it — a notebook, a note on your phone, or paper on the wall. THE WEEKLY REVIEW — 15 MINUTES THAT CHANGE EVERYTHING Pick one fixed moment each week — Sunday evening works well for many people. Ask yourself three questions: What did I finish this week? What got in my way? What is my next step for the coming week? Write the answers down. This small habit catches problems while they are still small, and it reminds you that you are moving, even when progress feels slow. IF-THEN PLANS: DECIDE BEFORE THE OBSTACLE ARRIVES Most plans fail at the same predictable moments: the data bundle runs out, a friend invites you out on study night, rain cancels the job you planned. An if-then plan is a decision you make now, so a hard moment does not require willpower later. The format is simple: 'IF [obstacle happens], THEN I will [specific action].' - IF my data finishes, THEN I will study from my downloaded offline lessons instead. - IF it rains on the day I planned to visit shops, THEN I will call them instead and visit the next day. - IF I feel too tired to study at night, THEN I will do just 10 minutes — starting is the hard part. - IF a customer delays payment, THEN I will send one polite reminder after three days, not argue. [A note on visualisation] Imagining your goal can help — but picture the steps, not just the reward. Instead of only dreaming about the certificate on your wall, picture yourself opening the lesson, answering the quiz, and messaging the customer. Picturing the process prepares you; picturing only the prize can actually relax you into doing nothing. [Try this today] Write one goal with a date, then write two if-then plans for the obstacles most likely to stop you. Keep them somewhere you will see this week. PRACTICE QUESTIONS 1. What makes a goal 'checkable'? A) It is written in English B) You can clearly say whether it is done or not done C) Other people approve of it D) It is ambitious enough to impress people Answer: B — A checkable goal has a clear finish line: 'finish 8 lessons by Friday' can be marked done or not done. 'Do my best' cannot — and vague goals are easy to quietly abandon. 2. Your study night arrives and your data bundle has run out. What does a good if-then plan do? A) It forces you to buy more data immediately B) It tells you to skip studying until next week C) It gives you a decision you made in advance, like switching to your downloaded offline lessons D) It punishes you for not planning better Answer: C — An if-then plan removes the need for willpower in the moment: you decided earlier that IF data runs out, THEN you study offline. The decision is already made, so you just follow it. ---------------------------------------- Welder & Metal Fabricator — Lesson 11: Introduce Yourself in 30 Seconds 8 min read OBJECTIVE: Prepare and practise a short, confident self-introduction you can use with employers, customers and new contacts. Many capable people miss opportunities because they freeze when someone asks 'So, what do you do?' A self-introduction is a short, prepared answer — about 30 seconds — that you have practised until it feels natural. It is not showing off. It is simply making it easy for people to understand how you can help them. THE THREE-PART SCRIPT - Who you are: your name and your trade or skill. 'My name is Amina. I am a trained pharmacy assistant.' - What you can do: one or two concrete things, with proof if you have it. 'I have completed training in dispensing support and stock management, and I helped in a busy pharmacy for three months.' - What you are looking for: say it clearly. 'I am looking for a position in a pharmacy or clinic in this area.' or 'I take catering orders for events of up to 100 people.' Put together, it sounds like this: 'Good morning, my name is Kofi. I am a solar technician — I have finished certified training in home solar installation, and I have already installed systems for three families in this town. I am looking for more customers, and I also do repairs and maintenance. Here is my number.' Thirty seconds, and the listener knows exactly what you offer. MAKE IT YOURS - Adjust the ending for the listener: a customer hears what you sell; an employer hears what job you want; a contact hears how they can help you. - Practise out loud, not in your head — say it to a friend, a mirror, or your phone's voice recorder, five times. - Keep it honest. A small true claim beats a big exaggerated one that falls apart at the first question. - End with a way to reach you: your number, your WhatsApp, or where your shop is. [For shy learners] Feeling nervous is normal and does not mean you are bad at this. Preparation is the cure: a practised script means you never have to invent sentences while nervous. Start by using it in low-pressure moments — with a neighbour, then a shopkeeper — before the big interview or the important customer. [Try this today] Write your three-part introduction in your notes, then say it out loud three times. Use it once this week with a real person. PRACTICE QUESTIONS 1. What are the three parts of a good 30-second introduction? A) Your family background, your education, your hobbies B) Who you are, what you can do, what you are looking for C) Your salary expectation, your location, your age D) Your problems, your needs, your complaints Answer: B — The script answers the three questions every listener has: who is this person, what can they do for me, and what do they want? Keep it short, honest and practised. 2. What is the best way to prepare your introduction? A) Memorise a long speech about your whole life B) Wait for inspiration in the moment C) Practise a short script out loud several times before you need it D) Copy someone else's introduction word for word Answer: C — Saying it out loud — to a friend, mirror or voice recorder — is what makes it feel natural under pressure. A short, honest, practised script beats both improvisation and a long memorised speech. ---------------------------------------- Get the full app: https://miva-skillsnav.lovable.app