Metal Fabricator (Fitter) Study Guide — Year 1

Year 1 Exam Topics

Study each topic below — these are the core knowledge areas tested in Year 1. Build a solid foundation here before advancing to Year 2 material.

🏗️Structural Steel Shapes

W-shapes (wide flange): designated by depth × weight/m (e.g., W310×97)
HSS (Hollow Structural Section): square, rectangular, round — used for columns and bracing
Channels (C), Angles (L), Tees (WT/ST): used for secondary members and connections
Plate steel: flat rolled product used for base plates, gussets, stiffeners

📖Layout & Template Development

Layout: marking cut lines, hole locations, and bends from drawings onto raw material
Flat pattern development: unfolding 3D shapes to 2D for cutting (e.g., elbows, transitions)
Bend allowance: extra material needed for bend = (π/180) × inside radius × angle
Scribing tools: soapstone, scriber, dividers, combination square, protractor

📖Weld Joint Types

Butt joint: two pieces end-to-end; requires groove weld; complete or partial penetration
T-joint: one piece perpendicular to another; fillet weld on one or both sides
Corner joint: two pieces at 90° forming a corner; fillet or groove weld
Lap joint: two pieces overlapping; fillet weld on one or both sides

📖Fit-Up & Tacking

Fit-up: positioning members to correct dimension, alignment, and angle before welding
Root opening: gap between parts; controls penetration and prevents burn-through
Tack weld size: at least 2× final weld size; minimum 40 mm for heavy structural
Check squareness with carpenter's square and measuring diagonals — must be equal

⚙️Cutting Methods

Oxy-fuel cutting: carbon steel only; bevel and profile cutting on plate
Plasma cutting: all conductive metals; faster, narrower kerf than oxy-fuel
Saw cutting: cold cut — precise, no HAZ, used for structural sections
Grinder/cut-off wheel: small cuts and notches; maximum wheel RPM must not be exceeded

🦺Safety in the Fabrication Shop

WHMIS required for all welding consumables, cutting gases, coatings
Lifting: use crane/hoist for anything over ~25 kg; never lift over co-workers
Machine guards must be in place; hard hat, safety glasses, leather gloves required
Ventilation: minimum 100 cfm per welder; MEL for welding fumes must not be exceeded

Study each topic below — these are the core knowledge areas tested in Year 1. Build a solid foundation here before advancing to Year 2 material.

📖Distortion Control

Angular distortion: pre-set joint (back-angle) before welding to anticipate pull
Longitudinal shrinkage: weld from centre outward; alternate sides on long welds
Backstep welding: deposit short segments from right to left while overall progressing left to right
Jigs and fixtures: restrain work during welding; release after weld cools to reduce spring-back

📖CWB Certification — W47.1

CSA W47.1: governs certification of welding companies in Canada (Division 1, 2, 3)
Welding procedure specification (WPS): qualified procedure tested per W47.1 or ASME IX
Procedure Qualification Record (PQR): test results proving WPS is valid
Welder qualification: test piece position, process, and material matches production work

📖CSA W59 — Welded Joints

W59 specifies fabrication tolerances, prequalified joint details, and inspection requirements
Prequalified joints: no PQR needed if all W59 conditions met (geometry, preheat, process)
Weld size tolerances: fillet weld may be −0/+2 mm from specified size
NDT requirements: visual always; UT, RT, or MP required for critical or CJP welds

⚙️NDT Methods

Visual (VT): always first; checks profile, cracks, porosity, undercut — no equipment needed
Ultrasonic (UT): detects internal flaws; phased array UT increasingly replacing RT
Magnetic particle (MT): surface and near-surface cracks in ferromagnetic materials only
Dye penetrant (PT): surface cracks in any material — liquid penetrant drawn into defect

📖Weld Symbols — Reading Drawings

Arrow side vs. other side: symbol below reference line = arrow side; above = other side
Fillet weld: triangle symbol with leg size to left; length to right if not full length
CJP groove: no size callout = full penetration required on that joint
Field weld flag: weld to be made in field (not shop); flagged on reference line tail