September
Welding/Cutting Safety
Cylinder Cyclone isn’t just heavy — he’s lethal. Leave him unchained and he turns into a 200-pound missile, blasting through walls and bodies at over 200 mph. He lurks in unsecured storage racks, on truck beds without straps, and anywhere a valve can snap. One slip and he doesn’t just knock you over — he tears through everything in his path like a runaway freight train. The only way to stop him is to chain him up, cap him tight, and never give him the chance to roll
Welding/ Cutting Villains.
Stay sharp—because the Welding or Cutting Villains never take a day off.
Galvo Ghoul hides in galvanized steel, waiting for a spark to strip his armor and release a toxic cloud. When heated, he spews zinc oxide fumes that sneak into your lungs and hammer you with “metal fume fever” — chills, shakes, and bone-deep aches that feel like the flu from hell. He doesn’t stop there — repeated hits can scar lungs and wear you down over time. You won’t see him coming; you’ll only feel his grip hours later. The only way to keep him buried is to grind off coatings, ventilate the zone, and block his poison at the source
He doesn’t roar — he waits. Rising with the smoke of stainless steel, Hex Haze Harbinger drifts unseen, slipping into your lungs with every breath. His first touch is harsh — burning eyes, a raw throat — but his true cruelty is patience. He plants sickness that blooms years later: cancer, organ failure, a body that betrays you slowly.
And he doesn’t stay at the jobsite. He clings to clothes, boots, and hair, following you home, spreading into the air your family breathes. You won’t smell him, you won’t see him. By the time you realize he was there, it’s already too late.
She doesn’t shout — she glows. Wrapped in ultraviolet fire, Spectra Scorch strikes with light hotter than the sun, slipping past your lids to brand your eyes from the inside out.
Her curse is delayed. Hours after you lift your hood too soon, the pain arrives — every blink like sandpaper, every tear like acid. She scars bare skin with invisible burns and ricochets off steel and glass to strike the bystanders who thought they were safe.
She doesn’t need chaos. Just one moment of carelessness, and Spectra Scorch will blind you in silence.
Welding Safety: Arc, Heat & Immediate Hazards
Welding doesn’t just ‘stick metal together’ — it brings the heat, the light, and the kind of power that can hurt you in a second if you don’t respect it. Arc Nemesis is lurking in the puddles on the floor, waiting to shock you when your gloves get damp. Spark Slinger is firing sparks 35 feet across the shop, looking for an open pocket or a pile of rags to ignite. And Ember Wraith? She’s the patient one — smoldering slag and hidden hot spots that burst into flames hours after you’ve gone home.
​
This week, we’re focusing on how to spot these villains before they score. We’ll break down how to stay dry, check your leads, use the right shade of lens, and keep your fire watch strong. Real OSHA case studies show just how fast things go wrong when someone shrugs off the basics. With the right PPE and the right habits, you don’t just survive the shift — you win against hazards that never stop playing.
Week 1 is about setting the tone: eyes protected, skin covered, sparks contained, and fire watch locked in. Get it right here, and you’ve built the foundation for safe welding all month long.
WEEK 1
Multiple Choice Arc Nemesis can strike with as little as: a) 12 volts b) 24 volts c) 50 volts d) 120 volts Sparks from welding can travel up to: a) 10 ft b) 20 ft c) 35 ft d) 50 ft Flash burn to the eye feels most like: a) Soap in your eyes b) Sandpaper grinding every blink c) Heat rash d) Dust irritation In OSHA Case #95648, burns were worse because the welder wore: a) Wool undergarments b) Synthetic fabric under PPE c) Fire-retardant cotton d) Leather sleeves Ember Wraith often strikes after hours because: a) She thrives in water b) Sparks and slag smolder in combustibles c) Flashback ignites hoses d) Arc reflection blinds workers What shade lens is required for SMAW (stick welding)? a) 6–8 b) 8–10 c) 10–14 d) 15–18 Which hazard is most likely if welding cables are cracked and the floor is wet? a) Ember Wraith b) Electrical shock c) Metal fume fever d) Ozone irritation The surface temperature of an arc flash is hotter than: a) Jet engine exhaust b) Lava c) The sun’s surface d) Molten steel Fire watch should remain for at least: a) 10 minutes b) 30 minutes c) 2 hours d) Until lunch break Which villain thrives in sealed containers filled with vapor? a) Spark Slinger b) Backdraft Banshee c) Ember Wraith d) Lung Leech One rookie mistake that invites Arc Nemesis is: a) Wearing earplugs b) Touching the electrode holder with bare skin c) Using a welding screen d) Wearing FR cotton Limited Response Minimum voltage across the chest that can stop a heart: 50 volts Welding sparks can travel up to: The painful eye condition from UV exposure is called: Discussion Spark Slinger loves open pockets and cuffs. What clothing habits do you see most often on site that give him an opening?
WEEK 2
Cutting Safety: Sparks, Heat, and Control
Cutting doesn’t ask for permission — it slices, it sparks, it drops molten dross hotter than lava.
Whether it’s oxy-fuel or plasma, cutting is all raw energy. At over 6,000°F, sparks leap more than 35 feet, molten dross rains down like fire from above, and noise and light pound the senses. One sloppy setup, one missing flashback arrestor, or one unprotected pocket, and the villains move in fast. Backdraft Banshee thrives on clogged tips and poor lighting technique, waiting to send a flame racing backward through hoses. Spark Slinger hunts for open cuffs, rag piles, and unzipped hoodies, turning them into his personal bullseyes.
But chaos doesn’t have to win. This week is about bringing the fire under control. That means purging lines before lighting, securing hoses so they don’t kink or cut, shielding lower levels from falling slag, and always assigning a fire watch — not just during the job but for at least 30 minutes after. It’s about gearing up with FR clothing, metatarsal boots, face shields, and the right lens shades so sparks, slag, and arc light don’t land a hit.
​
Real OSHA cases prove the stakes: one bad position under overhead cutting, and molten dross in a boot can mean skin grafts and weeks off the job. Cutting is one of the most powerful tools in the trade — but only if you respect the process.
​
The fix is simple: Fire watch. FR gear. Clear your zone. Purge and protect your hoses. Stay sharp, stay in control, and you walk away clean.
Multiple Choice Cutting operations can generate temps over: a) 2,000°F b) 4,000°F c) 6,000°F d) 8,000°F Sparks from cutting can leap as far as: a) 20 ft b) 25 ft c) 35 ft d) 50 ft A flashback occurs when: a) Gas leaks from a regulator b) Flame races backward into hoses/regulators c) Sparks hit a fire hazard d) Torch pressure is too high Which villain represents uncontrolled sparks and molten dross? a) Ember Wraith b) Spark Slinger c) Hex-Haze Harbinger d) Cylinder Cyclone Plasma cutting light requires what minimum lens shade? a) 3 b) 5 c) 8 d) 12 Molten slag can stay >2,000°F for: a) Milliseconds b) 1 second c) Several seconds d) 1 minute In OSHA Case #201565342, molten dross burned through a worker’s: a) Gloves b) Face shield c) Boot d) Welding jacket Plasma cutting noise often exceeds: a) 70–80 dB b) 85–90 dB c) 95–100 dB d) 100–110 dB Limited Response Plasma cutting requires a lens shade of at least: Sparks and dross can travel up to: Maximum safe acetylene pressure: Discussion Points Spark Slinger can launch sparks 35 ft or more. What areas in your work zone are most likely overlooked when creating a safe cutting radius?
Respiratory Safety & Ventilation
Some hazards don’t announce themselves with sparks or flames — they float in quietly, invisible and deadly. Welding, cutting, and grinding all release toxic fumes that can change your health forever if you’re not prepared. Hex-Haze Harbinger is the silent striker, filling dead-air pockets with hexavalent chromium that scars your lungs and raises your cancer risk. Manganese sneaks in with every arc on mild steel, chipping away at your nervous system. Zinc burns off galvanized coatings and gives you metal fume fever — the chills, the aches, the shakes. And Spark Slinger? He’s still here, carrying those toxic particles through the air like smoke signals aimed right at your lungs.
This week is all about awareness and defense. We’ll break down where these toxins come from, the symptoms they cause, and how to block them before they ever reach your airway. Local exhaust ventilation, fresh air flow, and the right respirator aren’t optional — they’re the difference between going home healthy or going home with permanent damage. Real OSHA cases prove just how fast confined spaces can turn deadly when the fumes build up.
Week 3 is about breathing smart: know your materials, keep the air moving, and put the right filter on your face. You can’t fight what you can’t see, but with the right protection, you’ll outlast the hazards and breathe easy for years to come.
​
​
WEEK 3
Multiple Choice 1.OSHA’s PEL for hexavalent chromium is: a) 50 µg/m³ b) 10 µg/m³ c) 5 µg/m³ d) 1 µg/m³ 2.Metal fume fever usually disappears within: a) 1 hour b) 24–48 hours c) 1 week d) Permanently 3.Welders often report what unusual taste after zinc oxide exposure? a) Sweet b) Metallic c) Bitter d) Sour 4.Which villain steals oxygen in tanks and makes workers collapse without warning? a) Ozone Ogre b) Lung Leech c) Hex-Haze Harbinger d) Spark Slinger 5.Ozone Ogre often announces his presence with a smell similar to: a) Rotten eggs b) Gasoline c) Bleach d) Burnt wood 6.The first symptom of manganese overexposure is often: a) Rash b) Headache/dizziness c) Vision loss d) Chest pain 7.Chronic exposure to manganese can cause a condition similar to: a) Asthma b) Cancer c) Parkinson’s disease d) Diabetes 8.Welders in confined tanks face the highest risk from: a) Sparks b) Noise c) Fume buildup in dead air zones d) Bright light Limited Response Welders exposed to zinc fumes often complain of a: Chronic manganese exposure can cause: Ozone fumes smell like: Discussion Points In the stainless tank case, fans were running but fumes still built up. What lessons can we learn about positioning ventilation and respirators in confined spaces?
By the time we reach Week 4, we’re dealing with raw stored energy — compressed gas cylinders and the hoses and attachments that control them. A 200-pound cylinder isn’t just heavy, it’s a rocket waiting to launch if the valve snaps. Cylinder Cyclone is the heavyweight here, ready to turn steel into a 200-mph missile. Backdraft Banshee is still in the game, lurking in poor lighting practices and clogged tips, ready to send a flame racing backward into hoses. And Spark Slinger? He never misses a chance, burning through hoses left in his path.
This week is about respect — respect for the pressure, respect for the setup, and respect for the details that save lives. We’ll cover how to chain and cap cylinders, bleed the lines, and keep oil and grease away from oxygen equipment. Real OSHA cases show how a single unsecured tank or pressurized hose left overnight can level walls, take lives, and leave scars that never heal.
Week 4 is about discipline: secure it, cap it, bleed it, and keep it clean. Cylinders don’t forgive mistakes, and there are no second chances when one goes wrong. Respect the pressure every single time.
WEEK 4
Cylinder, Hose, and Attachments: Control the Pressure
Multiple Choice 1.A 200 lb cylinder with a broken valve can rocket at speeds close to: a) 100 mph b) 150 mph c) 200 mph d) 300 mph 2.After being stored on its side, acetylene cylinders must stand upright for at least: a) 15 minutes b) 30 minutes c) 1 hour d) 4 hours 3.Acetylene is stabilized inside its cylinder using: a) Double walls b) Porous filler and acetone c) Nitrogen purge d) Extra-thick steel 4.Oil or grease on oxygen valves or fittings can cause: a) Corrosion b) Slippery surfaces c) Spontaneous ignition/explosion d) Valve blockage 5.Cylinders in storage must be separated by at least: a) 10 ft b) 20 ft (or 5 ft fire barrier) c) 25 ft d) 50 ft 6.Which villain represents an unsecured cylinder that turns into a rocket? a) Spark Slinger b) Ember Wraith c) Cylinder Cyclone d) Backdraft Banshee 7.Which villain strikes when flame runs backward into hoses and regulators? a) Backdraft Banshee b) Spark Slinger c) Ember Wraith d) Hex-Haze Harbinger 8.What’s the safest way to move cylinders around a site? a) Drag carefully b) Roll on the ground c) Use a cylinder cart with chains d) Carry by valve cap Limited Response 1.Max safe acetylene pressure: 2.Acetylene cylinders contain: 3.Cylinder separation distance: 4.Oxygen fittings must never contact: Discussion Spark Slinger loves hoses stretched across walkways or crushed under wheels. How could you re-route hoses or redesign work zones to keep him from striking?
Cenutrion Safety Hub
Safety Tools for Craft Workers