Level 2 NVQ in Fabrication and Welding (1681) · 4 Brazing and/or Soldering ... Level 2 NVQ in...

Level 2 NVQ in Fabricationand Welding (1681)National occupational standardsand assessment requirements www.city-and-guilds.co.uk

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Level 2 NVQ in Fabricationand Welding (1681)National occupational standardsand assessment requirements

09.04/F00042905/ST85554

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05 Foreword

08 The award

09 Qualification structure – Fabrication and Welding Level 2

13 Assessment requirements

22 National occupational standards and evidence recording sheets

325 Key skills signposting

330 Further information

Contents

This guide aims to provide information to centres and candidates for theadministration and assessment of The Level 2 National Vocational Qualification(NVQ) in Fabrication and Welding. It provides details of the requirements specific tothis N/SVQ qualification which includes• the requirements for occupational competence for all those involved in assessing

and verifying performance• specific assessment requirements• The National Occupational Standards.• There are three sections to the Guide.

Section 1 Scheme informationSection 2 Assessment requirementsSection 3 National occupational standards and Evidence profiles

The first section contains information on who will benefit from the awards and thestructure and scope of the NVQs. The second section gives the specific informationon assessment and evidence requirements.

This document is designed to be used in conjunction with:the N/SVQ Candidate Guide (stock reference TS-11-0001)andthe N/SVQ Centre Guide (stock reference EN-11-0001).

Check the City & Guilds website: www.city-and-guilds.co.uk, for latest version.

Packs of multiple copies of the recording forms are also available from PublicationsSales (Recording forms for N/SVQs, stock reference TS-22-0001).

In the case of any inconsistency between the N/SVQ Centre Guide or the N/SVQCandidate Guide and this N/SVQ specific document, this document shall prevail.

For details of centre and scheme approval refer to the document: ‘Providing City andGuilds qualifications’ (stock code EN-00-1111) available free of charge from the SalesDepartment or your regional/national City & Guilds office (details in Furtherinformation section of this document).

Details of general regulations, administrative, registration and certificationprocedures and fees appear on City & Guilds web site http://www.city-and-guilds.co.uk

The following documents also include information on policy and guidance on qualityassurance within NVQs and assessors and verifiers should be aware of the contents.

Foreword

05Level 2 NVQ in Fabrication and Welding (1681)

City & Guilds policy document ‘Ensuring Quality’ – aimed at those involved in theassessment and verification of City & Guilds awards. Issued 3-4 times a year(available from Sales Department) NB Edition 12 – December 2001 summarisespolicy from all previous editions)Joint Awarding Body Guidance on Internal Verification of NVQs, issued November2001, published by the DfES, also available on City & Guilds web site.

General NVQ informationCentres should refer to the City & Guilds Centre Guide for NVQs for information onNVQs, the people involved, the assessment process and model recording forms.

Specific evidence profile formsSpecific evidence profile forms have been designed for these awards. There is aseparate form for each unit. The forms provide a convenient method of ensuringcandidates have all the necessary evidence to achieve a unit.

Restrictions on entryThere are no restrictions on entry to this award, however, candidates should notregister for this award if they hold or are registered with City & Guilds or anotherawarding body for a similar award at the same level.

06 Level 2 NVQ in Fabrication and Welding (1681)

Scope of the awardNVQs for the engineering sector are work-based qualifications designed to reflectthe roles and responsibilities of personnel within the sector.

This level 2 award is based on a mandatory and optional unit structure. Themandatory units cover those areas which have a common approach such as safety,engineering communications and team working. The optional units are combined into ‘pathways’ which offer a choice to meet the needs of the main occupationalpatterns within typical fabrication and welding organisations.

National occupational standards and key skillsThe full National Occupational Standards and Key Skills mapping are enclosed within this document. Centres may access whichever units are appropriate to their requirements.

Restrictions on entryThere are no restrictions on entry to this award, however candidates should notregister for this award if they hold or are registered with City & Guilds or anotherawarding body for a similar award at the same level.

NVQ Level 2 in Fabrication and Welding Engineering


The Level 2 NVQ in Fabrication and Welding consists of 53 units. All candidates musttake the THREE core units plus a specified number of optional units from one of theeleven occupational pathways to achieve the award. Additional units may be taken,for which the candidate will receive a Certificate of Unit Credit.

The certificates referred to in this guide are as followsLevel 2 NVQ in Fabrication and Welding (Manual Welding)Level 2 NVQ in Fabrication and Welding (Welding Machine Operating)Level 2 NVQ in Fabrication and Welding (Rail Welding)Level 2 NVQ in Fabrication and Welding (Plastics Welding)Level 2 NVQ in Fabrication and Welding (Sheet Metalwork)Level 2 NVQ in Fabrication and Welding (Plateworker)Level 2 NVQ in Fabrication and Welding (Structural steelwork)Level 2 NVQ in Fabrication and Welding (Pipework Fabrication)Level 2 NVQ in Fabrication and Welding (Composite Fabrication)Level 2 NVQ in Fabrication and Welding (Thermal Cutting)

The Units have been contextualised by SEMTA from the National EngineeringCompetency Standards (ECS).

The award


Mandatory units for all pathways (all three units must be completed)Unit 1: Complying with Statutory Regulations and Organisational Safety RequirementsUnit 2: Using and Interpreting Engineering Data and DocumentationUnit 3: Working Efficiently and Effectively in Engineering

Pathways1 Manual WeldingMust complete any one of the following units:Unit 4: Joining Materials by the Manual Metal Arc Welding ProcessUnit 5: Joining Materials by Manual MIG/MAG and other Continuous

Wire Welding ProcessesUnit 6: Joining materials by Manual TIG and Plasma-arc Welding ProcessesUnit 7: Joining Materials by the Manual Gas Welding ProcessUnit 8: Producing Fillet Welded Joints using a Manual Welding Process

2 Welding Machine OperatingMust complete any one of the following units:Unit 9: Welding Materials with Mechanised Arc Welding EquipmentUnit 10: Welding Materials using Resistance Spot, Seam and Projection

Welding MachinesUnit 11: Welding Materials using Laser Welding MachinesUnit 12: Welding Materials using Electron Beam Welding MachinesUnit 13: Welding Materials using Friction Welding Machines

3 Rail WeldingMust complete any one of the following units:Unit 14: Joining Rails using the Aluminothermic Welding ProcessUnit 15: Restore Rails to Operational Condition using an Arc Welding ProcessUnit 16: Welding Rails using Flash Welding Equipment

4 Brazing and/or SolderingMust complete any one of the following units:Unit 17: Joining Materials by Manual Torch Brazing and SolderingUnit 18: Joining Materials using Brazing Machines

5 Plastics WeldingMust complete any one of the following units:Unit 19: Joining Plastics using Manual Welding ProcessesUnit 20: Joining Materials using Plastics Welding Machines

Qualification structure


6 Sheet Metalwork (3 mm or less)Must complete two of the following units:Unit 21: Marking Out Components for FabricationUnit 22: Cutting Sheet Metal to Shape using Hand and Machine ToolsUnit 23: Forming Sheet Metal using Hand and Machine toolsUnit 24: Producing Sheet Metal AssembliesUnit 25: Heat Treating Materials for Fabrication ActivitiesUnit 26: Cutting and Shaping Materials using NC/CNC Laser Profiling MachinesUnit 27: Cutting and Shaping using NC/CNC Plasma or Gas Cutting Machines

Plus one more unit from the following:Unit 28: Assembling Components using Mechanical FastenersUnit 29: Bonding Engineering Materials using AdhesivesUnit 30: Joining Materials by Resistance Spot WeldingUnit 5: Joining Materials by Manual MIG/MAG and other Continuous

Wire ProcessesUnit 6: Joining Materials by Manual TIG and Plasma-arc Welding ProcessesUnit 7: Joining Materials by the Manual Gas Welding ProcessUnit 31: Slinging, Lifting and Moving Materials and Components

7 Plateworker (3 mm upwards)Must complete the following unit:Unit 21: Marking Out Components for Fabrication

Plus one more unit from the following:Unit 32: Cutting Plate and Sections using Shearing MachinesUnit 33: Cutting Materials using Hand Operated Thermal Cutting EquipmentUnit 34: Cutting and Shaping Materials using Gas Cutting MachinesUnit 35: Cutting Materials using Saws and Abrasive DiscsUnit 26: Cutting and Shaping Materials using NC/CNC Laser Profiling MachinesUnit 27: Cutting and Shaping using NC/CNC Plasma or Gas Cutting Machines

Plus one more unit from the following:Unit 36: Bending and Forming Plate using Power Operated MachinesUnit 37: Forming Platework using Power Rolling MachinesUnit 38: Producing Platework AssembliesUnit 39: Producing Holes using Drilling Machines

Plus one more unit from the following:Unit 28: Assembling Components using Mechanical FastenersUnit 8: Producing Fillet Welded Joints using a Manual Welding ProcessUnit 9: Welding Materials with Mechanised Arc Welding EquipmentUnit 31: Slinging, Lifting and Moving Materials and Components


8 Structural steelworkMust complete the following unit:Unit 21: Marking Out Components for Fabrication

Plus one more unit from: Unit 32: Cutting Plate and Sections using Shearing MachinesUnit 33: Cutting Materials using Hand Operated Thermal Cutting EquipmentUnit 34: Cutting and Shaping Materials using Gas Cutting MachinesUnit 35: Cutting Materials using Saws and Abrasive Discs

Plus two more units from the following:Unit 40: Forming of Structural Sections using MachinesUnit 41: Producing Structural Steel Ancillary ComponentsUnit 39: Producing Holes using Drilling MachinesUnit 28: Assembling Components using Mechanical FastenersUnit 8: Producing Fillet Welded Joints using a Manual Welding ProcessUnit 9: Welding Materials with Mechanised Arc Welding EquipmentUnit 42: Assembling Structural SteelworkUnit 31: Slinging, Lifting and Moving Materials and Components

9 Pipework FabricationMust complete the following unit:Unit 21: Marking Out Components for Fabrication

Plus one unit from:Unit 33: Cutting Materials using Hand Operated Thermal Cutting EquipmentUnit 34: Cutting and Shaping Materials using Gas Cutting MachinesUnit 35: Cutting Materials using Saws and Abrasive Discs

Plus two more units from the following:Unit 39: Producing Holes using Drilling MachinesUnit 43: Forming Pipework by Machine BendingUnit 28: Assembling Components using Mechanical FastenersUnit 29: Bonding Engineering Materials using AdhesivesUnit 44: Producing Socket and Flange Fillet Welded Joints in Pipe using

a Manual Welding Process


10 Composite FabricationMust complete two of the following units:Unit 45: Producing Composite Mouldings using Wet Lay-up TechniquesUnit 46: Producing Composite Mouldings using Pre-Preg Laminating TechniquesUnit 47: Producing Components by Acrylic MouldingUnit 48: Vacuum Forming Composite MaterialsUnit 49: Trimming Composite Mouldings using Hand ToolsUnit 50: Identifying Defects in Composite MouldingsUnit 51: Applying Surface Finishes to Composite MouldingsUnit 52: Bonding Composite MouldingsUnit 53: Producing Composite Assemblies

11 Thermal CuttingMust complete any two units from the following:Unit 33: Cutting Materials using Hand Operated Thermal Cutting EquipmentUnit 34: Cutting and Shaping Materials using Gas Cutting MachinesUnit 26: Cutting and Shaping Materials using NC/CNC Laser Profiling MachinesUnit 27: Cutting and Shaping using NC/CNC Plasma or Gas Cutting Machines


IntroductionThe purpose of the assessment strategy is to• assist assessors, internal verifiers and external verifiers• encourage and promote consistent assessment of the qualification• promote cost effective assessment strategies• promote the use of external quality control of assessment methods

The assessment strategy also specifies• the qualifications and experience required for assessors and verifiers• the assessment environment and standard of equipment that should be used• access to the qualification• the evidence required to support competent performance against the standards• carrying out assessments• assessing knowledge and understanding

Section A General requirementsThe assessment strategy for City and Guilds awards based on SEMTA units is detailedbelow. It applies throughout the standards and must be used as the basis for allindividual assessments.

In the implementation of all SEMTA standards, reference should be made back to thisstrategy when specifying the assessment requirements for each unit or element ofcompetence. The internal and external verifier will seek evidence that therequirements have been fulfilled by candidates and assessors at all times.

Scope of the awardEvidence of competence must be assessed against the requirements of the relevantNational Occupational Standards. For this award, the relevant standards arecontextualised versions of the Engineering Competence Standards (ECS).

Qualification structureThe qualification structure for this award requires candidates to complete commonmandatory units, followed by a choice of pathways. Candidates may then be requiredto complete further mandatory units within their chosen pathway, followed by anumber of optional units from a provided selection. The range of optional units allowsfor any variations in the occupation in different organisations and across the sector.

Assessment requirements for awards within the Engineering Sector


Assessor requirementsAssessment must be carried out by competent assessors who hold, or are workingtowards, the nationally recognised Assessor units (A1/A2) (formerly D32/D33).

Assessors must be able to demonstrate that they have sufficient technicalcompetence to evaluate and judge evidence for this award. This will bedemonstrated either by holding a relevant technical qualification or by provensuitable experience of the technical areas to be assessed. The assessor’scompetence must, at the very least, be at the same level as that required of thecandidate(s) in the units being assessed.

Specific technical requirements for assessors of this qualification are outlined onpage 18.

Assessors must also know:• the content and meaning of the National Occupational Standards against which

assessments are to be carried out• the appropriate Regulatory Body’s system of vocational qualifications• the relevant Awarding Body’s documentation and system of vocational

qualifications within which the assessment is taking place.

Verifier requirementsInternal Verifiers must hold, or be working towards, the nationally recognisedInternal Verifier unit (V1) (formerly D34), and would be expected to be familiar with,and preferably hold, the nationally recognised Assessor units.

External Verifiers must hold, or be working towards, the nationally recognisedExternal Verifier unit (V2) (formerly D35), and would be expected to be familiar with,and preferably hold, the nationally recognised Assessor units, and possibly even thenationally recognised Internal Verifier unit.

Verifiers, both internal and external, will also be expected to be fully conversant withthe standards against which the assessments and verification are to be carried out,the appropriate Regulatory Body’s system of vocational qualifications, and therelevant Awarding Body’s documentation and system of vocational qualificationswithin which the assessment and verification is taking place.

Additionally verifiers, both internal and external, should be technically familiar withthe skill area being verified.

Specific technical requirements for verifiers of this qualification are outlined on page 18.

Witness testimonyWhere observation of process is used to obtain the performance evidence, thisobservation must be carried out against the standards. Best practice would requirethat such observation is carried out by a qualified assessor. If this is not practicablethen alternative sources of evidence may be used.


For example, the observation may be carried out against the standards by someoneelse in close contact with the candidate. This could be a supervisor, colleague,mentor or manager, who may be regarded as a suitable witness to the candidate’scompetency. However, the witness must be technically competent in the process orskills that they are providing testimony for to at least the same level of expertise asthat required of the candidate. It will be the responsibility of the assessor to makesure that any witness testimonies accepted as evidence of a candidate’scompetency are reliable and technically valid.

Assessment environmentEvidence for this award should be obtained from the working environment where thework activities or work outcomes to be assessed are clearly attributable to thecandidate. However, in certain circumstances, replication of work activities may be acceptable. Where replication is considered necessary, assessors must beconfident that the environment replicates the workplace to such an extent thatcompetencies gained will be fully transferable to the workplace. In this caseassessors must clearly identify those aspects of the workplace that are critical toperformance, and make sure that they have been replicated satisfactorily. Wherereplication is involved, assessors must obtain agreement with internal and externalverifiers before assessing any candidates.

Examples of critical aspects could be:• environmental conditions such as, noise levels, lighting conditions and the

presence of hazards• the use of industrial equipment and procedures• pressure of work such as time constraints and repetitive activities• carrying out work on actual work pieces and the consequences of

making mistakes• customer/supplier/departmental relationships

Access to assessmentThere are no entry qualifications or age limits required for these qualifications unlessthis is a legal requirement of the process or the environment. Assessment is open toany candidate who has the potential to reach the standards laid down for thisqualification. However centres should refer to the statement on access toassessment in the City & Guilds Centre Guide for NVQs on not entering for similarawards at the same level.

Aids or appliances which are designed to alleviate disability may be used duringassessment providing they do not compromise the standard required.


Carrying out assessmentsSEMTA strongly recommends that the majority of assessment evidence for themandatory units is gathered during the performance of the optional units. Evidenceshould be obtained as a whole, where practically possible, since competentperformance in the optional units is often dependent on competence in themandatory units. Although it is possible to achieve this qualification with theminimum number of optional units, organisations may wish their candidates to beassessed for more than this.

Where key skills are required, these may be included as additional units and assessedin conjunction with the mandatory and optional units, where this is appropriate.

The standards were developed to cover a range of activities. The evidence producedfor this award will, therefore, depend on the candidate’s choice of ‘scope’ items inthe standard, which are intended to help the candidate to seek the appropriateinformation and to acquire the necessary skills, techniques and knowledge beforebeing able to demonstrate competent performance.

Where the scope section gives a choice (for example ‘any three from five’), assessorsshould note that candidates do not need to cover the other (in this example, two)items, particularly where these additional items may relate to other activities ormethods which are not part of the candidate’s normal workplace activity or area of expertise.

Performance evidence requirementsPerformance evidence must be the main form of evidence gathered.

In order to demonstrate consistent, competent performance for a unit, a minimumof three different evidence examples of performance evidence will be required, toshow that the tasks reflected by the unit title have been carried out to the statedstandards. The number of items required in each of the scope statements specifiedfor a unit (e.g., four from a choice of six) must all be covered. It is possible that someof the scope items may be covered more than once. If, however, the three examplesof performance evidence are not sufficient to cover all the specified scope items,then further examples of performance evidence will be required to ensure thiscoverage is achieved.

Assessors must make sure that the evidence provided reflects the candidate’scompetence and not just the achievement of the training programme.

Items of performance evidence often contain features that apply to more than oneunit, and can be used as evidence in any unit where appropriate.

Performance evidence may be either:• products of the candidate’s work, such as items that have been produced or

worked on, documents produced as part of a work activity, records orphotographs of the product


or• evidence of the way the candidates carried out the activities such as witness

testimonies, assessor observations or authenticated candidate reports of theactivity undertaken

Competent performance is more than just carrying out a series of individual settasks. Many of the units contain statements that require the candidate to provideevidence that proves they are capable of combining the various features andtechniques. Where this is the case, separate fragments of evidence would notprovide this combination of features and techniques and will not, therefore, beacceptable as demonstrating competent performance.

If there is any doubt as to what constitutes suitable evidence, the external verifiershould be consulted.

Assessing Knowledge and UnderstandingKnowledge and understanding are key components of competent performance, butit is unlikely that performance evidence alone will provide enough evidence in thisarea. Where the candidate’s knowledge and understanding (and the handling ofcontingency situations) is not apparent from performance evidence, it must beassessed by other means and be supported by suitable evidence.

Knowledge and understanding can be demonstrated in a number of different ways,but it is suggested that the most appropriate methods for this qualification are oralquestioning and practical demonstrations. Assessors should ask enough questionsto be able to determine that the candidate has an appropriate level of knowledgeand understanding as required by the unit.

Where oral questioning is used the assessor must retain a record of the questionsasked, together with the candidate’s answers.

Section B Qualification-Specific requirements for the N/SVQin Fabrication and Welding Level 2Scope of the awardThis qualification is for people who are occupied primarily in welding and/orfabrication, and who have a high level of technical skill and knowledge in that activity.They will be expected to demonstrate safe working practices and procedures at alltimes and work with minimum supervision, taking personal responsibility for thequality and accuracy of the work they carry out.

Candidates for this qualification will have gained a high level of skill ability andacquired sound knowledge and understanding of the relevant techniques, materials,tools and equipment used, in order to enable them to carry out the activities, solverelated problems, correct any faults and ensure the work output meets the requiredspecification standard.


Specific technical requirements for assessorsAssessors of this qualification should have a minimum of three years’ relevant skillsexperience, and should have a thorough working knowledge of welding andfabrication processes, techniques, and procedures used.

Specific technical requirements for verifiersVerifiers should have some relevant skills experience, and should have held aposition of engineering responsibility. They should have sufficient technicalknowledge to enable them to verify that assessments have been carried out to thetechnical and safety standards required, and to ask relevant questions of assessorsor candidates, where necessary.

Specific evidence requirementsCandidates must carry out at least THREE separate assessment tasks. The unitguidance and scope for each unit indicate in detail what evidence is required. There is a specific Unit Checklist provided for EACH unit in this guide.

Completing the unit checklistsThe candidate must carry out at least three separate assessment tasks. Thelocation of all items of evidence, that must cover ALL of the criteria given in thestandards, should entered on the checklist provided after each unit under the‘Performance Evidence’ columns. These locations must be identified in a way thatallows the verifiers (internal and external) to easily trace and audit the evidence egPage 6 – could refer to the position in the portfolio of the inspection sheet covering‘Weld Quality B and C and Dimensional Accuracy. Drawing 1 could provide thespecification for the same task. Also Job 1234 could refer to an actual product.

Note that it may not be possible to cover all of the required criteria by completingthree tasks. In such cases supplementary work may be needed to cover thisshortfall, this will be referenced in the fourth column’

In addition to the unit checklist, the required evidence must also contain• Actual product evidence where practical – e.g. taking into account its weight, size

and or if it is an actual production item for customer use. Photographs or videos maybe used in lieu provided they show the skill areas in sufficient detail for the verifiers(internal and external) to make a decision regarding the practical standards achieved

• A work sheet (company or centre devised) that clearly lays down the requiredproduct specification in terms of materials, tolerances and any time restrictionsplus a drawing.Notei it is not necessary for the candidate to personally reproduce drawings, method

descriptors etc. unless these items do not exist.ii in cases of industrial confidentiality or sensitivity then it may be permissible to

exclude certain items from the evidence, but a description of the general natureof the work/activity must be provided. In cases of doubt the EV should beconsulted about the validity of a proposed assessment before the candidatecommences any such work.


• An inspection sheet or report that clearly identifies that the product has beenreliably tested against the specification. If there are any discrepancies of a non-critical nature then the assessment may be deemed acceptable provided that thereis a statement to this effect signed by a duly appointed and responsible person.

• A brief report, prepared by the candidate, that identifies any hazards ordifficulties associated with the work and how these were dealt with. It should alsohighlight any specific requirements or special skill areas that were involved e.g.non standard tools, tool and work holding methods (use of jigs and fixtures etc.)Note that where relevant some aspects of this could also form part of the requiredknowledge evidence e.g. items 8 and 9 of this unit.

Knowledge evidenceWhere the required knowledge and understanding cannot be obviously andpositively inferred from an assessor or expert witness observing the practical tasks,then the candidate must be formally questioned using either short written answer ororal types of questions.

The questions should only relate to the specific areas defined by the criteria for thisunit. e.g. if only AC equipment is used then the questions should not ask for settingdetails etc. of DC equipment. (Note that this knowledge may well form part of an allround underpinning knowledge programme but in such cases it would beassessed separately.

Assessors must carefully plan all types of questioning procedures beforehand. Theactual questions (oral and written) must be kept under secure conditions and onlymade available to the candidates during the assessment process. The candidateswill retain a copy of their results, including comments made by the assessor duringoral questioning. (See the separate information section regarding the use of oralquestioning techniques).

Assessors must make the questions available to verifiers so that the latter cancompare them against the results sheets held by the candidates.

The knowledge evidence should be referenced in a similar fashion to that used forperformance evidence.

Note that it is not necessary to assess the knowledge criteria on threeseparate occasions

Further guidanceFurther guidance to general procedures for the assessment of NVQs and samplerecording forms is found in the N/SVQ Centre Guide (stock reference EN-11-0001).



Occupational Relevant NQFRoles Qualifications Level

Director Chartered Engineer 5Senior manager Higher Hons/Hons DegreeSenior engineer Bachelors Degree/Certificate

Management N/SVQsProject manager Incorporated engineer

City & Guilds Higher level qualifications 4Product Development Accounting/Admin N/SVQsEngineer Training & Development N/SVQTechnician Business-improvement techniques NVQ

BTEC Engineering (B.Tech) HNC/HND

AMA Engineering 3Engineering NVQs

Supervisor/Leader Management N/SVQsCraftsperson Engineering design N/SVQProduction/Quality Controller Business-improvement techniques NVQHealth & Safety Controller Technical services N/SVQ

Information Technology N/SVQTraining and Development N/SVQBTEC Engineering (B.Tech) NC/NDCity & Guilds Engineering vocational awards

FMA engineering 2Engineering NVQs

Semi-skilled operative City & Guilds Engineering vocational awardsPerforming engineering operations NVQBusiness-improvement techniques NVQPerforming manufacturing operations NVQHealth and Safety Certs

Operative Performing engineering operations NVQ 1Performing manufacturing operations NVQApplying engineering principles awardGCSE engineering

Engineering sector progression routes

ENTRANTS

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Knowledge Method(s) used Candidate’s Assessor Result Datereference Written Oral Inferred Evidence Reference assessed

location

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Name Signature

Candidate: Date:

Assessor: Date:

Internal Verifier Date:

External Verifier Date:

NVQ in Fabrication and Welding Level 2 Knowledge evidence recording sheet(this should be copied for each unit)

National Occupation Standards – Fabrication andWelding Level 2Supplied by SEMTA


Unit summaryThis unit identifies the competencies you need to deal with statutory andorganisational safety requirements in accordance with approved regulations, codesof practice and procedures. You will be required to comply with all relevantregulations that apply to your area of work as well as your general responsibilities asdefined in the Health and Safety at Work Act. You will also need to be able to identifythe relevant qualified first aiders or appointed person and know the location of thefirst aid facilities. You will have an understanding of the procedures to be adopted inthe case of accidents involving injury and in situations where there are dangerousoccurrences or hazardous malfunctions of equipment, processes or machinery. Youwill also need to be fully conversant with the organisation’s procedures for fire alertsand the evacuation of premises.

You will also be required to identify the hazards and risks that are associated with yourjob. Typically these will focus on your working environment, the tools and equipmentthat you use, materials and substances that you use and working practices that do notfollow laid down procedures, and manual lifting and carrying techniques.

Your responsibilities will require you to comply with organisational policy andprocedures for the Statutory Regulations and organisational safety activitiesundertaken and to report any problems with the safety activities that you cannotpersonally resolve, or are outside your permitted authority, to the relevant people.You will be expected to work with minimum supervision, taking personalresponsibility for your own actions and the way in which you carry out the requiredengineering activities.

Your underpinning knowledge will provide a good understanding of your work, andprovide an informed approach to applying Statutory Regulations and organisationalsafety requirements and procedures. You will understand the safety requirementsand their application, and will know about the safety requirements in adequatedepth to provide a sound basis for carrying out the activities safely and correctly.

Unit 1Complying with statutory regulations and organisational safety requirements


Performance statements:You must:a Comply with your duties and obligations as defined in the Health and Safety

at Work Actb Present yourself in the workplace suitably prepared for the activities

to be undertakenc Follow organisational accident and emergency proceduresd Recognise and control hazards in the workplacee Use correct manual lifting and carrying techniquesf Apply safe working practices and procedures

Scope of the unit:The numbers of scope items specified (below) indicate the minimum requirementsfor this Occupational Standard.

You must:1 Demonstrate your understanding of your duties and obligations to health and

safety by carrying out all of the following:• applying, in principle, your duties and responsibilities as an individual under the

Health and Safety at Work Act and other relevant current legislation• identifying, within your organisation, appropriate sources of information and

guidance on health and safety issues, to include:– Eye protection and personal protective equipment– COSHH regulations– Risk assessments

• identifying the warning signs and labels of the main groups of hazardous ordangerous substances

• complying with the appropriate statutory regulations at all times

2 Comply with all emergency requirements to include:• identifying the appropriate qualified first aiders or appointed person and the

location of first aid facilities• identifying the procedures to be followed in the event of injury to self or others• following organisational procedures in the event of fire and the evacuation

of premises• identifying the procedures to be followed in the event of dangerous

occurrences or hazardous malfunctions

3 Identify the hazards and risks that are associated with all of the following:• your working environment• the tools and equipment that you use• materials and substances that you use• using working practices that do not follow laid down procedures



4 Demonstrate two methods of manual lifting and carrying techniques:• lifting alone• with assistance of others• with mechanical assistance

5 Apply safe working practices in an industrial environment to include all of the following:• maintaining a tidy workplace with exits and gangways free from obstructions• using tools and equipment safely and only for the purpose intended• observing organisational safety rules, signs and hazard warnings• taking measures to protect others from harm by any work you are carrying out

Knowledge statements:You must have knowledge and understanding of :1 The roles and responsibilities of yourself and others under the Health and Safety

at Work Act 1974 and current legislation (e.g. The Management of Health andSafety at Work Regulations; Workplace Health and Safety and WelfareRegulations; Personal Protective Equipment at Work Regulations; ManualHandling Operations Regulations; Provision and use of Work EquipmentRegulations; Display Screen at Work Regulations)

2 The specific regulations and safe working practices and procedures that applyto your work activities

3 The warning signs for the seven main groups of hazardous substances definedby Classification, Packaging and Labelling of Dangerous Substances Regulations

4 How to locate relevant health and safety information for your tasks and thesources of expert assistance when help is needed

5 What constitutes a hazard in the workplace (such as moving parts of machinery,electricity, slippery and uneven surfaces, dust and fumes, handling andtransporting, contaminants and irritants, material ejection, fire, working atheight, environment, pressure/stored energy systems, volatile or toxicmaterials, unshielded processes)

6 Your responsibilities for dealing with hazards and reducing risks in theworkplace (such as hazard spotting and safety inspections; the use of hazardcheck lists, carrying out risk assessments, COSHH assessments and safesystems of working)

7 The risks associated with your working environment, the tools, materials andequipment that you use, spillages of oil and chemicals, not reporting accidentalbreakages of tools or equipment and not following laid down working practicesand procedures

8 The first aid facilities that exist within your work area and within theorganisation in general and the procedures to be followed in the case ofaccidents involving injury

9 What constitutes dangerous occurrences and hazardous malfunctions and whythese must be reported even when no one was injured

10 The procedures for sounding the emergency alarms, evacuation proceduresand escape routes to be used and the need to report your presence at theappropriate assembly point



11 The organisational policy with regard to fire fighting procedures, the commoncauses of fire and what you can do to help prevent them

12 The protective clothing and equipment that is available for your areas of activity13 How to lift and carry loads safely and the manual and mechanical aids available14 How to prepare and maintain safe working areas, standards and procedures to

ensure good housekeeping15 The importance of safe storage of tools, equipment, materials and products16 The extent of your own authority and whom you should report to, in the event

of problems that you cannot resolve





evidence type

date

health & safety-understanding application of duties and equipment (all)

H & S at Work Act

PPE

COSHH

risk assessments

hazardous substances

statutory regulations

emergency requirements (all)

first aider/facilities

injury procedures

fire procedures

danger/hazard procedures

environmental hazards/risks (all)

working environment

tools & equipment

materials and substances

bad working practices

manual lifting & carrying techniques (two)

lifting alone

with assistance of others

with mechanical assistance

safe working practices (all)

tidy workplace

tools & equipment

safety/hazard warnings

protect others

Knowledge and understanding reference:

Candidate Date

Assessor Date

additional performance

performance performance performance evidence evidence record sheet evidence 1 evidence 2 evidence 3 (if required)

Unit summaryThis unit identifies the competencies you need to make effective use of text, numericand graphical information by interpreting and using technical information extractedfrom engineering drawings, technical manuals, reference tables, specifications andcharts in accordance with approved procedures. You will be required to extract thenecessary information from the various drawings and related documents in order toestablish and carry out the work requirements and to make valid decisions about thequality and accuracy of the work produced in accordance with approved procedures.

Your responsibilities will require you to comply with organisational policy andprocedures for obtaining and using the drawings and related specifications. You willbe expected to report any problems with the use and interpretation of the drawingsand specifications that you cannot personally resolve, or are outside your permittedauthority, to the relevant people. You will be expected to work with minimumsupervision, taking personal responsibility for your own actions and the quality andaccuracy of the work that you carry out.

Your underpinning knowledge will provide a good understanding of the types ofdrawings and documents used and provide an informed approach to applyinginstructions and procedures. You will be able to read and interpret the drawings anddocuments used and will know about the conventions, symbols and abbreviations inadequate depth to provide a sound basis for carrying out the activities to therequired specification.

Unit 2Using and interpreting engineering drawings and documents


Performance statements:You must:a Use the approved source to obtain the required drawings and specificationsb Correctly interpret the drawings and specificationsc Identify, extract and interpret the required informationd Use the information obtained to ensure that work output meets the specificatione Deal promptly and effectively with any problems within your control and report

those which cannot be solvedf Report any inaccuracies or discrepancies in drawings and specifications


You must:1 Use approved sources to obtain the necessary drawings and related

specifications and carry out all of the following: • check the currency and validity of the drawings and documents used• exercise care and control over the documents at all times• correctly extract all necessary data in order to carry out the required tasks• seek out additional information where there are gaps or deficiencies in the

information obtained• deal with or report any problems found with the drawings/specifications• make valid decisions based on the evaluation of the engineering

information gained• return all drawings and related specifications to the approved location on

completion of the work• complete all necessary production documentation

2 Use information extracted from engineering drawings to include one or moretypes of drawing from the following:• detailed component drawings• general assembly drawings• repair drawings• fluid power drawings• wiring/circuit diagrams• installation drawings• modification drawings• sub-assembly drawings• schematic diagrams• fabrication drawings• welding drawings



3 Use information extracted from related documentation to include two from the following:• job instructions• drawing instructions• test schedules• manufacturers instructions• weld procedure specifications• reference tables/charts• national, international and organisational standards• planning documentation• quality control documents

4 Extract information that includes three of the following:• materials or components required• dimensions• tolerances• build quality• installation requirements• surface texture requirements• location/orientation of parts• process or treatments required• assembly sequence• weld type and size• operations required• connections to be made• circuit characteristics (such as pressure, flow, current, voltage, speed)

Knowledge statements:You must have knowledge and understanding of:1 The information sources used for the drawings and specifications that you use

in your work activities2 How drawings and documents are obtained and how to check that they are

current and valid3 How to use other sources of information to support the drawings (such as

electronic component pin configuration specifications, standard referencecharts for limits and fits, tapping drill reference charts, bend allowancesrequired for material thickness, electrical conditions required for specificwelding rods)

4 The procedures for reporting discrepancies in the drawings or documents andfor reporting lost or damaged drawings/documents

5 Care and control procedures for the drawings and documents and theimportance of returning them to the designated location on completion of thework activities

6 The basic drawing conventions that are used and why there needs to bedifferent types of drawings



7 The types of drawings used and how they interrelate (such as isometric andorthographic, first and third angle, assembly drawings, circuit and wiringdiagrams, block and schematic diagrams)

8 Imperial and metric systems of measurement, tolerancing and fixed reference points

9 The meaning of the different symbols and abbreviations found on the drawingsthat you use (such as surface finish, electronic components, weld symbols,linear and geometric tolerances, pressure and flow characteristics)

10 Care and control procedures for drawings and specifications and how damageor graffiti on drawings can lead to scrapped work

11 The extent of your own responsibility, when to act on your own initiative to find,clarify and evaluate information and whom you should report to if you haveproblems that you cannot solve





evidence type

date

necessary drawings & specifications (all)

check currency & validity

care & control

extract data

additional information

problems

decisions

return drawings etc

production documentation

information extracted from engineering drawings (one or more)

component

assembly

repair

fluid power

wiring/circuit

installation

modification

sub-assembly

schematic

fabrication

welding

information extracted from related documentation (two)

job instructions

drawing instructions

test schedules

manufacturers instructions

weld procedure spec’s

reference tables/charts

standards

planning docs

quality control docs



extract information (three)

materials/components

dimensions

tolerances

build quality

installation

circuit characteristics

surface texture

location/orientation of parts

process or treatments

assembly sequence

weld type/size

operations

connections


Candidate Date

Assessor Date





Unit summaryThis unit identifies the competencies you need to work efficiently and effectively inthe work place in accordance with approved procedures and practices. Prior toundertaking the engineering activity you will be required to carry out all necessarypreparations within the scope of your responsibility. This may include preparing thework area and ensuring that it is in a safe condition to carry out the intendedactivities, ensuring you have the appropriate job specifications and instructions, thatany tools, equipment, materials and other resources required are available and in asafe and usable condition.

On completion of the engineering activity you will be required to return yourimmediate work area to an acceptable condition before recommencing further workrequirements. This may involve placing completed work in the correct location,return and / or store any tools and equipment in the correct area, identifying anywaste and / or scrapped materials and arranging for their disposal, reporting anydefects or damage to tools and equipment used.

In order to be efficient and effective in the workplace you will also be required todemonstrate that you can create and maintain effective working relationships withcolleagues and line management, review objectives and targets for your personaldevelopment, contribute to and communicate any opportunities for improvementsthat could be made to working practices and procedures.

Your responsibilities will require you to comply with organisational policy andprocedures for the engineering activities undertaken and to report any problemswith the activities, or the tools and equipment that are used that you cannotpersonally resolve, or are outside your permitted authority, to the relevant people.You will be expected to take personal responsibility for your own actions and thequality and accuracy of the work that you carry out.

Your underpinning knowledge will provide a good understanding of your work, andprovide an informed approach to working efficiently and effectively in anengineering environment. You will understand the need to work efficiently andeffectively and its application, and will know about the areas you need to considerwhen preparing and tidying up the work area, how to contribute to improvements,deal with problems, maintain effective working relationships and agree yourdevelopment objectives and targets in adequate depth to provide a sound basis forcarrying out the activities safely and correctly. You will understand the safetyprecautions required when carrying out engineering activities. You will be requiredto demonstrate safe working practices throughout, and will understand theresponsibility you owe to yourself and others in the workplace.

Unit 3Working efficiently & effectively in engineering


Performance statements:You must:a Work safely at all times, complying with health and safety and other relevant

regulations and guidelinesb Prepare the work area to carry out the engineering activityc Check there are sufficient supplies of materials and/or consumables and that they

meet work requirementsd Ensure completed products or resources are stored in the appropriate location on

completion of the activitiese Tidy up the work area on completion of the engineering activityf Deal promptly and effectively with problems within you control and report those

that cannot be resolvedg Contribute and communicate opportunities for improvement to working practices

and proceduresh Maintain effective working relationships with colleaguesi Review personal training and development as is appropriate to the job role


You must:1 Prepare to carry out the engineering activity taking into consideration all of the

following as is applicable to the work to be undertaken:• the work area is free from hazards and suitably prepared for the activities

to be undertaken• any required safety procedures are implemented• any necessary personal protection equipment is obtained and is in a

usable condition• tools and equipment required are obtained and checked that they are in a safe

and useable condition• all necessary drawings, specifications and associated documentation

is obtained• job instructions are obtained and understood• the correct materials or components are obtained• storage arrangements for work are appropriate• appropriate authorisation to carry out the work is obtained

2 Complete work activities to include all of the following:• completing all necessary documentation accurately and legibly• returning tools and equipment• returning drawings and work instructions• identifying where appropriate any unusable tools, equipment and components• arranging for disposal of waste materials



3 Contribute to organisational procedures for identifying opportunities forimprovement to one of the following:• working practices• working methods• quality• safety• tools and equipment• suppliers• internal communication• customer service• training and development• teamwork• other

4 Deal with problems affecting the engineering process to include two of the following:• materials• tools and equipment• drawings• job specification• quality• people• timescales• safety• activities or procedures

5 Maintain effective working relationships to include two of the following:• colleagues within own working group• colleagues outside normal working group• line management• external contacts

6 Review personal development objectives and targets to include one of the following:• dual or multi skilling• training on new equipment / technology• increased responsibility• understanding of company working practices, procedures, plans and policies• other specific requirements



Knowledge statements:You must have a knowledge and understanding of:1 The safe working practices and procedures to be followed whilst preparing and

tidying up your work environment2 The correct use of any equipment used to protect the health and safety of you

and your colleagues3 The procedure for ensuring that all documentation relating to the work being

carried out is available and current prior to starting the activity4 The action that should be taken if documentation received is incomplete

and / or incorrect5 The procedure for ensuring all tools and equipment are available prior to

undertaking the activity6 The checks to be carried out to ensure tools and equipment are in full working

order prior to undertaking the activity7 The action that should be taken if tools and equipment are not in full working8 The checks to be carried out to ensure all materials required are correct and

complete prior to undertaking the activity9 The action that should be taken if materials do not meet the requirements

of the activity10 Who to inform when the work activity has been completed11 The information and / or documentation they require to confirm the activity has

been completed12 What materials, equipment and tools can be re-used13 How any waste materials and / or products are transferred, stored and

disposed of14 Where tools and equipment should be stored and located15 The importance of making a contribution to improving working practices16 The procedure and format for making suggestions for improvements17 What the benefits are to you and the organisation if improvements can

be identified18 The importance of maintaining effective working relationships within

the workplace19 The procedures to deal with and report any problems that can affect

working relationships20 The type of difficulties that can occur in working relationships21 The regulations that affect how you should be treated at work (such as Equal

Opportunities Act, Race and Sex Discrimination, Working Time Directive)22 The benefits of continuous personal development23 The training opportunities that are available in the workplace24 The importance of why your training and development should be reviewed25 Who to discuss training and development issues with26 The extent of your own responsibility and whom you should report to if you

have any problems that you cannot resolve





evidence type

date

preparation for engineering activity (all)

work area free of hazards

safety procedures

PPE

tools/equipment

drawings/specs/docs

job instructions

materials/components

storage

authorisation

work activities (all)

necessary docs

return tools/equipment

return drawings

unusable tools/components

waste materials

identify opportunities for improvement (one)

working practices

working methods

quality

safety

tools/equipment

suppliers

internal communication

customer service

training/development

teamwork

other



problems affecting engineering process (two)

materials

tools/equipment

drawings

job specification

quality

people

timescales

safety

activities/procedures

maintain effective working relationships (two)

own working group

outside own working group

line management

external contacts

personal development objectives (one)

dual or multi-skilling

new equipment/technology

responsibility

company working policies

other


Candidate Date

Assessor Date





Unit summaryThis unit identifies the competencies you need to prepare and operate manual metalarc welding equipment, in accordance with instructions and/or approved weldingprocedures. You will be required to check that all the workholding equipment andmanipulating devices required are available and in a usable condition. You will beexpected to check the welding equipment to ensure that all the leads/cables,electrode holder and workpiece earthing arrangements are securely connected andfree from damage. In preparing to weld, you will need to set and adjust the weldingconditions in line with the instructions or welding procedure specification. You mustoperate the equipment safely and correctly, and make any necessary adjustments tosettings in line with your permitted authority, in order to produce the welded jointsto the required specification.

Your responsibilities will require you to comply with organisational policy andprocedures for the welding activities undertaken, and to report any problems withthe welding equipment, or welding activities that you cannot resolve, or are outsideyour permitted authority, to the relevant people. You will be expected to work toinstructions, with a minimum of supervision, taking personal responsibility for yourown actions and for the quality and accuracy of the work that you carry out.

Your underpinning knowledge will be sufficient to provide a sound basis for yourwork, and will provide an understanding of how the manual metal arc process works.You will know about the equipment, materials and consumables, in adequate depthto provide a sound background for the welding operations to be performed, and forensuring the work output is produced to the required specification.

You will understand the safety precautions required when working with the welding equipment. You will be required to demonstrate safe working practicesthroughout, and will understand the responsibility you owe to yourself and others in the workplace.

Unit 4Joining materials by the manual metal arc welding process



regulations and guidelinesb Follow the relevant joining procedure and job instructionsc Check that the joint preparation complies with the specificationd Check that joining and related equipment and consumables are as specified and

fit for purposee Make the joints as specified using the appropriate thermal joining techniquef Produce joints of the required quality and of specified dimensional accuracyg Shut down the equipment to a safe condition on completion of joining activitiesh Deal promptly with excess and waste materials and temporary attachments, in

line with approved and agreed proceduresi Deal promptly and effectively with problems within your control and report those

that cannot be solved


You must:1 Set up, check, adjust and use manual metal arc welding and related equipment, to

include either:• alternating current (AC) equipment• direct current (DC) equipment

2 Use two types of electrode from the following, including two different sizes ofeach chosen type:• rutile• basic• nickel alloy• cellulosic• stainless steel• other electrodes

3 Produce welded joints which incorporate both:• Fillet welds• Butt welds



4 Produce joints in one form of specified material from the following:• plate• section• pipe/tube• other forms

5 Weld joints according to approved welding procedures, in good access situationsin two of the following BS EN287 positions:• Flat (PA)• Horizontal vertical (PB)• Horizontal (PC)• Vertical upwards (PF)• Vertical downwards (PG)

6 Produce welded components which:• achieve a minimum weld quality equivalent to the level given in the relevant

European / International Standard (eg, EN 25817 / ISO 5187 and EN 30042 / ISO10042) required by the application standard or specification

• meet the required dimensional accuracy within specified tolerances

Knowledge statements:You must have knowledge and understanding of:1 The safe working practices and procedures to be observed when working with

MMA welding equipment (general workshop and site safety; appropriatepersonal protective equipment; fire prevention; protecting other workers fromstray arcs; safety in enclosed/confined spaces; fume control; accidentprocedure; statutory requirements, risk assessment procedures and relevantrequirements of HASAWA, COSHH and Work Equipment Regulations; safedisposal of waste materials)

2 The hazards associated with MMA welding (live electrical components; poorearthing; the electric arc; fumes and gases; spatter; hot slag and metal;grinding and mechanical metal/slag removal; elevated working; enclosedspaces; slips, trips and falls), and how they can be minimised

3 The manual metal arc welding process (basic principles of fusion welding, AC and DC power sources, ancillary equipment; care of equipment;consumables; power ranges)

4 Types of electrodes; correct control, storage and drying of electrodes5 The types of welded joints to be produced (fillet and butt welds, single and

multi-run welds, joints in pipe, plate and sections, welding positions)6 Setting up and restraining the joint (the use of jigs and fixtures, manipulators

and positioners, restraining devices, tack welding size and spacing inrelationship to material thickness)

7 Checks to be made prior to welding (confirming correct set-up of joint andcleanliness of materials; condition of electrical connections, power return andearthing arrangements; operating parameters; calibration before use; care andmaintenance of equipment)



8 The techniques of operating the welding equipment to produce a range ofjoints in the various joint positions (fine tuning parameters; correctmanipulation of electrode; safe closing down of the welding equipment)

9 The importance of complying with the job instructions and the weldingprocedure specification

10 Problems that can occur with the welding activities and how these can beovercome (causes of distortion and methods of control; effects of welding onmaterials and sources of weld defects; methods of prevention)

11 The organisational quality control systems used, and weld standards to be achieved

12 Weld inspection and test procedures used (including destructive and non-destructive methods)

13 Personal approval tests and their applicability to your work14 The extent of your own authority and whom you should report to if you have

problems that you cannot resolve15 Reporting lines and procedures, line supervision and technical experts





evidence type

date

set up, check, adjust and use manual metal arc welding and related equipment (either)

alternating current (AC) equipment

direct current (DC) equipment

use two types of electrode from the following, including two different sizes of each chosen type

rutile

basic

nickel alloy

cellulosic

stainless steel

other electrodes

produce welded joints which incorporate both

fillet welds

butt welds

produce joints in one form of specified material from the following

plate

section

pipe/tube

other forms

weld joints according to approved welding procedures, in good access situations in the following BS EN287 positions (two)

flat (PA)

horizontal vertical (PB)

horizontal (PC)

vertical upwards (PF)

vertical downwards (PG)



produce welded components which:

achieve a minimum weld qualityequivalent to the level given in therelevant European/InternationalStandard (eg, EN 25817/ISO 5187 andEN 30042/ISO 10042) required by theapplication standard or specification

meet the required dimensionalaccuracy within specified tolerances


Candidate Date

Assessor Date





Unit summaryThis unit identifies the competencies you need to prepare and operate manual MIG,MAG or cored-wire arc welding equipment, in accordance with instructions and/orapproved welding procedures. You will be required to check that all the workholdingequipment and manipulating devices required are available and in a usablecondition. You will be expected to check the welding equipment to ensure that all theleads/cables, shielding gas system, hoses and wire feed mechanisms are securelyconnected and free from damage. In preparing to weld, you will need to set andadjust the welding conditions, in line with the instructions or welding procedurespecification. You must operate the equipment safely and correctly and make anynecessary adjustments to settings, in line with your permitted authority, in order toproduce the welded joints to the required specification.


Your underpinning knowledge will be sufficient to provide a sound basis for yourwork, and will provide an understanding of how the MIG, MAG or cored-wire arcwelding process works. You will know about the equipment, materials andconsumables, in adequate depth to provide a sound background for the weldingoperations to be performed, and for ensuring the work output is produced to therequired specification.

You will understand the safety precautions required when working with the welding equipment. You will be required to demonstrate safe working practicesthroughout and will understand the responsibility you owe to yourself and others in the workplace.

Unit 5Joining materials by the manual MIG/MAG and other continuous wire processes








You must:1 Set up, check, adjust and use welding and related equipment for one of the

following welding processes:• MIG• MAG• cored wire

2 Use consumables appropriate to the material and application, to include both ofthe following:• two wire types from different material groups• two different shielding gases (where applicable)

3 Produce welded joints which incorporates both:• Fillet welds• Butt welds

4 Produce joints in one form of specified material from the following:• plate• section• other forms• pipe/tube• sheet (<3mm)



5 Weld joints according to approved welding procedures, in good access situations,in two of the following BS EN287 positions:• Flat (PA):• Horizontal vertical (PB)• Horizontal (PC)• Vertical upwards (PF• Vertical downwards (PG)



• meet the required dimensional accuracy within specified tolerance


MIG, MAG or cored wire arc welding equipment (general workshop and sitesafety; appropriate personal protective equipment; fire prevention; protectingother workers from the effects of the welding arc; safety in enclosed/confinedspaces; fume control; accident procedure; statutory requirements, riskassessment procedures and relevant requirements of HASAWA, COSHH andWork Equipment Regulations; safe disposal of waste materials)

2 The correct handling and storage of gas cylinders (manual handling and use ofcylinder trolley, leak detection procedures, relevant BCGA codes of practice,cylinder identification, gas pressures, cylinder and equipment safety features,emergency shutdown procedures)

3 The hazards associated with arc welding (live electrical components; poorearthing; the electric arc; fumes and gases; gas supply leaks; spatter, hot slagand metal; elevated working; enclosed spaces; slips, trips and falls), and howthey can be minimised

4 The manual MIG, MAG or cored wire arc welding process (basic principles offusion welding, AC and DC power sources, ancillary equipment, power ranges,care of equipment)

5 The consumables associated with MIG, MAG or cored wire arc welding (types ofwire and their application (solid and cored), types of shielding gas and theirapplication, gas supply and control)

6 The types of welded joints to be produced (fillet and butt welds, single andmulti-run welds, joints in pipe, plate, sheet and sections; welding positions)

7 Setting up and restraining the joint (the use of jigs and fixtures, manipulatorsand positioners, restraining devices, tack welding size and spacing inrelationship to material thickness)

8 Preparing the welding equipment and checks that need to be made to ensurethat it is safe and ready to use (electrical connections, power return andearthing arrangements; wire feed mechanisms, gas supply, setting weldingparameters, correct joint set-up, cleanliness of materials used; calibrationbefore use; routine care and maintenance of equipment)



9 The techniques of operating the welding equipment to produce a range ofjoints in the various joint positions (fine tuning parameters, correctmanipulation of the welding gun, safe closing down of the welding equipment)

10 The importance of complying with job instructions and the welding procedure specification

11 Problems that can occur with the welding activities and how these can beovercome (causes of distortion and methods of control, effects of welding onmaterials and sources of weld defects; methods of prevention)

12 The organisational quality systems used and weld standards to be achieved; weld inspection and test procedures used (including visual and non-destructive tests)

13 Personal approval tests, and their applicability to your work14 The extent of your own authority and whom you should report to if you have






evidence type

date

set up, check, adjust and use welding and related equipment for welding process (one)

MIG

MAG

cored wire

use consumables appropriate to the material and application, to include (both)

two wire types from different materialgroups

two different shielding gases (whereapplicable)

produce welded joints which incorporate (both)

fillet welds

butt welds


plate

section

pipe/tube

sheet (<3mm)

other forms

weld joints according to approved welding procedures, in good access situations in BS EN287 positions (two)

flat (PA)


horizontal (PC)





produce welded components which (all)




Candidate Date

Assessor Date





Unit summaryThis unit identifies the competencies you need to prepare and operate manual TIG orPlasma-arc welding equipment, in accordance with instructions and/or approvedwelding procedures. You will be required to check that all the workholdingequipment and manipulating devices required are available and in a usablecondition. You will be expected to check the welding equipment to ensure that all theleads/cables, hoses and torch are securely connected and free from damage. Inpreparing to weld, you will need to set and adjust the welding conditions, in line withthe instructions or welding procedure specification. You must operate theequipment safely and correctly and make any necessary adjustments to settings, inline with your permitted authority, in order to produce the welded joints to therequired specification.


Your underpinning knowledge will be sufficient to provide a sound basis for yourwork, and will provide an understanding of how the TIG or Plasma-arc weldingprocess works. You will know about the equipment, materials and consumables, in adequate depth to provide a sound background for the welding operations to be performed, and for ensuring the work output is produced to the required specification.


Unit 6Joining materials by the manual TIG and plasma-arcwelding processes








You must:1 Set up, check, adjust and use manual welding and related equipment for one of

the following welding processes:• TIG• Plasma-arc

2 Use consumables appropriate to the material and application, to include bothof the following:

• one size of electrode• two types of filler wire from different material groups

3 Produce welded joints which incorporate the following:• butt weldsand• fillet welds OR welds made autogenously (without filler wire)

4 Produce joints in one form of specified materials from the following:• plate• section• other forms• pipe/tube• sheet (<3mm)



5 Weld joints according to approved welding procedures, in good access situations,in two of the following BS EN287 positions:• Flat (PA):• Horizontal (PC)• Vertical upwards (PF• Horizontal vertical (PB)• Vertical downwards (PG)





TIG or Plasma-arc welding equipment (general workshop and site safety;appropriate personal protective equipment; fire prevention; protecting otherworkers from the effects of the electric arc; safety in enclosed/confined spaces;fume control; accident procedure; statutory requirements, risk assessmentprocedures and relevant requirements of HASAWA, COSHH and WorkEquipment Regulations; safe disposal of waste materials)

2 The hazards associated with arc welding (live electrical components; poorearthing arrangements; the electric arc; fumes and gases; gas supply leaks;spatter; hot slag and metal; grinding and mechanical metal/slag removal;elevated working; enclosed spaces; slips, trips and falls), and how they can be minimised


4 The manual TIG or Plasma-arc welding process (basic principles of fusionwelding; power sources; ancillary equipment; power ranges; arc initiationsystem; care and maintenance of equipment)

5 The consumables associated with TIG or Plasma-arc welding (types of filler wire,types of shielding gas, welding electrodes, gas supply and control, control andstorage of consumables)

6 The types of welded joints to be produced (fillet and butt welds, single andmulti-run welds, joints in pipe plate, sheet and sections; welding positions)

7 Setting up and restraining the joint (confirming correct set-up of joint;cleanliness of materials used; the use of jigs and fixtures, manipulators andpositioners, restraining devices; tack welding size and spacing in relationship to material thickness)

8 Preparing the equipment, and checks that need to be made to ensure that it issafe to use (condition of electrical connections, power return and earthingarrangements, operating parameters)



9 The techniques of operating the welding equipment to produce a range ofjoints in the various joint positions (fine tuning parameters, correctmanipulation of torch, safe closing down of the welding equipment)










evidence type

date

set up, check, adjust and use manual welding and related equipment for welding process (one)

TIG

plasma arc

use consumables appropriate to the material and application, to include (both)

one size of electrode

two types of filler wire from differentmaterial groups


fillet welds

butt welds or welds madeautogenously (without filler wire)


plate

section

pipe/tube

sheet (<3mm)

other forms

weld joints according to approved welding procedures, in good access situations in BS EN287 positions (two)

flat (PA)


horizontal (PC)





produce welded components which: (both)




Candidate Date

Assessor Date





Unit summaryThis unit identifies the competencies you need to prepare and operate gas-weldingequipment, in accordance with instructions and/or approved welding procedures.You will be required to check that all the workholding and manipulating devicesrequired are available and in a usable condition. You will be expected to check thewelding equipment to ensure that the regulators, hoses, flashback arrestor andwelding torch are securely connected and are free from leaks or damage. Inpreparing to weld, you will need to set and adjust the gas pressures/weldingconditions, in line with the instructions or welding procedure specification. You mustoperate the equipment safely and correctly and make any necessary adjustments tosettings, in line with your permitted authority, in order to produce the welded jointsto the required specification.


Your underpinning knowledge will be sufficient to provide a sound basis for yourwork, and will provide an understanding of how the gas welding process works. Youwill know about the equipment, materials and consumables, in adequate depth toprovide a sound background for the welding operations to be performed, and forensuring the work output is produced to the required specification.


Unit 7Joining materials by the manual gas welding process








You must:1 Prepare the gas welding equipment for use, to include all of the following:

• checking regulators, hoses and valves are securely connected and free fromleaks and damage

• checking/fitting the correct gas nozzle to the torch• checking that a flashback arrestor is fitted• setting appropriate gas pressures• using the correct procedure for lighting, adjusting and extinguishing the

welding flame• using appropriate and safe procedures for handling an storing of gas cylinders

2 Use a range of filler wire, to include both of the following:• two different sizes• two different material groups

3 Produce welded joints which incorporate the following:• Butt weldsand• Fillet welds OR• welds made autogenously (without filler wire)



4 Produce joints in one form of specified materials from the following:• plate• section• other forms• pipe/tube• sheet (<3mm)

5 Weld joints according to approved welding procedures, and in good accesssituations, in two of the following BS EN287 positions:• Flat (PA)• Horizontal (PC)• Horizontal vertical (PB)• Vertical upwards (PF)• Vertical downwards (PG)





gas welding equipment (general workshop and site safety, appropriate personalprotective equipment, fire and explosion prevention, protecting other workers,safety in enclosed/confined spaces; fume control; accident procedure;statutory regulations; risk assessment procedures and relevant requirementsof HASAWA, COSHH and Work Equipment Regulations; safe disposal of waste materials)


3 The hazards associated with gas welding (naked flames, fumes and gases,explosive gas mixtures, oxygen enrichment, spatter, hot slag and metal,grinding and mechanical slag removal, elevated working, enclosed spaces, slipstrips and falls), and how they can be minimised

4 The gas welding process (basic principles of gas welding and relatedequipment; care of the equipment)

5 The consumables associated with gas welding (types of filler wire, fluxes, gassupply and control)

6 The types of welded joints to be produced (fillet and butt welds, single andmulti-run welds, welding positions, joints in sheet, pipe and plate)

7 Setting up and restraining the joint (the use of jigs/fixtures, manipulators andpositioners, restraining devices, tack welding size and spacing in relationship tomaterial thickness, correct joint set-up, cleanliness of materials used)



8 Preparing the welding equipment, and checks that need to be made to ensurethat it is safe and ready to use (connection of hoses, torch, flashback arrestors,hose check valves, regulators, connections for leaks, setting welding parameters)

9 The techniques of operating the welding equipment to produce a range ofjoints in the various joint positions (selection of nozzle, flame adjustment,correct manipulation of torch and filler rods, safe closing down of the welding equipment)










evidence type

date

prepare the gas welding equipment for use (all)

checking regulators /hoses /valvessecurely connected free from leaks anddamage

checking/fitting the correct gas nozzle

checking that a flashback arrestor isfitted

setting appropriate gas pressures

using correct procedure for lighting,adjusting and extinguishing weldingflame

using appropriate/safe procedures forhandling storing of gas cylinders

use a range of filler wire (both)

two different sizes

two different material groups


fillet welds

butt welds or welds madeautogenously


plate

section

pipe/tube

sheet (<3mm)

other forms



weld joints to approved welding procedures, in good access situations in BS EN287 positions (two)

flat (PA)


horizontal (PC)




achieve a minimum weld qualityequivalent to the level in relevantStandard (eg, EN 25817/ISO 5187 EN30042/ISO 10042)

meet required dimensional accuracywithin tolerances


Candidate Date

Assessor Date





Unit summaryThis unit identifies the competencies you need to produce fillet welds in plate, sheetor sections, and/or fillet welded joints in pipe/tube, using a manual welding processsuch as manual metal arc, MIG, MAG, TIG, flux- cored wire, inert shield or gas weldingequipment, in accordance with instructions and/or approved welding procedures.You will be required to check that all the workholding equipment and manipulatingdevices required are available and in a usable condition. You will be expected tocheck the welding equipment to ensure that all the leads/cables, hoses and wire feedmechanisms are securely connected and free from damage.

In preparing to weld, you will need to set and adjust the welding conditions, in linewith the instructions or welding procedure specification. You must operate theequipment safely and correctly and make any necessary adjustments to settings, inline with your permitted authority, in order to produce the welded joints to therequired specification. You will be required to demonstrate your capability toproduce the fillet welds of the required quality, and this could be through testsaccording to BS 4872 or EN 287.

Your responsibilities will require you to comply with organisational policy andprocedures for the welding activities undertaken, and to report any problems withthe welding equipment, or welding activities that you cannot resolve, or are outsideyour permitted authority, to the relevant people. You will be expected to work toinstructions, with a minimum of supervision, taking personal responsibility for yourown actions and for the quality and accuracy of the work that you produce.

Your underpinning knowledge will be sufficient to provide a sound basis for yourwork, and will provide an understanding of how the particular welding processworks. You will know about the equipment, materials and consumables, in adequatedepth to provide a sound background for the welding operations to be performed,and for ensuring the work output is produced to the required specification.

You will understand the safety precautions required when working with the weldingequipment. You will be required to demonstrate safe working practices throughout,and will understand the responsibility you owe to yourself and others in the workplace.

Unit 8Producing fillet welded joints using a manual welding process









following welding processes:• Manual Metal Arc• MIG/MAG• TIG• Plasma Arc• Cored wire• Gas welding

2 Use consumables as specified in the welding procedure specification, covering either:• two types of electrode from:• rutile• basic• cellulosic• nickel alloy• stainless steel• otherOR• two types of filler wire from different material groups



3 Produce fillet welded joints in two of the following forms of material:• plate• sections• pipe/tube• sheet• other

4 Weld joints according to approved welding procedures, in good access situations,in two of the following BS EN287 positions:• Flat (PA)• Horizontal (PC)• Horizontal Vertical (PB)• Vertical Upwards (PF)• Vertical Downwards (PG)• Overhead (PE or PD)




Knowledge statements:You must have knowledge and understanding (as applicable to the weldingprocess selected) of:1 The safe working practices and procedures to be observed when working with

the selected welding equipment (general workshop and site safety, appropriatepersonal protective equipment, fire prevention, protecting other workers from‘arc eye’, safety in enclosed/confined spaces; fume control; accidentprocedure; statutory requirements, risk assessment procedures and relevantrequirements of HASAWA, COSHH and Work Equipment Regulations; safedisposal of waste materials)


3 The hazards associated with the selected welding process (live electricalcomponents, poor earthing, arc radiation, fumes and gases, gas supply leaks,spatter, hot slag and metal, grinding and mechanical metal/slag removal;elevated working, enclosed spaces, slips, trips and falls), and how they can be minimised

4 The manual welding process selected and an awareness of the different typesof welding equipment (basic principles of fusion welding, AC and DC powersources, ancillary equipment, power ranges, care of equipment, terminologyused in welding, flame setting)



5 Extracting information required from drawings and welding procedurespecifications (interpretation of welding symbols, scope, content andapplication of the welding procedure specification)

6 The consumables associated with the chosen welding process (types ofelectrodes and/or filler metal and their application; types of shielding gas andtheir application, gas supply and control; correct control, storage and drying ofelectrodes and filler wire)

7 The types and features of welded joints in pipe (fillet and butt welds, single andmulti-run welds, welding positions, weld quality)

8 Methods of setting up and restraining the joint to achieve correct location ofcomponents and control of distortion (edge preparation, use of jigs andfixtures, manipulators and positioners, tack welding size and spacing inrelationship to material thickness and component size, use of temporaryattachments, pre-setting)

9 Preparing the welding equipment, and checks that need to be made to ensurethat it is safe and ready to use (electrical connections, power return andearthing arrangements; equipment calibration before use, setting weldingparameters, care and maintenance of the equipment)

10 The techniques of operating the welding equipment to produce a range ofjoints in the various joint positions (fine tuning parameters, correctmanipulation of the welding gun or electrode, safe closing down of the welding equipment)


12 Problems that can occur with the welding activities, and how these can beovercome (causes of distortion and methods of control, effects of welding onmaterials and sources of weld defects; methods of prevention)



problems that you cannot resolve





evidence type

date

set up, check, adjust and use welding and related equipment for welding process (one)

manual metal arc

MIG/MAG

TIG

plasma arc

cored wire

gas welding

use consumables as specified in the welding procedure specification, covering (either)

two types of electrode from

rutile

basic

cellulosic

nickel alloy

stainless steel

other

or


produce fillet welded joints in forms of material (two)

plate

section

pipe/tube

sheet (<3mm)

other forms



weld joints to approved welding procedures, in good access situations in BS EN287 positions (two)

flat (PA)


horizontal (PC)



Overhead (PE or PD)


achieve a minimum weld qualityequivalent to the level in relevantStandard (eg, EN 25817/ISO 5187 EN30042/ISO 10042)

meet required dimensional accuracywithin tolerances


Candidate Date

Assessor Date





Unit summaryThis unit identifies the competencies you need to operate one type of mechanisedMIG/MAG, cored wire, submerged arc, TIG, or plasma arc welding installation, whichhas already been prepared for production, in accordance with approved instructionsor welding procedures. You will be expected to check that the equipment has beenapproved for production, and that sufficient supplies of all the required materials and consumables are present and correct, and ready for production operations tobe performed.

You must operate the installation safely and correctly, in accordance withinstructions and approved procedures, and achieve a weld quality and tolerancesthat meet the product specification. The production output may be inspected byvisual and non-destructive testing methods, to check that the specified quality isbeing achieved. You must continuously monitor the operation of the installation andmake any necessary adjustments to equipment settings, in line with your permittedauthority, in order to produce the welded joints to the required specification.Meeting production requirements will be an important issue, and your productionrecords must show consistent and satisfactory performance.

Your responsibilities will require you to comply with organisational policy andprocedures for operating the welding installation, and to report any problems oradjustments to the installation that you cannot resolve, or are outside yourpermitted authority, to the relevant people. You will be expected to work toinstructions, with a minimum of supervision, taking personal responsibility for yourown actions and for the quality and accuracy of the work that you produce.

Your underpinning knowledge will be sufficient to provide a sound basis for yourwork, enabling you to adopt an informed approach to applying welding proceduresand instructions. You will have an understanding of how the welding process worksand is applied in mechanised form, and will know about the equipment, materialsand consumables, in adequate depth to provide a sound background to the processoperation and for carrying out the welding activities to the required specification.

You will understand the safety precautions required when working with the machineand its associated tools and equipment. You will be required to demonstrate safeworking practices throughout, and will understand the responsibility you owe toyourself and others in the workplace.

Unit 9Welding materials with mechanised arc welding equipment



regulations and guidelinesb Follow the relevant joining procedure and work instructionsc Confirm that the machine is set up and operating correctly, ready for the joining

operations to be carried outd Check that the parent material, components, consumables and joint preparation

comply with specificationse Carry out and monitor the machine operations in accordance with specifications

and job instructionsf Achieve joints of the required quality and specified dimensional accuracyg Make sure that the rate of output is as specifiedh Deal promptly and effectively with problems within your control and report those

that you cannot solvei Shut down the equipment to a safe condition on conclusion of the joining activities


You must:1 Confirm that the installation is ready for production operations, to include

checking all of the following:• the installation has been approved for production• supplies of components and consumables are adequate and correctly prepared• machine settings comply with instructions and the welding

procedure specification• all machine functions operate correctly• all safety equipment is in place and functioning correctly

2 Operate one of the following mechanised arc welding processes in the specifiedmaterials, forms and positions:• MIG/MAG• cored wire• TIG• submerged arc• plasma arc

3 Produce welded components covering both of the following:• two different joint configurations• two different material groups



4 Monitor the process operation and machine functions, and make adjustments asrequired to parameters and mechanisms within your permitted authority andtolerances, to include adjusting all of the following:• electrical parameters• welding speed• flux dispensing and recovery mechanisms• safety devices• wire feed rate• gas shielding system• mechanical functions (handling, loading, workholding, transfer)

5 Produce welded components which:• achieve a weld quality equivalent to the relevant level of EN 25817/ISO 5817,

as required by the application standard (for aluminium, EN 30042/ISO 10042 applies)

• meet the required dimensional accuracy within specified tolerances

Knowledge statements:You must have knowledge and understanding of:1 The safe working practices and procedures to be observed when operating

mechanised arc welding installations (working with machinery; the use ofpersonal protective equipment; protecting others from the effects of theelectric arc; appropriate machine guards; operation of machine safety devices;stopping the machine in an emergency; closing the machine down oncompletion of activities; statutory requirements, risk assessment proceduresand relevant requirements of HASAWA, COSHH and Work EquipmentRegulations; safe disposal of waste materials)

2 The hazards associated with arc welding machines (dangers from the electricarc; live electrical components; fumes and gases; hot metal; grinding andmechanical metal/slag removal; moving parts of machinery), and how they canbe minimised

3 The principles of mechanised and automated welding (types of installations;machine functions; control systems; safety features)

4 The key components and features of the equipment used (power source;electrical parameters such as arc voltage, current, wire dispensing and feedmechanisms; flux dispensing and recovery; shielding gas supply; control andstorage of consumables; how variations in the parameters influence weldfeatures, quality and output)

5 Extracting the necessary information from drawings and welding procedurespecifications; welding symbols and abbreviations used

6 Operation of the machine controls and their function; care of equipment7 Setting up and aligning the workpiece, and the equipment to be used8 Monitoring the installation during the welding process; recognition of problems

and action to be taken9 Problems that can occur with the welding activities (distortion, material and

weld defects)



10 Self inspection of completed work, methods and equipment to be used11 Organisational quality systems (standards to be achieved; production records

to be kept)12 Personal approval tests and their applicability to your work13 The extent of your own authority and whom you should report to if you have






evidence type

date

Confirm that the installation is ready for production operations, to include checking all of the following:

the installation has been approved forproduction

supplies of components andconsumables are adequate andcorrectly prepared

machine settings comply withinstructions and the welding procedurespecification

all machine functions operate correctly

all safety equipment is in place andfunctioning correctly

Operate one of the following mechanised arc welding processes in the specified materials, forms and positions:

MIG/MAG

cored wire

TIG

submerged arc

plasma arc

Produce welded components covering both of the following:

two different joint configurations


Monitor the process operation and machine functions, and make adjustments as required to parameters and mechanisms within your permitted authority and tolerances, to include adjusting all of the following:

electrical parameters

welding speed

flux dispensing and recoverymechanisms

safety devices

wire feed rate

gas shielding system

mechanical functions (handling,loading, workholding, transfer)



Produce welded components which:

achieve a weld quality equivalent to therelevant level of EN 25817/ISO 5817, asrequired by the application standard(for aluminium, EN 30042/ISO 10042applies)



Candidate Date

Assessor Date





Unit summaryThis unit identifies the competencies you need to operate resistance spot, seam orprojection welding installations, which have already been prepared for production,in accordance with approved instructions or welding procedures. You will beexpected to check that the installation has been approved for production, and thatsufficient supplies of all required materials and consumables are present andcorrect, and ready for production operations to be performed.


Your responsibilities will require you to comply with organisational policy andprocedures for operating the welding installation, and to report any problems oradjustments to the installation that you cannot resolve, or are outside yourpermitted authority, to the relevant people. You will be expected to work toinstructions, with a minimum of supervision, taking personal responsibility for yourown actions and for the quality and accuracy of the work that you produce.

Your underpinning knowledge will provide a sound basis for your work, enabling youto adopt an informed approach to applying welding procedures and instructions.You will have an understanding of how the resistance welding process works and isapplied in mechanised form, and will know about the equipment, materials andconsumables, in adequate depth to provide a sound background to the processoperation and for carrying out the activities to the required specification.


Unit 10Welding materials using resistance spot, seam andprojection welding machines









You must:1 Confirm that the installation is ready for operation, to include checking all of the

following:• the installation has been approved for production• supplies of components and consumables are adequate and correctly prepared• machine settings comply with instructions and the welding procedure specification• all machine functions operate correctly• all safety equipment is in place and functioning correctly

2 Operate one of the following resistance welding installations:• spot welding• seam welding• projection welding

3 Produce welded components in the specified materials and forms that cover bothof the following:• two different material thicknesses• two different joint configurations



4 Monitor the process operation, electrode condition and machine function andmake adjustments to required parameters and mechanisms, to include all of thefollowing as appropriate to the machine type:• welding current• welding and squeeze times• electrode pressure cycle• welding speed (seam)• weld pitch (spot)• mechanical functions

5 Produce welded components which:• achieve a weld quality as specified in the application standard• spot and projection welds are correctly located• seam welds are of the correct dimensions• meet the required dimensional accuracy within specified tolerance

Knowledge statements:You must have knowledge and understanding of:1 The specific safety precautions to be taken when operating resistance welding

installations (working with machinery; the use of appropriate personalprotective equipment machine guards; operation of machine safety devices;stopping the machine in an emergency; closing down the machine oncompletion of the welding activities; statutory requirements, risk assessmentprocedures and relevant requirements of HASAWA, COSHH and WorkEquipment Regulations; safe disposal of waste materials)

2 The hazards associated with resistance welding machines (dangers from liveinternal electrical components, fumes, hot metal, expulsion of hot particles,moving parts of machines), and how they can be minimised

3 The basic principles of resistance welding; terminology used in welding4 Mechanised and automated welding basics (types of installation; machine

functions; control systems; safety features)5 The key components and features of the equipment used (power source;

electrical parameters such as arc voltage, current, electrode pressure andwelding time; systems for parameter control; how variation in the parametersinfluence weld features, quality and output)

6 Extracting the information required from drawings and welding procedure specifications

7 Operation of the machine controls and their function; clamping and transfer ofcomponents; equipment care procedures

8 Setting up and aligning the workpiece9 Monitoring the installation during the welding process; recognition of

problems, and action to be taken10 Problems that can occur with the welding activities, materials and weld defects11 Self inspection of completed work



12 Organisational quality systems (standards to be achieved; production recordsto be kept)







evidence type

date

Confirm that the installation is ready for operation, to include checking all of the following:






Operate one of the following resistance welding installations:

spot welding

seam welding

projection welding

Produce welded components in the specified materials and forms that cover both of the following:

two different material thicknesses


Monitor the process operation, electrode condition and machine function and make adjustments to required parameters and mechanisms, to include all of the following as appropriate to the machine type:

welding current

welding and squeeze times

electrode pressure cycle

welding speed (seam)

weld pitch (spot)

mechanical functions




achieve a weld quality as specified inthe application standard

spot and projection welds are correctlylocated

seam welds are of the correctdimensions

meet the required dimensionalaccuracy within specified tolerance


Candidate Date

Assessor Date





Unit summaryThis unit identifies the competencies you need to operate laser welding installationsthat have already been prepared for production, in accordance with approvedinstructions or welding procedures. You will be expected to check that theinstallation has been approved for production and that sufficient supplies of allrequired materials and consumables are present and correct, and ready forproduction operations to be performed.

You must operate the installation safely and correctly, in accordance withinstructions and approved procedures, and achieve a weld quality and tolerancesthat meet the product specification. The production output may be inspected byvisual and non-destructive testing methods to check that the specified quality isbeing achieved. You must continuously monitor the operation of the installation andmake any necessary adjustments to equipment settings, in line with your permittedauthority, in order to produce the welded joints to the required specification.Meeting production requirements will be an important issue, and your productionrecords must show consistent and satisfactory performance.

Your responsibilities will require you to comply with organisational policy andprocedures for operating the welding installation, and to report any problems oradjustments to the installation that you cannot resolve, or are outside yourpermitted authority, to the relevant people. You will be expected to work toinstructions, with a minimum of supervision, taking personal responsibility for yourown actions and for the quality and accuracy of the work that you carry out.

Your underpinning knowledge will be sufficient to provide a sound basis of your work,enabling you to adopt an informed approach to applying welding procedures andinstructions. You will have an understanding of how the laser welding process worksand is applied in mechanised form, and will know about the equipment, materials andconsumables, in adequate depth to provide a sound background to the processoperation and for carrying out the activities to the required specification.


Unit 11Welding materials using laser welding machines









You must:1 Confirm that the installation is ready for operation, to include checking all

of the following:• the installation has been approved for production• supplies of components and consumables are adequate and correctly prepared• machine settings comply with instructions and the welding


2 Produce welded components covering both of the following:• two different components• two different material groups

3 Monitor the process operation and machine function and make adjustments asrequired to parameters and mechanisms, to include all of the following, asappropriate to the machine type:• electrical parameters• welding speed• weld alignment and characteristics• beam tracking• beam characteristics (focal spot)• gas shielding (where applicable)• mechanical mechanisms for workholding, traversing and transfer



4 Produce welded components which:• achieve a weld quality equivalent to the relevant level of EN/ISO 13919, as

required by the application standard• meet the required dimensional accuracy within specified tolerances


laser welding installations (working with machinery; care when working withlaser beams; the use of appropriate personal protective equipment; protectingother workers; machine guards; operation of machine safety devices; stoppingthe machine in an emergency; closing the machine down on completion ofactivities; statutory requirements, risk assessment procedures and relevantrequirements of HASAWA, COSHH and Work Equipment Regulations; safedisposal of waste materials)

2 The hazards associated with laser welding machines (dangers from the laserbeam; live electrical components; fumes and gases; hot metal; moving parts ofmachinery), and how they can be minimised

3 Principles of laser welding; terminology used in welding4 The key components and features of the equipment (types of laser beam

generators, beam characteristics, power ranges; beam guiding and focussingarrangements; power sources; materials and thickness capabilities; facilities formanipulating the components for welding; safety features; shielding gas supplyand control)

5 Mechanised and automated welding basics (types of installations; machinefunctions; safety features)

6 Extracting the information required from drawings and welding procedurespecifications

7 Operation of the machine; controls and their function; care of equipment8 Setting up and aligning the workpiece9 Monitoring the installation during the welding process; recognition of

problems, and action to be taken10 Problems that can occur with the welding activities, materials and weld defects11 Self inspection of completed work12 Organisational quality systems (standards to be achieved; production records





evidence type

date




machine settings comply withinstructions and the welding procedure specification




two different components


Monitor the process operation and machine function and make adjustments as required to parameters and mechanisms, to include all of the following, as appropriate to the machine type:


welding speed

weld alignment and characteristics

beam tracking

beam characteristics (focal spot)

gas shielding (where applicable)

mechanical mechanisms forworkholding, traversing and transfer








achieve a weld quality equivalent to therelevant level of EN/ISO 13919, asrequired by the application standard



Candidate Date

Assessor Date



Unit summaryThis unit identifies the competencies you need to operate electron beam weldinginstallations that have already been prepared for production, in accordance withapproved instructions or welding procedures. You will be expected to check that theinstallation has been approved for production and that sufficient supplies of allrequired materials and consumables are present and correct, and are ready forproduction operations to be performed.



Your underpinning knowledge will be sufficient to provide a sound basis of yourwork, enabling you to adopt an informed approach to applying welding proceduresand instructions. You will have an understanding of how the electron beam weldingprocess works and is applied in mechanised form, and will know about theequipment, materials and consumables, in adequate depth to provide a soundbackground to the process operation and for carrying out the activities to therequired specification.


Unit 12Welding materials using electron beam welding machines













3 Monitor the process operation and machine function and make adjustments asrequired to parameters and mechanisms, to include all of the following, asappropriate to the machine type:• electrical parameters• welding speed• chamber pressure• weld alignment and characteristics• beam tracking• mechanical functions



4 Produce welded components which:• achieve a weld quality equivalent to the relevant level of EN/ISO 13919, as

required by the application standard• meet the required dimensional accuracy within specified tolerances


electron beam welding installations (working with machinery; care in presenceof high voltage; the use of appropriate personal protective equipment;protecting other workers; machine guards; operation of machine safetydevices; x-ray dosimeters; closing the machine down on completion ofactivities; statutory requirements, risk assessment procedures and relevantrequirements of HASAWA, COSHH and Work Equipment Regulations; safedisposal of waste materials)

2 The hazards associated with electron beam welding machines (dangers fromthe mains and high voltage supplies; live electrical components; emission of x-rays, fumes and gases; hot metal; moving parts of machinery), and how theycan be minimised

3 Principles of electron-beam welding; terminology used in welding4 The key components and features of the equipment (electron gun and control

of beam power and characteristics; vacuum chamber and its construction;vacuum system and controls; in-chamber manipulating equipment; powersources and power range; material and thickness capabilities; safety features;facilities for loading chamber and work handling)



problems, and action to be taken9 Problems that can occur with the welding activities (materials and weld defects;

beam instability, loss of alignment, increase in chamber pressure)10 Self inspection of completed work11 Organisational quality systems (standards to be achieved; production records





evidence type

date










Monitor the process operation and machine function and make adjustments as required to parameters and mechanisms, to include all of the following, as appropriate to the machine type:


welding speed

chamber pressure

weld alignment and characteristics

beam tracking

mechanical functions


achieve a weld quality equivalent to therelevant level of EN/ISO 13919, asrequired by the application standard



Candidate Date

Assessor Date





Unit summaryThis unit identifies the competencies you need to operate friction weldinginstallations that have already been prepared for production, in accordance withapproved instructions or welding procedures. You will be expected to check that theinstallation has been approved for production and that sufficient supplies of allrequired materials and consumables are present and correct, and are ready forproduction operations to be performed.

You must operate the installation safely and correctly, in accordance withinstructions and approved procedures, and achieve a weld quality and tolerancesthat meet the product specification. The production output may be inspected byvisual and non-destructive testing methods, to check that the specified quality isbeing achieved. You must continuously monitor the operation of the installation,using the in-process monitoring features of the welding machine, and make anynecessary adjustments to equipment settings, in line with your permitted authority,in order to produce the welded joints to the required specification. Meetingproduction requirements will be an important issue, and your production recordsmust show consistent and satisfactory performance.


Your underpinning knowledge will be sufficient to provide a sound basis for yourwork, enabling you to adopt an informed approach to applying welding proceduresand instructions. You will have an understanding of how the friction welding processworks and is applied in mechanised form, and will know about the equipment,materials and consumables, in adequate depth to provide a sound background to theprocess operation and for carrying out the activities to the required specification.


Unit 13Welding materials using friction welding machines









You must:1 Confirm that the installation is ready for operation, to include checking all of

the following:• the installation has been approved for production• supplies of components and consumables are adequate and correctly prepared• machine settings comply with instructions and the welding



3 Monitor the process operation and machine functions and make adjustments asrequired to settings and mechanisms, to include all of the following, asappropriate to the machine type:• friction and forge cycle time• friction and forge loads (forces)• rotational speed or other friction conditions, eg, orbital• frictional burn-off characteristics and forge displacement• weld appearance (correct up-set)• braking effort



4 Produce welded components which:• achieve a weld quality as specified in the application standard or specification• meet the required dimensional accuracy within specified tolerances


friction welding installations (working with machinery; the use of appropriatepersonal protective equipment; machine guards; operation of machine safetydevices; stopping the machine in an emergency; closing the machine down oncompletion of activities; statutory requirements, risk assessment proceduresand relevant requirements of HASAWA, COSHH and Work EquipmentRegulations; safe disposal of waste materials)

2 The hazards associated with friction welding machines (dangers from liveelectrical components; fumes; hot metal; moving parts of machinery andcomponents), and how they can be minimised

3 Principles of friction welding; terminology used in welding4 The key components and features of the equipment (types of machines;

constructional features, mechanical features, drive train, driven and stationarycomponent holding devices, force generation and control systems, brakingsystems; welding cycle control; feedback and recording)

5 Mechanised and automated welding basics; types of installations; machinefunctions; safety features

6 Extracting information required from drawings and welding procedure specifications

7 Operation of the machine; controls and their function; care of equipment8 Setting up and aligning the workpiece9 Monitoring the installation during the welding process; the various types of

monitoring features used on friction welding machines; recognition ofproblems, and action to be taken

10 Problems that can occur with the welding activities, materials and weld defects11 Self inspection of completed work12 Organisational quality systems (standards to be achieved; feedback from

machine; corrective actions; production records to be kept)13 Personal approval tests and their applicability to your work14 The extent of your own authority and whom you should report to if you have




evidence type

date










Monitor the process operation and machine functions and make adjustments as required to settings and mechanisms, to include all of the following, as appropriate to the machine type:

friction and forge cycle time

friction and forge loads (forces)

rotational speed or other frictionconditions, eg, orbital

frictional burn-off characteristics andforge displacement

weld appearance (correct up-set)

braking effort








achieve a weld quality as specified inthe application standard orspecification



Candidate Date

Assessor Date



Unit summaryThis unit identifies the competences you need to assist a Level 3 welder to prepareand operate an aluminothermic welding process, in accordance with instructionsand/or approved procedures. In this context, ‘steel rail’ means materials andsections as used in the UK permanent way rail infrastructure.

You will be required to check that all the welding and ancillary equipment, such assaws, grinders and shearing tools, are available and in a usable condition. You will beexpected to check that gases are available and that gas equipment, burners andhoses, are of the correct type, securely connected and free from leaks and damage.You will also need to ensure that appropriate crucibles, moulds and portions areavailable and in good condition. In preparing the weld you will need to identify therail grade and profile, and to take account of any wear on the railhead. You mustoperate and handle the equipment safely and correctly and make any adjustmentsto equipment or settings, in line with your permitted authority, in order to produceand finish the welds to the required specification.

Your responsibilities will require you to comply with organisational policy andprocedures for the welding activities undertaken, and to report any problems withthe welding equipment, or the welding activities that you cannot resolve, or areoutside your permitted authority, to the relevant people. You will be expected towork in accordance with instructions from a Level 3 aluminothermic welder, takingpersonal responsibility for your own actions.

Your underpinning knowledge will be sufficient to provide a sound basis for yourwork, and will provide an understanding of how the aluminothermic welding processworks. You will know about the equipment, materials and consumables, in adequatedepth to provide a sound background for the welding operations to be performed,and for ensuring the work output is produced to the required specification.

You will understand the safety precautions required when working with the weldingequipment and associated tools and equipment. You will be required todemonstrate safe working practices throughout, and will understand theresponsibility you owe to yourself and others in the workplace.

Unit 14Joining rails using the aluminothermic welding process








You must:1 Assist in the preparation of rails for welding, in accordance with applicable

specifications, to include all of the following:• confirming welding equipment, consumables and ancillary equipment is

available and fit for purpose• identifying and measuring rail wear and condition• cutting the rail using the oxy-fuel process, a band saw or an abrasive disc• datum marking and aligning the rail• preheating the crucible and the joint area• joining the rails using safe and approved welding methods and procedures• reinstating the track to the required standard on completion of the

welding activities• disposing of waste and surplus materials in accordance with

approved procedures

2 Assist in the setting up, checking, adjustment and use of aluminothermic weldingequipment for one of the following process variants, in accordance with theappropriate process manual:• Thermit• Railtech



3 Assist in the use of moulds and consumables appropriate to the material andapplication, to include all of the following:• two different rail profiles (unworn)• two different rail materials• join new rail to worn rail• join worn rail to worn rail

4 Assist in the welding of joints according to approved welding procedures in bothof the following:• normal gap• wide gap

5 Assist in the production of welds which:• achieve a minimum weld quality required by the application standard• meet the required dimensional accuracy within specified tolerance• have been finished to the required specification in terms of removal of risers

and excess metal• are ground to the required standard

Knowledge statements:You must have knowledge and understanding of:1 The safe working practices and procedures to be observed when working on rail

construction sites using aluminothermic welding equipment (general site safety,appropriate personal protective equipment, fire prevention, protecting otherworkers, accident procedure; client requirements statutory requirements, riskassessment procedures and relevant requirements of HASAWA, COSHH andWork Equipment Regulations; safe disposal of waste materials)

2 The hazards associated with aluminothermic welding (poor gas supply, leaks,hot metal, explosive gas mixtures, naked flames and exothermic reactions), andhow they can be minimised

3 Equipment and consumables for aluminothermic welding4 The aluminothermic welding process and the use of process manuals5 The types of rail grades and profiles, and welded joints to be produced6 Setting up the joint (cutting, alignment, moulds, luting, etc)7 Setting up the welding equipment and checks that need to be made to ensure

that it is safe and ready to use (gas supply, correct joint set-up, cleanliness ofmaterials used)

8 The techniques of operating the welding equipment, to produce a range ofjoints in accordance with the appropriate process manual

9 The importance of complying with job instructions and the welding process specification

10 Problems that can occur with the welding activities, and how these can beovercome; effects of welding on rail materials and sources of weld defects;methods of prevention





evidence type

date

Assist in the preparation of rails for welding, in accordance with applicable specifications, to include all of the following:

confirming welding equipment,consumables and ancillary equipmentis available and fit for purpose

identifying and measuring rail wear andcondition

cutting the rail using the oxy-fuelprocess, a band saw or an abrasive disc

datum marking and aligning the rail

preheating the crucible and the jointarea

joining the rails using safe andapproved welding methods andprocedures

reinstating the track to the requiredstandard on completion of the welding activities

disposing of waste and surplusmaterials in accordance with approved procedures

Assist in the setting up, checking, adjustment and use of aluminothermic welding equipment for one of the following process variants, in accordance with the appropriate process manual:

Thermit

Railtech

Assist in the use of moulds and consumables appropriate to the material and application, to include all of the following:

two different rail profiles (unworn)

two different rail materials

join new rail to worn rail

join worn rail to worn rail



Assist in the welding of joints according to approved welding procedures in both of the following:

normal gap

wide gap

Assist in the production of welds which:

achieve a minimum weld qualityrequired by the application standard


have been finished to the requiredspecification in terms of removal ofrisers and excess metal

are ground to the required standard


Candidate Date

Assessor Date





Unit summaryThis unit identifies the competencies you need to restore rails to operationalcondition by resurfacing or repair, using either manual arc or self-shielded flux coredwire arc welding equipment, in accordance with instructions and/or approvedwelding procedures. You will be expected to check the welding equipment to ensurethat all the leads/cables, electrode holders and wire feed mechanisms are securelyconnected and free from damage. In preparing to weld, you will need to set andadjust the welding conditions in line with the instructions or welding procedurespecification. You must operate the equipment safely and correctly and make anynecessary adjustments to settings, in line with your permitted authority, in order toproduce the repairs to the required specification.

Your responsibilities will require you to comply with organisational policy andprocedures for the welding activities undertaken, and to report any problems withthe welding equipment, or welding activities, that you cannot resolve, or are outsideyour permitted authority, to the relevant people. You will be expected to work toinstructions, with a minimum of supervision, taking personal responsibility for yourown actions and for the quality and accuracy of the work that you carry out.

Your underpinning knowledge will be sufficient to provide a sound basis for yourwork, and will provide an informed approach to applying rail welding repairprocedures and instructions. You will have an understanding of the manual arc orself-shielded flux cored arc welding process used, and its application, and will knowabout the equipment, materials and consumables, in adequate depth to provide asound basis for setting up and operating the equipment, recognising and correctingfaults and ensuring the work output is produced to the required specification.

You will understand the safety precautions required when working with the weldingequipment and its associated tools and equipment. You will be required todemonstrate safe working practices throughout, and will understand theresponsibility you owe to yourself and others in the workplace.

Unit 15Restore rails to operational condition using an arc welding process



regulations and guidelinesb Follow the relevant specifications for the component to be repairedc Prepare the component for repaird Carry out the repairs within agreed timescale using approved materials,

components, methods and procedurese Ensure that the repaired component meets the specified operating conditionsf Produce accurate and complete records of all the repair work carried out.


You must:1 Carry out all of the following during the repair activities:

• determine or confirm the specific repair to be carried out• prepare the area of the rail to be repaired using grinding and penetrant testing• use safe and approved repair welding procedures at all times• finish the repair using approved methods and techniques• test the repaired area using the penetrant method• reinstate the track to the required standard on completion of the

repair activities• dispose of waste and surplus materials in accordance with

approved procedures

2 Set up, check, adjust and use arc welding and related equipment, to include all ofthe following:• confirming welding equipment, consumables and ancillary equipment

is available• checking that all leads/cables are secure and in a safe and usable condition• checking that the wire feed mechanism or electrode holder is securely

connected and free from damage• ensuring that the correct type and size of wire or electrode is loaded to the wire

feed mechanism or electrode holder• setting and adjusting the welding conditions in line with the instructions or

welding procedure specification• carrying out the repair welding activities safely and correctly, in line with the

repair specification

3 Use one of the following arc welding processes:• manual metal arc• self-shielded flux cored wire arc



3 Use consumables appropriate to the rail material and application, to include bothof the following:• two different wire or electrode types• two different wire or electrode sizes

4 Produce welded repairs in good access situations, to include both of the following:• normal grade rail• austenitic-manganese rail

5 Produce repairs which include both of the following:• resurfacing• repair

6 Produce welded components which:• achieve a minimum weld quality as required by the application standard• meet the required dimensional accuracy within specified tolerances• are ground to the required standard


manual metal arc or self-shielded flux cored wire arc welding equipment(general site safety, appropriate personal protective equipment, fireprevention, protecting other workers from arc eye, safety in enclosed/confinedspaces; fume control; accident procedure; statutory requirements, riskassessment procedures and relevant requirements of HASAWA, COSHH andWork Equipment Regulations; safe disposal of waste materials)

2 The hazards associated with arc welding (live electrical components, poorearthing, the electric arc, fumes and gases, spatter, hot metal), and how theycan be minimised

3 The arc welding process (basic principles of fusion welding, AC and DC powersources, ancillary equipment and power ranges, care of equipment)

4 The consumables associated with manual metal arc or flux cored wire arcwelding (types of wire/electrode and their application)

5 The types of repairs to be produced (resurfacing and repair)6 How to identify the various steels used in rails, switches and crossings and how

they will effect the welding repair procedure7 Preparation techniques for the area of the rail to be repaired by grinding and

penetrant testing8 Preparation techniques for the welding equipment, and checks that need to be

made to ensure that it is safe and ready to use (electrical connections, earthingarrangements; wire feed mechanisms, setting welding parameters, correctworkpiece set-up, cleanliness of materials used)




10 The techniques for completing and finishing the repaired rails (grinding offexcess material, finish profiling and penetrant testing)

11 The procedures for reinstating the track on completion of the repair activities12 Problems that can occur with the welding activities and how these can be

overcome (causes of distortion and methods of control, effects of welding onmaterials and sources of weld defects; methods of prevention)

13 The techniques of operating the welding equipment to produce a range ofrepairs (fine tuning parameters, correct manipulation of the weldinggun/electrode, safe closing down of the welding equipment)

14 The organisational quality systems used and weld standards to be achieved15 Weld inspection and test procedures used (including destructive and non-

destructive methods)16 Personal approval tests and their applicability to your work17 The extent of your own authority and whom you should report to if you have






evidence type

date

Carry out all of the following during the repair activities:

determine or confirm the specific repairto be carried out

prepare the area of the rail to berepaired using grinding and penetranttesting

use safe and approved repair weldingprocedures at all times

finish the repair using approvedmethods and techniques

test the repaired area using thepenetrant method

reinstate the track to the requiredstandard on completion of the repairactivities

dispose of waste and surplus materialsin accordance with approvedprocedures

Set up, check, adjust and use arc welding and related equipment, to include all of the following:

confirming welding equipment,consumables and ancillary equipmentis available

checking that all leads/cables aresecure and in a safe and usablecondition

checking that the wire feed mechanismor electrode holder is securelyconnected and free from damage

ensuring that the correct type and sizeof wire or electrode is loaded to thewire feed mechanism or electrodeholder

setting and adjusting the weldingconditions in line with the instructionsor welding procedure specification



carrying out the repair weldingactivities safely and correctly, in linewith the repair specification

Use one of the following arc welding processes:

manual metal arc

self-shielded flux cored wire arc

Use consumables appropriate to the rail material and application, to include both of the following:

two different wire or electrode types

two different wire or electrode sizes

Produce welded repairs in good access situations, to include both of the following:

normal grade rail

austenitic-manganese rail

Produce repairs which include both of the following:

resurfacing

repair


achieve a minimum weld quality asrequired by the application standard


are ground to the required standard


Candidate Date

Assessor Date





Unit summaryThis unit identifies the competencies you need to operate flash welding installationsthat have already been prepared for production, in accordance with approvedinstructions or welding procedures. You will be expected to check that theinstallation has been approved for production, and that sufficient supplies of allrequired materials and consumables are present and correct, and ready forproduction operations to be performed.

You must operate the installation safely and correctly, in accordance withinstructions and approved procedures, and achieve a weld quality and tolerancesthat meet the product specification. The production output may be inspected byvisual and non-destructive testing methods to check that the specified quality isbeing achieved. You must continuously monitor the operation of the installation andmake any necessary adjustments to equipment settings, in line with your permittedauthority, in order to produce the welded joints to the required specification.Meeting production requirements will be an important issue, and your productionrecords must show consistent and satisfactory performance.


Your underpinning knowledge will be sufficient to provide a sound basis of yourwork, and will enable you to adopt an informed approach to applying flash weldingprocedures and instructions. You will have an understanding of how the flashwelding process works and is applied in mechanised form, and will know about theequipment, materials and consumables, in adequate depth to provide a soundbackground to the process operation and for carrying out the activities to therequired specification.


Unit 16Welding rails using flash welding equipment







that you cannot solvei Shut down the equipment to a safe condition on conclusion of the

joining activities.

Scope of the unit:The numbers of scope items specified (below) indicate the minimum requirementsfor this Occupational Standard

You must:1 Confirm that the installation is ready for operation, to include checking all of

the following:• the installation has been approved for production• supplies of components and consumables are adequate and correctly prepared• machine settings comply with instructions and the welding


2 Produce welded components covering both of the following:• two different rail sections• two different rail material groups

3 Monitor the process operation and machine function and make adjustments asrequired to parameters and mechanisms, to include all of the following, asappropriate to machine type:• heat and forge cycle time• heat and forge loads (forces)• electrical conditions• weld and forge travel• weld appearance (correct extrusion)



4 Produce welded rails which:• achieve a weld quality as specified in the application standard• meet the required dimensional accuracy within specified tolerances


flash welding installations (working with machinery; the use of appropriatepersonal protective equipment; machine guards; operation of machine safetydevices; stopping the machine in an emergency; closing the machine down oncompletion of activities; statutory requirements, risk assessment proceduresand relevant requirements of HASAWA, COSHH and Work EquipmentRegulations; safe disposal of waste materials)

2 The hazards associated with flash welding machines (dangers from liveelectrical components; fumes; hot metal; moving parts of machinery), and howthey can be minimised

3 Principles of flash welding; terminology used in welding4 The key components and features of the equipment (types of machines;

constructional features, mechanical and electrical features, component holdingdevices, force generation and control systems, welding cycle control; feedbackand recording)

5 Mechanised and automated welding basics; types of installations; machinefunctions; safety features


7 Operation of the machine; controls and their function; care of equipment8 Setting up and aligning the rails for the welding operation9 Monitoring the installation during the welding process; recognition of problems

and action to be taken10 Problems that can occur with the welding activities, materials and weld defects11 Self inspection of completed work12 Organisational quality systems (standards to be achieved; feedback from

machine; corrective actions; production records to be kept)13 Personal approval tests and their applicability to your work14 The extent of your own authority and whom you should report to if you have




evidence type

date








two different rail sections

two different rail material groups

Monitor the process operation and machine function and make adjustments as required to parameters and mechanisms, to include all of the following, as appropriate to machine type:

heat and forge cycle time

heat and forge loads (forces)

electrical conditions

weld and forge travel

weld appearance (correct extrusion)

Produce welded rails which:




Candidate Date

Assessor Date





Unit summaryThis unit identifies the competencies you need to set up and use manual torchbrazing and soldering equipment, in accordance with approved instructions orprocedures. You will be required to check that all the hoses and equipment arecorrectly connected, free from leaks or damage, and are ready for use. You will berequired to set and adjust the brazing conditions, in line with the specification. Youwill also need to select and use workholding and manipulating devices that areappropriate to the size and shape of materials and joint configuration beingproduced. You must operate the equipment safely and correctly and make anyadjustments to settings, in order to produce the joints to the required specification.

Your responsibilities will require you to comply with organisational policy andprocedures for carrying out the brazing activities, and to report any problems withthe brazing equipment, or brazing activities that you cannot resolve, or are outsideyour permitted authority, to the relevant people. You will be expected to work toinstructions, with a minimum of supervision, taking personal responsibility for yourown actions and for the quality and accuracy of the work that you carry out.

Your underpinning knowledge will be sufficient to provide a sound basis for yourwork, and will provide an understanding of how the torch brazing process works. Youwill know about the equipment, materials and consumables, in adequate depth toprovide a sound background for the brazing operations to be performed, and forensuring the work output is produced to the required specification.

You will understand the safety precautions required when working with the brazing equipment. You will be required to demonstrate safe working practicesthroughout, and will understand the responsibility you owe to yourself and others in the workplace.

Unit 17Joining materials by manual torch brazing and soldering








You must:1 Set up, check, adjust and use one of the following processes and related

equipment:• brazing• soldering

2 Use specified consumables appropriate to the parent metals, to include both ofthe following:• two different filler metals• appropriate fluxes

3 Produce brazed or soldered joints according to work procedures, and in goodaccess situations, covering both of the following:• two different components or assemblies• two different parent metal groups

4 Produce components which:• achieve the specified joint quality as required by the application standard• meet the required dimensional accuracy within specified tolerance• are of good appearance, free from flux residues and excess filler metal




gas brazing and soldering equipment (general workshop and site safety,appropriate personal protective equipment, fire and explosion prevention,fume extraction, protecting other workers, safety in enclosed/confined spaces,statutory regulations, risk assessment procedures and COSHH regulations)

2 The hazards associated with torch brazing and soldering (naked flames,explosive gas mixes, oxygen enrichment, fumes and gasses, hot metal,enclosed spaces), and how they can be minimised

3 The torch brazing and soldering process (basic principles of the process,wetting and capillary flow, role of fluxes, equipment type and its care)

4 Types of filler metal and fluxes; forms of filler metal5 The types of joints to be produced6 Setting up and locating the joint (methods of cleaning joint faces; use of jigs and

fixtures, restraining devices; self-locating joints; pre-placement of filler metaland flux)

7 How to prepare to braze or solder (checks to confirm correct set-up andcleanliness; use of gauges, setting up the equipment, checking connections forleaks, checking operating parameters)

8 The techniques of operating the equipment to produce a range of joints(selection of nozzle and flame adjustment, application of flux, correctmanipulation of torch and filler wire, safe closing down of the equipment)

9 The importance of complying with job instructions and the joining procedure specification

10 Problems that can occur with the joining activities and how these can beovercome (causes of distortion and methods of control; effects of heat onmaterials and sources of defects; methods of prevention)

11 Methods of removing flux residues and cleaning the finished joint12 Organisational quality control systems and standards to be achieved; visual and

non-destructive tests13 Personal approval tests and their applicability to your work14 The extent of your own authority and whom you should report to if you have




evidence type

date

Set up, check, adjust and use one of the following processes and related equipment:

brazing

soldering

Use specified consumables appropriate to the parent metals, to include both of the following:

two different filler metals

appropriate fluxes

Produce brazed or soldered joints according to work procedures, and in good access situations, covering both of the following:

two different components orassemblies

two different parent metal groups

Produce components which:

achieve the specified joint quality asrequired by the application standard


are of good appearance, free from fluxresidues and excess filler metal


Candidate Date

Assessor Date





Unit summaryThis unit identifies the competencies you need to operate torch, inductance,resistance or furnace brazing installations that have already been prepared forproduction, in accordance with approved instructions or procedures. You will beexpected to check that the equipment has been approved for production, and thatsufficient supplies of all the required materials and consumables are present andcorrect, and are ready for production operations to be performed.

You must operate the installation safely and correctly, in accordance withinstructions and approved procedures, and achieve a joint quality and tolerancesthat meet the product specification. You must continuously monitor the operation ofthe installation, and make any necessary adjustments to equipment settings, in linewith your permitted authority, in order to produce the brazed joints to the requiredspecification. Meeting production requirements will be an important issue, and yourproduction records must show consistent and satisfactory performance.

Your responsibilities will require you to comply with organisational policy andprocedures for operating the brazing installation, and to report any problems oradjustments to the installation that you cannot resolve, or are outside yourpermitted authority, to the relevant people. You will be expected to work toinstructions, with a minimum of supervision, taking personal responsibility for yourown actions and for the quality and accuracy of the work that you carry out.

Your underpinning knowledge will be sufficient to provide a sound basis for yourwork, enabling you to adopt an informed approach to applying brazing proceduresand instructions. You will have an understanding of how the brazing process worksand is applied in mechanised form, and will know about the equipment, materialsand consumables, in adequate depth to provide a sound background to the processoperation and for carrying out the brazing activities to the required specification.


Unit 18Joining materials using brazing machines









You must:1 Confirm that the installation is ready for production operations, to include

checking all of the following:• the installation has been approved for production• supplies of components and consumables are adequate and correctly prepared• machine settings comply with instructions and the brazing


2 Operate one of the following mechanised brazing processes in the specifiedmaterials, forms and positions:• torch• induction• furnace• resistance

3 Produced brazed assemblies covering both of the following:• two different joint configurations• two different material groups



4 Monitor the process operation and machine functions, and make adjustments asrequired to parameters and mechanisms within your permitted authority andtolerances, to include adjusting all of the following, as applicable to the machine type: • brazing temperature• brazing time• flux and filler metal dispensing• brazing atmosphere• flame condition• mechanical functions (handling, loading, workholding, transfer)• safety devices

5 Produce brazed components or assemblies which:• achieve the quality specified in the application standard• meet the required dimensional accuracy within specified tolerances


brazing installations (working with machinery; the use of appropriate personalprotective equipment; machine guards; operation of machine safety devices;stopping the machine in an emergency; closing the machine down oncompletion of activities; statutory requirements, risk assessment proceduresand relevant requirements of HASAWA, COSHH and Work EquipmentRegulations; safe disposal of waste materials)

2 The hazards associated with brazing machines (dangers from relevantequipment sources; fumes and gases; hot metal; moving parts of machinery),and how they can be minimised

3 Principles of the relevant brazing process; terminology used in brazing4 The key components and features of the equipment5 Mechanised and automated brazing basics (types of installations; machine

functions; safety features)6 How to extract the information required from drawings and brazing

procedure specifications7 Operation of the machine controls and their function; care of equipment;

control and storage of consumables8 Setting up and aligning the workpieces9 Monitoring the installation during the brazing process; recognition of problems,

and action to be taken10 Problems that can occur with the brazing activities, materials, filler metals and

joint defects11 Self inspection of completed work12 Organisational quality systems (standards to be achieved; production records

to be kept)





evidence type

date

Confirm that the installation is ready for production operations, to include checking all of the following:



machine settings comply withinstructions and the brazing procedurespecification



Operate one of the following mechanised brazing processes in the specified materials, forms and positions:

torch

induction

furnace

resistance

Produced brazed assemblies covering both of the following:



Monitor the process operation and machine functions, and make adjustments as required to parameters and mechanisms within your permitted authority and tolerances, to include adjusting all of the following, as applicable to the machine type:

brazing temperature

brazing time

flux and filler metal dispensing

brazing atmosphere

flame condition

mechanical functions (handling,loading, workholding, transfer)

safety devices



Produce brazed components or assemblies which:

achieve the quality specified in theapplication standard



Candidate Date

Assessor Date





Unit summaryThis unit identifies the competencies you need to prepare and operate manualplastics welding equipment, in accordance with instructions and/or approvedwelding procedures. You will be required to check that all the workholdingequipment and manipulating devices required are available and in a usablecondition. You will be expected to check the welding equipment, to ensure that allgas supplies and electrical inputs are securely connected and free from damage. Inpreparing to weld, you will need to set and adjust the welding conditions, in line withthe instructions or welding procedure specification. You must operate theequipment safely and correctly and make any necessary adjustments to settings, inline with your permitted authority, in order to produce the welded joints to therequired specification.

Your responsibilities will require you to comply with organisational policy andprocedures for the welding activities undertaken, and to report any problems withthe welding equipment, or welding activities that you cannot personally resolve, orare outside your permitted authority, to the relevant people. You will be expected towork to instructions, with a minimum of supervision, taking personal responsibilityfor your own actions and for the quality and accuracy of the work that you carry out.

Your underpinning knowledge will be sufficient to provide a sound basis for yourwork, and will provide an understanding of how manual plastics welding processeswork. You will know about the equipment, materials and consumables in adequatedepth to provide a sound background for the welding operations to be performed,and for ensuring the work output is produced to the required specification.

You will understand the safety precautions required when carrying out the weldingactivities and when using the associated tools and equipment. You will be requiredto demonstrate safe working practices throughout, and will understand theresponsibility you owe to yourself and others in the workplace.

Unit 19Joining plastics using manual welding processes





line with approved and agree proceduresi Deal promptly and effectively with problems within your control and report those



You must:1 Set up, check, adjust and use plastics welding and related equipment, to include

two of the following:Note: one of the processes chosen must be hot gas or extrusion welding• hot gas• extrusion• socket fusion• heated wedge

2 Use materials and consumables as appropriate to the welding process used, toinclude both of the following:• two types of material from different material groups• two sizes or types of consumables

3 Produce welded joints as appropriate to the process, to include one of the following:• fillet welds• butt welds• socket welds• lap welds



4 Weld joints according to approved welding procedures, in good access situations,in two of the following BS EN287 positions or two other positions, as appropriateto the process:• Flat (PA)• Horizontal vertical (PB)• Horizontal (PC)• Vertical upwards (PF)• Vertical downwards (PG)

5 Produce welded components which:• achieve a minimum weld quality equivalent with prEN 13067, or as required by

the application standard• meet the required dimensional accuracy within specified tolerances


manual plastics welding equipment (general workshop and site safety,appropriate personal protective equipment, fire prevention, protecting otherworkers, safety in enclosed/confined spaces; fume control; accident procedure;statutory regulations; risk assessment procedures and relevant requirementsof HASAWA, COSHH and Work Equipment Regulations; safe disposal of waste materials)

2 The hazards associated with plastics welding (live electrical components,fumes and gases, hot material, elevated working temperature, enclosedspaces), and how they can be minimised

3 The manual plastics welding processes (basic principles of hot gas, extrusion,socket fusion and geomembrane welding; ancillary equipment; care ofequipment; consumables; power ranges)

4 Types of consumables; correct storage of consumables5 The types of welded joints to be produced (fillet and butt welds; single and

multi-run welds; joints in pipe, plate and sections; welding positions)6 Setting up and restraining the joint (the use of jigs and fixtures, restraining

devices, tack welding size and spacing in relationship to material thickness)7 Checks to be made prior to welding (confirming correct set-up of joint,

cleanliness of materials, condition of gas and electrical connections, earthingarrangements, operating parameters)

8 The techniques of operating the welding equipment to produce a range ofjoints in the various joint positions (fine tuning parameters, correctmanipulation of consumables, safe closing down of the welding equipment)

9 The importance of complying with the job instructions and the weldingprocedure specification

10 Problems that can occur with the welding activities and how these can beovercome (causes of distortion and methods of control; effects of welding onmaterials and sources of weld defects; methods of prevention)



11 The organisational quality control systems used, and weld standards to be achieved

12 Weld inspection and test procedures used (including destructive and non-destructive methods)







evidence type

date

Set up, check, adjust and use plastics welding and related equipment, to include two of the following:

Note: one of the processes chosen must be hot gas or extrusion welding

hot gas

extrusion

socket fusion

heated wedge

Use materials and consumables as appropriate to the welding process used, to include both of the following:

two types of material from differentmaterial groups

two sizes or types of consumables

Produce welded joints as appropriate to the process, to include one of the following:

fillet welds

butt welds

socket welds

lap welds

Weld joints according to approved welding procedures, in good access situations, in two of the following BS EN287 positions or two other positions, as appropriate to the process:

Flat (PA)

Horizontal vertical (PB)

Horizontal (PC)

Vertical upwards (PF)

Vertical downwards (PG)




achieve a minimum weld qualityequivalent with prEN 13067, or asrequired by the application standard



Candidate Date

Assessor Date





Unit summaryThis unit identifies the competencies you need to operate plastics weldinginstallations that have already been prepared for production, in accordance withapproved instructions or welding procedures. You will be expected to check that theinstallation has been approved for production, and that sufficient supplies of allrequired materials and consumables are present and correct, and are ready forproduction operations to be performed.



Your underpinning knowledge will be sufficient to provide a sound basis of yourwork, and will enable you to adopt an informed approach to applying machineplastic welding procedures and instructions. You will have an understanding of howthe plastics welding processes work and are applied in mechanised form, and willknow about the equipment, materials and consumables, in adequate depth toprovide a sound background to the process operation and for carrying out theactivities to the required specification.

You will understand the safety precautions required when carrying out the machinewelding activities, and when using the associated tools and equipment. You will berequired to demonstrate safe working practices throughout, and will understand theresponsibility you owe to yourself and others in the workplace.

Unit 20Joining materials using plastics welding machines












2 Produce welded components using two of the following types of equipment:• hot plate• electro-fusion• vibration• ultrasonic• laser• radio frequency• hot bar/impulse• spin• orbital• infrared



3 Produce welded components covering both of the following, as applicable to the process:• two different components• two different material groups

4 Monitor the process operation and machine function and make adjustments torequired parameters and mechanisms, to include all of the following, asappropriate to machine type:• time(s)• pressure(s)• speed• displacement• temperature/energy input

5 Produce welded components which:• achieve a weld quality equivalent with prEN13067 or the application standard• meet the required dimensional accuracy within specified tolerances

Knowledge statements:You must have knowledge and understanding of:1 The safe working practices and procedures to be observed when operating a

range of plastics welding installations (working with machinery; the use ofappropriate personal protective equipment; machine guards; operation ofmachine safety devices; stopping the machine in an emergency; closing themachine down on completion of activities; statutory requirements, riskassessment procedures and relevant requirements of HASAWA, COSHH andWork Equipment Regulations; safe disposal of waste materials)

2 The hazards associated with plastics welding machines (dangers from liveelectrical components; fumes; hot material; moving parts of machinery), andhow they can be minimised

3 Principles of plastics welding; terminology used in welding4 The key components and features of the equipment (types of machines;

constructional features, mechanical features, heat generation, force generationand control systems, welding cycle control; feedback and recording)

5 Mechanised and automated welding basics (types of installations; machinefunctions; safety features)

6 How to extract the information required from drawings and welding procedurespecifications


problems, and action to be taken10 Problems that can occur with the welding activities, materials and weld defects11 Self inspection of completed work



12 Organisational quality systems (standards to be achieved; feedback frommachine; corrective actions; production records to be kept)







evidence type

date







Produce welded components using two of the following types of equipment:

hot plate

electro-fusion

vibration

ultrasonic

laser

radio frequency

hot bar/impulse

spin

orbital

infrared

Produce welded components covering both of the following, as applicable to the process:





Monitor the process operation and machine function and make adjustments to required parameters and mechanisms, to include all of the following, as appropriate to machine type:

time(s)

pressure(s)

speed

displacement

temperature/energy input


achieve a weld quality equivalent withprEN13067 or the application standard



Candidate Date

Assessor Date





Unit summaryThis unit identifies the competencies you need for marking out sheet and plate work,rolled sections, and pipes/tubes using templates and basic tools, in accordance withapproved procedures. You will be required to select the required materials to useand the appropriate marking out tools and equipment, based on the informationpresented to you and the accuracy to be achieved. Marking out will be thepreparation required for cutting and shaping sheet materials, plate and sections, asappropriate to the application, and will include marking out workpiece datums,centre lines and cutting details, including hole centring and outlining details.

Items to be marked out may include ferrous and non-ferrous materials. Certainmaterials will require you to take the grain flow into account to avoid later productionprocess problems.

Your responsibilities will require you to comply with organisational policy andprocedures for the marking out activities undertaken, and to report any problemswith the materials, equipment or marking out activities that you cannot resolveyourself, or are outside your permitted authority, to the relevant people. You will beexpected to work to instructions, with a minimum of supervision, taking personalresponsibility for your own actions and for the quality and accuracy of the work thatyou carry out.

Your underpinning knowledge will be sufficient to provide a good understanding ofyour work, and will provide an informed approach to applying marking outprocedures. You will have an understanding of the marking out process, and itsapplication, and will know about the materials as well as the care and use of the toolsused, in adequate depth to provide a sound basis for carrying out the activities to therequired specification.

You will understand the safety procedures required when using marking mediums,and when carrying out the marking out activities. You will be required todemonstrate safe working practices throughout, and will understand theresponsibilities you owe to yourself and others in the workplace.

Unit 21Marking out components for fabrication



regulations and guidelinesb Obtain and use the correct information for marking outc Obtain the appropriate marking out equipment and check that it is in a

usable conditiond Prepare suitable datums and marking out surfacese Mark out using appropriate methodsf Check that the marking out complies with the specificationg Deal promptly and effectively with problems within your control and report those

that cannot be resolved


You must:1 Mark out sheet, plate or section materials on two appropriate materials from

the following: • hot-rolled mild steel (black)• cold-rolled mild steel (bright)• coated mild steel (tinned or galvanised)• stainless steel• aluminium• brass• copper• non-metallic materials

2 Mark out sheet or plate for three of the following forms/shapes of component:• bar and section lengths• cutting detail for flat covers and plates• frames or structures• fish plates, gussets• spars and brackets• pipe/tube sections• structural support pads, bed plates• columns, beams or struts• simple seatings (eg, boiler saddles, tank cradles)



3 Mark out directly onto sheet or plate from drawings, using four of the followingtools and instruments:• scriber• punch• rule and tape• straight edge• square• dividers or trammels• chalk, bluing or paint• templates

4 Mark out material to include three of the following features:• datum and centre lines• square/rectangular profiles• circles• curved profiles• cutting detail• hole centring and outlining (circular and linear)

5 Produce marked out component which meet all of the following quality andaccuracy standards:• dimensionally accurate (to drawing or specification)• uses recognised marking out conventions• clearly defined for required processes

Knowledge statements:You must have knowledge and understanding of:1 The specific safety precautions to be taken when working in a fabrication

environment with sheet, plate or rolled section materials (general workshopand site safety, appropriate personal protective equipment, accidentprocedure; statutory requirements, risk assessment procedures and relevantrequirements of HASAWA, COSHH and Work Equipment Regulations; safedisposal of waste materials)

2 The personal protective clothing and equipment to be worn when carrying outthe fabrication activities (leather gloves, eye protection, safety helmets, etc)

3 The correct methods of moving or lifting sheet, plate and rolled-section materials

4 The hazards associated with marking out fabricated components (such asworking in a fabrication environment, lifting and handling sheet/fabricatedcomponents, slivers/burrs on sheet materials, using marking out mediums,working with laser marking out equipment), and how they can be minimised

5 The procedures to be adopted to obtain the necessary drawings and job instructions

6 How to extract information from engineering drawings and relatedspecifications, to include symbols and conventions to appropriate BS or ISOstandards in relation to work undertaken



7 The preparations that need to be carried out on the material, prior to markingout, to enhance clarity and accuracy, and safety

8 Principles of marking out, developing basic shapes (flat, rectangular andcylindrical) from flat sheet, plate or rolled section materials

9 The effective use and care of tools/instruments10 Use of marking out conventions, datum edges/lines and centre lines11 Ways of laying out the shapes/patterns to maximise the use of plate or

sheet material12 The use of setting and adjusting tools, such as squares and protractors13 Methods of marking out large or long shapes14 Marking out and transferring information from templates15 The importance of using tools only for the purpose intended; the care that is

required when using the equipment and tools; the proper way of preservingand storing tools and equipment between operations

16 The need for clear and dimensional accuracy in marking out tospecifications/drawings

17 The things that can go wrong in marking out fabrication components, and howthese can be avoided

18 The extent of your own authority and whom you should report to if you haveproblems that you cannot resolve

19 Reporting lines and procedures, line supervision and technical experts





evidence type

date

Mark out sheet, plate or section materials on two appropriate materials from the following:

hot-rolled mild steel (black)

cold-rolled mild steel (bright)

coated mild steel (tinned or galvanised)

stainless steel

aluminium

brass

copper

non-metallic materials

Mark out sheet or plate for three of the following forms/shapes of component:

bar and section lengths

cutting detail for flat covers and plates

frames or structures

fish plates, gussets

spars and brackets

pipe/tube sections

structural support pads, bed plates

columns, beams or struts

simple seatings (eg, boiler saddles, tankcradles)

Mark out directly onto sheet or plate from drawings, using four of the following tools and instruments:

scriber

punch

rule and tape

straight edge

square

dividers or trammels

chalk, bluing or paint

templates



Mark out material to include three of the following features:

datum and centre lines

square/rectangular profiles

circles

curved profiles

cutting detail

hole centring and outlining (circular andlinear)

Produce marked out component which meet all of the following quality and accuracy standards:

dimensionally accurate (to drawing orspecification)

uses recognised marking outconventions

clearly defined for required processes


Candidate Date

Assessor Date





Unit summaryThis unit identifies the competencies you need to cut and shape sheet metal (uptoand including 3 mm), in order to fabricate clips, brackets, covers and similarcomponents, in accordance with approved procedures. You will be required to selectthe appropriate equipment to use for the material, thickness and accuracy to beachieved, and will use hand tools, hand power tools and machinery, as applicable. Thecutting and shaping will involve producing straight cuts and external curved contours.

Items to be cut and shaped may include ferrous and non-ferrous materials. This willcall for care in selecting the right tools, so as to avoid damage to the tools anddanger to oneself.

Your responsibilities will require you to comply with organisational policy andprocedures, seeking out relevant information, and to report any problems with thecutting equipment, materials or cutting activities that you cannot personal resolve,or are outside your permitted authority, to the relevant person. You will be expectedto work to instructions, with a minimum of supervision, taking personalresponsibility for your own actions and for the quality and accuracy of the work thatyou carry out.

Your underpinning knowledge will be sufficient to provide a good understanding ofyour work, and will provide an informed approach to applying sheet metal cuttingand shaping procedures. You will have an understanding of the cutting processesused, the equipment and its application, and will know about the materials inadequate depth to provide a sound basis for carrying out the activities to therequired specification.

You will understand the safety precautions required when working with fabricationtools and machinery. You will be required to demonstrate safe working practicesthroughout, and will understand the responsibility you owe to yourself and others inthe workplace.

Unit 22Cutting sheet metal to shape using hand and machine tools



regulations and guidelinesb Follow relevant specifications for the component to be producedc Obtain the appropriate tools and equipment for the shaping operations and check

they are in a safe and usable conditiond Shape the materials using appropriate methods and techniquese Check that all the required shaping operations have been completed to the

required specificationf Deal promptly and effectively with problems within your control and report those



You must:1 Cut and finish material to the marked out shape, using four of the following tools:

• tin snips• bench shears• guillotine• hacksaw• band saw• hand power tools (drill, nibbling)• pillar drill• files• punch/cropping machine

2 Perform operations to produce all of the following shapes:• straight cuts• external curved contours• round holes

3 Use sheet metal of various thicknesses, upto and including 3 mm, for twoappropriate materials and two thicknesses from the following:• hot-rolled mild steel (black)• cold-rolled mild steel (bright)• coated mild steel (eg, tinned, galvanised)• stainless steel• aluminium• brass• copper



4 Produce cut and shaped components which meet all the following quality andaccuracy standards:• dimensionally accurate (to drawing or specifications)• free from distortion• free from sharp edges, slivers or burrs

Knowledge statements:You must have knowledge and understanding of:1 The specific safety precautions to be taken when working with sheet metal

equipment and materials in a fabrication environment (general workshop andsite safety, appropriate personal protective equipment, accident procedure;statutory requirements, risk assessment procedures and relevant requirementsof HASAWA, COSHH and Work Equipment Regulations; safe disposal of waste materials)


3 The correct methods of moving or lifting sheet metal4 Safe working practices and procedures to be observed when using manual and

power-operated tools5 The hazards associated with fabrication work (such as using dangerous or badly

maintained tools and equipment, operating guillotines, and when using handand bench shears), and how they can be minimised

6 The procedures for obtaining the necessary drawings and specifications, andhow to check that they are the latest issue

7 How to extract information from engineering drawings and relatedspecifications (to include symbols and conventions to appropriate BS or ISOstandards in relation to work undertaken)

8 How to interpret the marking out conventions on the materials to be cut andshaped (such as cutting lines, centre lines, etc)

9 The tools and techniques available for cutting and shaping sheet metal (such astin snips, bench shears, guillotines, portable power tools, bench drills, saws, etc)

10 What preparations you may have to carry out on the material prior to cutting it11 The material characteristics and process considerations that need to be taken

into account when cutting and shaping sheet metal12 The use and care of tools and equipment, including checks that need to be

made to ensure that the tools are fit for purpose (sharp, undamaged, plugs andcables secure and free from damage, machine guards or safety devicesoperating correctly)

13 The importance of using tools or equipment only for the purpose intended; thecare that is required when using the tools or equipment; the proper way ofpreserving tools or equipment between operations

14 The things that can go wrong with cutting and shaping sheet metal, and howthese can be avoided



15 The importance of using the machine guards and safety protection equipmentat all times

16 Inspection techniques that can be applied to check that shape and dimensionalaccuracy are to specification and within acceptable limits







evidence type

date

Cut and finish material to the marked out shape, using four of the following tools:

tin snips

bench shears

guillotine

hacksaw

band saw

hand power tools (drill, nibbling)

pillar drill

files

punch/cropping machine

Perform operations to produce all of the following shapes:

straight cuts

external curved contours

round holes

Use sheet metal of various thicknesses, upto and including 3 mm, for two appropriate materials and two thicknesses from the following:

hot-rolled mild steel (black)

cold-rolled mild steel (bright)

coated mild steel (eg, tinned,galvanised)

stainless steel

aluminium

brass

copper



Produce cut and shaped components which meet all the following quality and accuracy standards:

dimensionally accurate (to drawing orspecifications)

free from distortion

free from sharp edges, slivers or burrs


Candidate Date

Assessor Date





Unit summaryThis unit identifies the competencies you need to form sheet metal (upto andincluding 3mm) using hand tools and machine tools, in accordance with approvedprocedures. You will be required to select the appropriate equipment to use, basedon the operations required, material to be formed and the accuracy to be achieved,and this will include such things as hammers and stakes, formers, bending machinesand rolling machines. The components/shapes to be produced will include bends,folds, cylinders and curved sections, ducting or trunking.

Your responsibilities will require you to comply with organisational policy andprocedures for the forming activities undertaken, and to report any problems withthe tools and equipment, materials or activities that you cannot personally resolve,or are outside your permitted authority, to the relevant people. You will be expectedto work to instructions, with a minimum of supervision, taking personalresponsibility for your own actions and for the quality and accuracy of the work thatyou carry out.

Your underpinning knowledge will be sufficient to provide a good understanding ofyour work, and will provide an informed approach to applying sheet metal formingprocedures. You will have an understanding of the forming processes, theequipment used and its application, and will know about the materials and formingtechniques, in adequate depth to provide a sound basis for carrying out the activitiesand producing the components to the required specification.

You will understand the safety precautions required when working with the formingmachines and their associated tools and equipment. You will be required todemonstrate safe working practices throughout, and will understand theresponsibility you owe to yourself and others in the workplace.

Unit 23Forming sheet metal using hand and machine tools



regulations and guidelinesb Follow the correct component drawing and any other related specifications for

the component to be producedc Determine what has to be done and how this will be achievedd Use the appropriate tools and equipment for the pressure shaping operations and

check that they are in a safe and usable conditione Shape the materials to the required specification using appropriate methods

and techniquesf Check that all the required shaping operations have been completed to the

required standardg Deal promptly and effectively with problems within your control and report those



You must:1 Ensure that the tools and equipment to be used are appropriate to the application

and are in a safe and usable condition, by carrying out all of the following checks:• hand tools are in a usable condition (hammer shafts secure; stakes, formers and

striking faces free from defects and damage)• the appropriate machine is selected for the operation being performed• the machine guards and safety devices are in position and function correctly• forming tools are appropriate and in a serviceable condition (secure, correct

shape, free from damage)

2 Use two of the following types of forming equipment/techniques:• hammers• stakes and formers• bending machine (hand or powered)• rolling machine (hand or powered)

3 Carry out forming operations which produce three of the following shapes:• bends• folds• curved panels• cylindrical sections• ducting or trunking



4 Produce components made from two different materials from the following:• bright mild steel• tinned steel• galvanised plate• stainless steel• aluminium• brass• copper

5 Produce components which meet all of the following quality and accuracystandards:• dimensional accuracy is within specification tolerances• finished components meet the required shape• completed components are free from excessive tooling marks,

deformation or cracking

Knowledge statements:You must have knowledge and understanding of:1 The specific safety precautions to be taken when working with sheet metal

equipment and materials in a fabrication environment (general workshop andsite safety, appropriate personal protective equipment, accident procedure;statutory requirements, risk assessment procedures and relevant requirementsof HASAWA, COSHH and Work Equipment Regulations; safe disposal of waste materials)

2 The personal protective clothing and equipment to be worn when carrying outthe fabrication activities (leather apron and gloves, eye protection, safetyhelmets, etc)

3 The correct methods of moving or lifting sheet or plate materials4 The hazards associated with sheet metalwork (such as handling

sheet/fabricated components, using machinery, using dangerous or badlymaintained tools and equipment), and how they can be minimised

5 How to obtain the necessary drawings, specifications and work instructions6 How to extract information from engineering drawings and related

specifications (to include symbols and conventions to appropriate BS or ISOstandards in relation to work undertaken)

7 Marking out conventions used in sheet metalwork, and how to recognisecutting detail and bending and folding lines

8 Hand tools are used in sheet metal forming activities, and typical operationsthat they are used for (range of hammers, stakes)

9 The various machine-tool forming equipment that can be used to produce arange of shapes (such as bends, cylinders and curved sections)

10 How the materials are to be prepared for the forming operations11 Tool and equipment care and maintenance procedures12 Dimensional and forming inspection checks that need to be carried out, and the

tools and equipment to be used



13 Limitations of the various forming processes,and accuracy that may realisticallybe achieved

14 Ways of avoiding inaccuracies in forming activities15 The extent of your own authority and whom you should report to if you have






evidence type

date

Ensure that the tools and equipment to be used are appropriate to the application and are in a safe and usable condition, by carrying out all of the following checks:

hand tools are in a usable condition(hammer shafts secure; stakes, formersand striking faces free from defects anddamage)

the appropriate machine is selected forthe operation being performed

the machine guards and safety devicesare in position and function correctly

forming tools are appropriate and in aserviceable condition (secure, correctshape, free from damage)

Use two of the following types of forming equipment/techniques:

hammers

stakes and formers

bending machine (hand or powered)

rolling machine (hand or powered)

Carry out forming operations which produce three of the following shapes:

bends

folds

curved panels

cylindrical sections

ducting or trunking

Produce components made from two different materials from the following:

bright mild steel

tinned steel

galvanised plate

stainless steel

aluminium

brass

copper



Produce components which meet all of the following quality and accuracy standards:

dimensional accuracy is withinspecification tolerances

finished components meet the requiredshape

completed components are free fromexcessive tooling marks, deformationor cracking


Candidate Date

Assessor Date





Unit summaryThis unit identifies the competencies you need to produce basic sheet metal (up toand including 3mm) assemblies, in accordance with approved procedures. You willbe required to work in accordance with instructions, to bring together, prepare forjoining and assemble, in the right order, sheet metal components and/or lightsections, in order to construct complete fabricated assemblies or sub-assemblies,such as ducting, tanks, cylindrical sections, etc. You will be required to lay out andsecure the various component parts of the structure using mechanical fastenings,clamps or jigs, ready for welding or to use self-securing methods, in the correctorder, and you will ensure they are assembled in a manner that is fit for purpose.

Your responsibilities will require you to comply with organisational policy andprocedures for the sheet metal fabrication activities to be undertaken, and to reportany problems with the activities, tools and equipment or materials that you cannotpersonally resolve, or are outside your permitted authority, to the relevant people.You will be expected to work to instructions, with a minimum of supervision, takingpersonal responsibility for your own actions and for the quality and accuracy of thework that you carry out.

Your underpinning knowledge will be sufficient to provide a good understanding ofyour work, and will provide an informed approach to applying sheet metalfabrication techniques and their assembly and fixing procedures. You will have anunderstanding of the requirements of the manufacturing and assemblingprocedures, the techniques used and their application. You will know about themethods of assembling components of the required strength, that are fit forpurpose, in adequate depth to provide a sound basis for carrying out the activities toensure the work output is produced to the required specification.

You will understand the safety precautions required when working with sheet metalcomponents and their associated tools and equipment. You will be required todemonstrate safe working practices throughout, and will understand theresponsibility you owe to yourself and others in the workplace.

Unit 24Producing sheet metal assemblies



regulations and guidelinesb Follow the relevant instructions, assembly drawings and any other specificationsc Ensure that the specified components are available and that they are in a usable

conditiond Use the appropriate methods and techniques to assemble the components in

their correct positionse Secure the components using the specified connectors and securing devicesf Check the completed assembly to ensure that all operations have been completed

and the finished assembly meets the required specificationg Deal promptly and effectively with problems within your control and report those



You must:1 Carry out all of the following during the sheet metal assembly operations:

• correctly prepare and set up the components and faces to be joined• use the correct datum faces• use the specified or appropriate fixing method• correctly align the components and faces to be joined• assemble/fabricate the sheet metal components in the correct order or manner• produce an assembly which meets the required specification

2 Produce four of the following sheet metal assemblies:• frames• tanks• ducting• guards• hoods• panels• sectional trunking• square, rectangular and box sections• cylindrical sections• conical sections• reduction pieces



3 Use three of the following types of components in the assemblies produced:• sheet metal covers• pre-fabricated square/rectangular components• pre-fabricated cylindrical/conical components• brackets• flanges• pipes• light rolled section (angle, channel or tee section)• stiffeners and frame components

4 Assemble sheet metal components using two of the following methods: • temporary tack welding• soldering or brazing• resistance spot welding• riveting (hollow or solid)• adhesive bonding• flanged and mechanically fastened (bolts, screws)

5 Produce sheet metal assemblies which meet all of the following quality andaccuracy standards:• all components are correctly assembled and aligned in accordance with

the specification• overall dimensions are within specification tolerances• assemblies meet appropriate geometric tolerances (square, straight, angles

free from twists)• where appropriate, pitches of erection holes meet specification requirements• completed assemblies have secure and firm joints, and are clean and free from

burrs or flash


environment and when producing sheet metal assemblies (general workshopand site safety, appropriate personal protective equipment, accidentprocedure; statutory requirements, risk assessment procedures and relevantrequirements of HASAWA, COSHH and Work Equipment Regulations; safedisposal of waste materials)

2 The personal protective clothing and equipment that needs to be worn whencarrying out the fabrication activities (leather gloves, eye protection, safetyhelmets, ear protection, etc)

3 The safe working practices and procedures to be used when producing sheetmetal assemblies

4 The correct methods of moving or lifting bulky fabrications5 The hazards associated with sheet metal fabrication and assembly work (such

using dangerous or badly maintained tools and equipment, lifting and handlinglong and heavy components, cuts, slips trips and falls), and how they can be minimised



6 How to obtain the necessary drawings and joining specifications7 How to extract information from engineering drawings and related


8 How to interpret marking out conventions (cutting lines, centre lines, etc)9 The preparations that need to be carried out on the components prior to

assembling them10 The various methods of securing the assembled components; the range of

mechanical fastening devices that are used (such as nuts and bolts, screws,special fasteners, resistance and tack welding methods and techniques,adhesive bonding of components)

11 How to set up and align the various components, and the tools and equipmentto be used

12 Methods of temporarily holding the joints together to aid the assemblyactivities (clamps, rivet clamps)

13 The use and care of tools and equipment, and their control procedures14 The importance of using tools or equipment only for the purpose intended; the

care that is required when using the tools or equipment; the proper way ofpreserving tools or equipment between operations

15 The things that can go wrong when producing sheet metal assemblies, and howthese can be avoided

16 Inspection techniques that can be applied to check that shape (includingstraightness) and dimensional accuracy are to specification and withinacceptable limits







evidence type

date

Carry out all of the following during the sheet metal assembly operations:

correctly prepare and set up thecomponents and faces to be joined

use the correct datum faces

use the specified or appropriate fixingmethod

correctly align the components andfaces to be joined

assemble/fabricate the sheet metalcomponents in the correct order ormanner

produce an assembly which meets therequired specification

Produce four of the following sheet metal assemblies:

frames

tanks

ducting

guards

hoods

panels

sectional trunking

square, rectangular and box sections

cylindrical sections

conical sections

reduction pieces

Use three of the following types of components in the assemblies produced:

sheet metal covers

pre-fabricated square/rectangularcomponents

pre-fabricated cylindrical/conicalcomponents

brackets



flanges

pipes

light rolled section (angle, channel ortee section)

stiffeners and frame components

Assemble sheet metal components using two of the following methods:

temporary tack welding

soldering or brazing

resistance spot welding

riveting (hollow or solid)

adhesive bonding

flanged and mechanically fastened(bolts, screws)

Produce sheet metal assemblies which meet all of the following quality and accuracy standards:

all components are correctlyassembled and aligned in accordancewith the specification

overall dimensions are withinspecification tolerances

assemblies meet appropriategeometric tolerances (square, straight,angles free from twists)

where appropriate, pitches of erectionholes meet specification requirements

completed assemblies have secure andfirm joints, and are clean and free fromburrs or flash


Candidate Date

Assessor Date





Unit summaryThis unit identifies the competencies you need to heat treat ferrous and non-ferrousmaterials in order to assist with the fabrication activities, in accordance withapproved procedures. You will be required to identify and use the appropriatematerials, apply the relevant processes and use appropriate tools and equipment,based on the information presented to you, in order to achieve the requiredcondition. The heat treatment processes will include hardening, tempering,annealing and normalising/stress relieving, and can be applied to the fabricator’stools, such as punches, chisels and scribers, or to the component/materials to beworked on.

Your responsibilities will require you to comply with organisational policy andprocedures for the heat treatment activities undertaken, and to report any problemswith the heat treatment equipment, materials used or heat treatment activities thatyou cannot personally resolve, or are outside your permitted authority, to therelevant people. You will be expected to work to instructions, with a minimum ofsupervision, taking personal responsibility for your own actions and for the qualityand accuracy of the work that you carry out.

Your underpinning knowledge will be sufficient to provide a good understanding ofyour work, and will provide a sound approach to applying the heat treatmentprocedures. You will have an understanding of the principles and application of heattreatment, and will know about the effects on the structure and characteristics of thematerials, in sufficient depth to provide a sound basis for ensuring the process iscarried out to the required specification.

You will understand the safety precautions to be observed when carrying out heattreatment processes and when using the associated equipment. You will be requiredto demonstrate safe working practices throughout, and will understand theresponsibility you owe to yourself and others in the workplace.

Unit 25Heat treating materials for fabrication activities



regulations and guidelinesb Ensure the materials to be processed are suitably prepared for the processing

operations to be carried outc Check and monitor that the processing equipment is set up and maintained at

satisfactory operating conditions throughout the processing operationsd Carry out the process in accordance with operating procedures and the

workpiece specification requirementse Ensure that the processed workpiece achieves the required characteristics and

meets the processing specificationf Deal promptly and effectively with problems within your control and report those

that you cannot solveg Dispose of waste and excess materials in line with agreed organisational

proceduresh Shut down the processing equipment to a safe condition on completion of the

processing activities


You must:1 Carry out all the following during the heat treatment activities:

• use the correct heat treatment procedure and quality documentation• follow relevant COSHH and risk assessment procedures• apply the required heat treatment processes, safely and correctly• ensure the safety of self and others while carrying out the processes• leave the work area in a safe condition on completion of the activities

2 Carry out one of the following heat treatment processes/techniques:• hardening• tempering• annealing• pre-heating• normalising/stress relieving

3 Apply the appropriate heat treatment process to one of the following:• ferrous components/sections• ferrous high carbon tools (punches, chisels, scribes)• hot steel rivets• non-ferrous sheet or plate



4 Carry out heat treatment processes to all of the following quality and accuracystandards, as applicable to the process carried out:• tools are of the correct hardness for the application and, where appropriate,

suitably tempered• hardened materials are free from cracks• materials/components are suitably treated to allow working• distortion is limited and controlled

Knowledge statements:You must have knowledge and understanding of:1 The specific safety precautions to be taken and safe working practices to be

employed when carrying out the heat treatment of materials in a fabricationenvironment (general workshop and site safety, appropriate personalprotective equipment, accident procedure; statutory requirements, riskassessment procedures and relevant requirements of HASAWA, COSHH andWork Equipment Regulations; safe disposal of waste materials)

2 The personal protective clothing and equipment to be worn when working onheat treatment processes (gloves, eye protection, etc)

3 The handling precautions and correct methods of moving materials,particularly when they are hot

4 The hazards associated with fabrication heat treatment processes (such ashandling sheet/fabricated components, handling hot materials, overheatingquenching oils), and how they can be minimised

5 Reasons for heat treating materials6 The various heat treatment processes, methods and procedures that

may be applied7 The type of equipment that can be used to carry out the various heat treatment

processes (furnaces, blacksmiths forge, gas torches)8 Handling techniques for hot metal components9 How the materials need to be prepared in readiness for the heat treatment

operations10 The type of materials that can be heat treated, and the processes that

may be applied11 The various cooling and quenching techniques that are applied to the

processes, and why it is important to use the correct process (water, oil, sand, air)

12 Ways of limiting distortion during the heat treatment process13 Quality control procedures and recognition of defects14 Limitations of the various processes15 Organisational procedures for disposing of and recycling of waste16 The extent of your own authority and whom you should report to if you have




evidence type

date

Carry out all the following during the heat treatment activities:

use the correct heat treatmentprocedure and quality documentation

follow relevant COSHH and riskassessment procedures

apply the required heat treatmentprocesses, safely and correctly

ensure the safety of self and otherswhile carrying out the processes

leave the work area in a safe conditionon completion of the activities

Carry out one of the following heat treatment processes/techniques:

hardening

tempering

annealing

pre-heating

normalising/stress relieving

Apply the appropriate heat treatment process to one of the following:

ferrous components/sections

ferrous high carbon tools (punches,chisels, scribes)

hot steel rivets

non-ferrous sheet or plate







Carry out heat treatment processes to all of the following quality and accuracy standards, as applicable to the process carried out:

tools are of the correct hardness for theapplication and, where appropriate,suitably tempered

hardened materials are free fromcracks

materials/components are suitablytreated to allow working

distortion is limited and controlled


Candidate Date

Assessor Date



Unit summaryThis unit identifies the competencies you need to carry out cutting and profilingoperations using NC/CNC laser profiling machines, in accordance with approvedprocedures. You will take charge of the prepared machine and check that it is readyfor the machining operations to be performed. This will involve checking that all therequired materials and consumables are present, and that the machine has beenapproved for production. In operating the machine, you will be expected to followthe correct procedures for calling up the machine-operating program, dealing withany error messages, and executing the program activities safely and correctly.

The components produced will have a number of different features, including squareand rectangular profiles, angular profiles, curved profiles, circles, slots, holes linearlypositioned and holes radially positioned. You will be required to continuouslymonitor the cutting operations, making any necessary adjustments to machineparameters, in line with your permitted authority. Meeting production targets will bean important issue, and your production records must show consistent andsatisfactory performance.

Your responsibilities will require you to comply with organisational policy andprocedures for the activities undertaken, and to report any problems with theequipment, program or materials that you cannot personally resolve, or are outsideyour permitted authority, to the relevant people. You will be expected to work toinstructions, with a minimum of supervision, taking personal responsibility for yourown actions and for the quality and accuracy of the work that you produce.

Your underpinning knowledge will be sufficient to provide a good understanding ofyour work, and will provide an informed approach to applying CNC laser cutting andprofiling procedures. You will have an understanding of the CNC cutting/profilingprocess, and its application, and will know about the equipment, materials andconsumables, in adequate depth to provide a sound basis for carrying out theactivities to the required specification.

You will understand the safety precautions required when working with the lasercutting/profiling machine and its associated equipment. You will be required todemonstrate safe working practices throughout, and will understand theresponsibility you owe to yourself and others in the workplace.

Setting up the machine, its tooling, workholding devices and associated equipment,are the subjects of other units.

Unit 26Cutting and shaping materials using NC/CNC laserprofiling machines



regulations and guidelinesb Confirm that the equipment is set up and ready for operationc Follow the defined procedures for starting and running the operating systemd Deal promptly and effectively with error messages or equipment faults that are

within your control and report those that cannot be solvede Monitor the computer process and ensure that the production output is to the

required specificationf Shut down the equipment to a safe condition on conclusion of the activities


You must:1 Confirm that the laser cutting equipment is ready for operation, to include

checking all of the following: • the machine has been approved for production• all safety equipment and guards are in place and functioning correctly• materials are correctly positioned and held securely without distortion• the laser lens is clean and in a suitable condition• the operating program is at the correct start point• safe working practices and startup procedures are observed• machine settings are adjusted as required to maintain accuracy

2 Produce cut and shaped components which cover five of the following features:• square/rectangular profiles• angular profiles• curved profiles• circles• ellipses• holes linearly positioned• holes radially positioned• slots and apertures• other features

3 Machine one of the following types of material:• ferrous• non-ferrous• stainless steel• alloy steel• other appropriate material



4 Produce components within all of the following quality and accuracy standards:• dimensional accuracy is within the tolerance specified on the

drawing/specification or within +/- 1.5mm• angled cuts are within specification requirements (perpendicular/angularity)• cuts are clean and smooth• components are free from distortion


NC/CNC laser cutting and profiling machines (care when working with highpower laser beams; machine guards; ventilation and fume extraction; machinesafety devices)

2 How to start and stop the machine in normal and emergency situations, andhow to close the machine down on completion of activities

3 The importance of ensuring the machine is isolated from the power supplybefore working with machinery; and the care needed, particularly whenworking with laser beams

4 The importance of wearing the appropriate protective clothing and equipment,and of keeping the work area clean and tidy

5 The hazards associated with using laser cutting and profiling machines(dangers from the laser beam; live electrical components; moving parts ofmachinery), and how they can be minimised

6 Principles and operation of lasers; laser machines; terminology used7 How to use and extract information from engineering drawings and related


8 How to interpret the visual display and understand the various messages displayed

9 The function of error messages, and what to do when an error message is displayed

10 How to find the correct restart point in the program when the machine has beenstopped before completion of the program

11 The operation of the various hand and automatic modes of machine control(such as hand wheels, joysticks, program operating and control buttons)

12 How to operate the machine using single block run, full program run and speedoverride controls

13 How to make adjustments to machine-operating programs to take account ofout-of-specification components

14 Care of equipment and operating programs, including safe storage of materialaway from electromagnetic forces

15 Monitoring the machine during the cutting process; recognition of problemsand action to be taken



16 Problems that can occur during the laser cutting activities, and how to prevent them


18 The extent of your own authority and whom you should report to if you haveproblems you cannot resolve





evidence type

date

Confirm that the laser cutting equipment is ready for operation, to include checking all of the following:

the machine has been approved forproduction

all safety equipment and guards are inplace and functioning correctly

materials are correctly positioned andheld securely without distortion

the laser lens is clean and in a suitablecondition

the operating program is at the correctstart point

safe working practices and startupprocedures are observed

machine settings are adjusted asrequired to maintain accuracy

Produce cut and shaped components which cover five of the following features:


angular profiles

curved profiles

circles

ellipses

holes linearly positioned

holes radially positioned

slots and apertures

other features

Machine one of the following types of material:

ferrous

non-ferrous

stainless steel

alloy steel

other appropriate material



Produce components within all of the following quality and accuracy standards:

dimensional accuracy is within thetolerance specified on thedrawing/specification or within +/-1.5mm

angled cuts are within specificationrequirements(perpendicular/angularity)

cuts are clean and smooth

components are free from distortion


Candidate Date

Assessor Date





Unit summaryThis unit identifies the competencies you need to carry out cutting and profilingoperations using NC/CNC plasma or gas cutting and profiling machines, inaccordance with approved procedures. You will take charge of the preparedmachine and check that it is ready for the cutting operations to be performed. Thiswill involve checking that all the required materials and consumables are present,and that the machine has been approved for production. In operating the machine,you will be expected to follow the correct procedures for calling up the machine-operating program, dealing with any error messages, and executing the programactivities safely and correctly.

The components produced will have a number of different features, including squareand rectangular profiles, angular profiles, curved profiles, circles, slots, holes linearlypositioned and holes radially positioned. You will be required to continuouslymonitor the cutting and shaping operations, making any necessary adjustments tomachine parameters, in line with your permitted authority.

Your responsibilities will require you to comply with organisational policy andprocedures for the activities undertaken, and to report any problems with theequipment, program or materials that you cannot personally resolve, or are outsideyour permitted authority, to the relevant people. You will be expected to work toinstructions, with a minimum of supervision, taking personal responsibility for yourown actions and for the quality and accuracy of the work that you produce.

Your underpinning knowledge will be sufficient to provide a good understanding ofyour work, and will provide an informed approach to applying CNC plasma or gascutting/profiling procedures. You will have an understanding of the CNC cuttingprocess, and its application, and will know about the equipment, materials andconsumables, in adequate depth to provide a sound basis for carrying out theactivities to the required specification.

You will understand the safety precautions required when working with theplasma/gas cutting machine and its associated equipment. You will be required todemonstrate safe working practices throughout, and will understand theresponsibility you owe to yourself and others in the workplace.

Setting up the machine, its tooling, workholding devices and associated equipment,are the subjects of other units.

Unit 27Cutting and shaping using NC/CNC plasma or gas cutting machines



regulations and guidelinesb Confirm that the equipment is set up and ready for operationc Follow the defined procedures for starting and running the operating systemd Deal promptly and effectively with error messages or equipment faults that are

within your control and reporte those that cannot be solvedf Monitor the computer process and ensure that the production output is to the

required specificationg Shut down the equipment to a safe condition on conclusion of the activities


You must:1 Confirm that the plasma/gas cutting installation is ready for operation, to include

checking all of the following: • the machine has been approved for production• all safety equipment and guards are in place and functioning correctly• materials are correctly positioned and held securely without distortion• the cutting nozzles are clean and in a suitable condition• the operating program is at the correct start point• the workpiece is clear of the machine spindle• safe working practices and startup procedures are observed• machine settings are adjusted as required to maintain accuracy

2 Use one of the following thermal cutting methods:• Oxy-fuel gas cutting• Plasma gas cutting

3 Produce components which are cut and shaped, and which cover six of thefollowing features:• square/rectangular profiles• angular profiles• curved profiles• circles• ellipses• round holes• slots and apertures• angled cuts• bevelled edge – weld preparations• other features



4 Machine one of the following types of material:• mild steel• carbon steel• stainless steel• other alloy steels• other appropriate material

5 Produce components within all of the following quality and accuracy standards:• dimensional accuracy is within the tolerance specified on the

drawing/specification or within +/- 1.5mm• angled cuts are within specification requirements (perpendicular/angularity)• cuts are clean and smooth with minimal drag lines• components are free from distortion


NC/CNC plasma and gas cutting/ profiling machines (general workshop and sitesafety, appropriate personal protective equipment, fire and explosionprevention, protecting other workers; fume control; accident procedure;statutory requirements, risk assessment procedures and relevant requirementsof HASAWA, COSHH and Work Equipment Regulations; safe disposal of wastematerials; machine safety devices)

2 How to start and stop the machine in normal and emergency situations, andhow to close the machine down on completion of activities

3 The importance of ensuring the machine is isolated from the power supplybefore working with machinery; and the care needed when working withcompressed gases

4 The equipment that needs to be worn when working with fabrications andthermal cutting equipment (leather aprons and gloves, eye protection, safetyhelmets, etc)

5 The hazards associated with using CNC thermal cutting equipment (nakedflames, fumes and gases, explosive gas mixtures, oxygen enrichment, spatter,hot metal, moving parts of machinery), and how they can be minimised

6 The correct methods of moving or lifting plate materials and components7 Principles and operation of the plasma or gas cutting equipment, and the

terminology used in thermal cutting, in relation to the operations being performed8 How to use and extract information from engineering drawings and related


9 How to interpret the visual display and understand the various messages displayed

10 The function of error messages, and what to do when an error message is displayed

11 How to find the correct restart point in the program when the machine has beenstopped before completion of the program



12 The operation of the various hand and automatic modes of machine control(such as hand wheels, joysticks, program operating and control buttons)

13 How to operate the machine using single block run, full program run and speedoverride controls

14 How to make adjustments to machine-operating programs to take account ofout-of-specification components

15 Setting of operating conditions; flame control and the effects of mixtures andpressures associated with thermal cutting

16 The effects of oil, grease, scale or dirt on the cutting process17 Care of equipment and operating programs, including safe storage of material

away from electromagnetic forces18 Monitoring the machine during the cutting process; recognition of problems

and action to be taken19 The actions to be taken prior to cutting (setting up the material/workpiece,

checking cleanliness of materials used)20 The holding methods that are used to aid thermal cutting, and equipment that

can be used21 The problems that can occur with thermal cutting and how they can be

avoided; causes of distortion during thermal cutting and methods of controlling distortion


23 The extent of your authority and whom you should report to if you haveproblems that you cannot resolve






evidence type

date

Confirm that the plasma/gas cutting installation is ready for operation, to include checking all of the following:

the machine has been approved forproduction

all safety equipment and guards are inplace and functioning correctly

materials are correctly positioned andheld securely without distortion

the cutting nozzles are clean and in asuitable condition

the operating program is at the correctstart point

the workpiece is clear of the machinespindle

safe working practices and startupprocedures are observed

machine settings are adjusted asrequired to maintain accuracy

Use one of the following thermal cutting methods:

Oxy-fuel gas cutting

Plasma gas cutting

Produce components which are cut and shaped, and which cover six of the following features:


angular profiles

curved profiles

circles

ellipses

round holes

slots and apertures

angled cuts

bevelled edge – weld preparations

other features



Machine one of the following types of material:

mild steel

carbon steel

stainless steel

other alloy steels

other appropriate material

Produce components within all of the following quality and accuracy standards:

dimensional accuracy is within thetolerance specified on thedrawing/specification or within +/-1.5mm


cuts are clean and smooth with minimaldrag lines

components are free from distortion


Candidate Date

Assessor Date





Unit summaryThis unit identifies the competencies you need to undertake the preparation andmaking of joints between fabricated components, using mechanical means, inaccordance with approved procedures. You will be required to produce suitable andappropriate joints, using appropriate methods for the materials to be joined thatmeet the specified conditions and subsequent operating conditions to bedemanded of the joint. Particular attention will be needed in the preparation andfinishing of the materials, so that the finished component is fit for purpose and meetsthe level of accuracy required. The mechanical fastenings used will include rivets,self-tapping screws, bolts and screwed fittings, anchor nuts and proprietaryfasteners, as appropriate to the application and/or specification. The joint will be oftwo or more materials, and may include non-metallic materials and joints ofdissimilar metals.

Your responsibilities will require you to comply with organisational policy andprocedures, or those of the fastener manufacturers. You will be expected to reportany problems with the mechanical fasteners, or the joining activities that you cannotresolve, or are outside your permitted authority, to the relevant people. You will beexpected to work to instructions, with a minimum of supervision, taking personalresponsibility for your own actions and for the quality and accuracy of the work thatyou produce.

Your underpinning knowledge will be sufficient to provide a good understanding ofyour work, and will provide an informed approach to the mechanical joining activitiescarried out. You will have an understanding of the basic characteristics of thematerials to be joined, the various processes used and the appropriate proceduresthat go with them, in adequate depth to provide a sound basis for achieving a soundand cohesive joint that is fit for purpose.

You will understand the safety precautions required when working with the tools andequipment, especially those for use in hot metal processes, and the safeguardsnecessary for undertaking the joining processes. You will be required todemonstrate safe working practices throughout, and will understand theresponsibilities you owe to yourself and others in the workplace.

Unit 28Assembling components using mechanical fasteners



regulations and guidelinesb Follow the relevant instructions, assembly drawings and any other specificationsc Ensure that the specified components are available and that they are in a

usable conditiond Use the appropriate methods and techniques to assemble the components in





You must:1 Carry out all of the following during the joining process:

• correctly prepare the faces of the materials to be joined• select the appropriate/specified fixings• correctly align the materials and faces to be joined• assemble the components in the correct order or manner• produce a joint that meets the requirements of the specification

2 Produce assemblies which include four of the following:• flat and flanged joints on flat or curved surfaces• square/rectangular trunking• circular trunking• access flanges and cover plates• tanks and tank covers• joints with gasket or sealant• pipes• structural components• long or critical alignments• permanent and temporary assemblies



3 Use four of the following assembly methods and techniques:• riveting using cold or/and hot rivets• riveting using pop/blind rivets• self-tapping screws• use of proprietary fasteners• crimping• assembling using bolt fittings• using screw fittings to tapped components• nuts and (spot welded) screw studs• locking methods and devices• clinching

4 Join the components in three of the following joining positions or access andenvironmental conditions:• horizontal• vertical• overhead• in workshop conditions• in the field• internal and confined spaces

5 Produce joints to all of the following quality and accuracy standards, as applicableto the application:• joints are accurately assembled and aligned in accordance with the

specifications• joints are secure and firm• bolted and screwed joints are tightened to the correct torque• riveted joints are free from excessive material deformation and hammer marks• pitch of holes meet the specification• completed joints are clean and free from burrs

Knowledge statements:You must have knowledge and understanding of:1 The specific safety precautions to be followed when working in a fabrication

environment and when carrying out joining activities using fabricatedcomponents (general workshop and site safety, appropriate personalprotective equipment, accident procedure; statutory regulations, riskassessment procedures and COSHH regulations)

2 The personal protective clothing and equipment to be worn when carrying outthe joining activities (leather gloves, eye protection, safety helmets, etc)

3 The hazards associated with the joining operations (such as handlingsheet/fabricated components, using hot metal riveting techniques, handlingand using sealants and cleaning agents, dangerous or badly maintained toolsand equipment), and how they can be minimised

4 How to obtain the necessary drawings and joining procedure specifications




6 The use of manufacturers’ specifications for the types of fasteners used7 The various joining processes that are used, and the tools and

equipment required8 The preparations to be carried out on the materials/components prior to joining

them (such as materials to be degreased, dry and clean, with holes and flangesde-burred)

9 How to set up and align the joints prior to fixing, and the tools and methods thatcan be used (such as clamps, rivet gripping tools, temporary fixings, jacking andsupporting devices)

10 How to produce a secure joint using blind rivets, and the type of riveting toolsthat are available

11 How to produce a good hot or cold riveted joint, and the use of the variousriveting tools

12 How to determine the length of the rivets required to give a properly formedrivet head

13 The range of bolts and screwed fasteners that are to be used; why it isimportant to use the correct type of washer; sequence of tightening bolts onflanged joints; and the tools and equipment used to ensure they are tightenedto the required torque

14 Checks to be carried out on the tools and equipment prior to use to ensure thatthey are in a safe and usable condition (such as condition of plugs and leads onpower tools, condition of striking faces on hammers, condition of riveting toolsand rivet snaps)

15 Equipment setting, operating and care procedures; why equipment and toolsneed to be correctly set up and in good condition

16 The importance of using the tools only for the purpose intended; the care that isrequired when using the equipment and tools; the proper way of preservingand storing tools and equipment between operations

17 The things that can go wrong with the joining operations, and how these can be avoided







evidence type

date

Carry out all of the following during the joining process:

correctly prepare the faces of thematerials to be joined

select the appropriate/specified fixings

correctly align the materials and facesto be joined

assemble the components in thecorrect order or manner

produce a joint that meets therequirements of the specification

Produce assemblies which include four of the following:

flat and flanged joints on flat or curvedsurfaces

square/rectangular trunking

circular trunking

access flanges and cover plates

tanks and tank covers

joints with gasket or sealant

pipes

structural components

long or critical alignments

permanent and temporary assemblies

Use four of the following assembly methods and techniques:

riveting using cold or/and hot rivets

riveting using pop/blind rivets

self-tapping screws

use of proprietary fasteners

crimping

assembling using bolt fittings

using screw fittings to tappedcomponents



nuts and (spot welded) screw studs

locking methods and devices

clinching

Join the components in three of the following joining positions or access and environmental conditions:

horizontal

vertical

overhead

in workshop conditions

in the field

internal and confined spaces

Produce joints to all of the following quality and accuracy standards, as applicable to the application:

joints are accurately assembled andaligned in accordance with thespecifications

joints are secure and firm

bolted and screwed joints are tightenedto the correct torque

riveted joints are free from excessivematerial deformation and hammermarks

pitch of holes meet the specification

completed joints are clean and freefrom burrs


Candidate Date

Assessor Date





Unit summaryThis unit identifies the competencies you need to undertake the joining ofengineering materials using adhesive bonding processes, in accordance withapproved procedures. You will be required to work to instructions, using appropriateor specified bonding agents for the materials to be joined, that meet the specifiedconditions and subsequent operating conditions to be demanded of the joint.Particular attention will be needed in the preparation of the materials and theapplication of the bonding agent, as well as the means of securing the joint until thesetting or curing process has been completed, so that the finished componentmeets the level of accuracy required. The adhesive bonding agents used will includeimpact adhesives, cold curing adhesives, rubber mastic, solvent adhesives, epoxyresins and thermally cured adhesives. The joint will be of two or more materials andmay include metallic and/or non-metallic materials and joints of dissimilar materials.

Your responsibilities will require you to comply with organisational policies andprocedures, and/or those of the bonding agent manufacturers. You will be expectedto report any problems with the bonding agents, materials or bonding activities thatyou cannot resolve yourself, or are outside your permitted authority, to the relevantpeople. You will be expected to work to instructions, with a minimum of supervision,taking personal responsibility for your own actions and for the quality and accuracyof the work that you carry out.

Your underpinning knowledge will be sufficient to provide a good understanding ofyour work, and will provide an informed approach to the adhesive bonding activitiescarried out. You will have an understanding of the basic characteristics of thematerials to be joined, the bonding agents used and the procedures that go withthem, in adequate depth to provide a sound basis for carrying out the activities safelyand correctly and for achieving a sound and cohesive joint that is fit for purpose.

You will understand the precautions required when working with the variousbonding agents, and the safeguards necessary for undertaking the process. You willbe required to demonstrate safe working practices throughout, and will understandthe responsibilities you owe to yourself and others in the workplace.

Unit 29Bonding engineering materials using adhesives



regulations and guidelinesb Follow the relevant bonding procedure specification and job instructionsc Check that the materials to be bonded and bonding agents comply with

the specificationd Correctly prepare the parent materials and bonding agents in line with the

bonding specificatione Carry out the bonding operations using the specified processes and techniques to

position and bond the materials in their correct locationsf Ensure that any equipment used to maintain surface contact during the bonding

activities is set up and usedcorrectlyg Achieve bonds of the required quality and within the specified

dimensional accuracyh Deal promptly and effectively with problems within your control and report those



You must:1 Carry out all of the following during the adhesive bonding process:

• correctly prepare the materials for bonding• select the right constituents and bonding methods• check the surfaces to be bonded mate properly to make a sound joint possible• ensure the joint is rigidly secure during the curing period• remove surplus material and clean up at the appropriate time

2 Carry out adhesive bonding activities using two of the following types of material:• metallic• non-metallic• combinations

3 Use two of the following types of adhesives:• impact adhesives• cold curing adhesives• rubber mastic• solvent adhesives• epoxy resins• thermally cured adhesives



4 Produce bonded joints in three of the following types of component:• flat and flanged joints on flat surfaces• flat and flanged joints on curved surfaces• vertical components• horizontal components• rectangular trunking• circular trunking• access flanges, panels and cover plates• tanks and tank covers• pipework

5 Use a range of bonding equipment and devices, to include four of the following:• mixing vessels• spatulas, brushes, knives• spray equipment• jigs• formers• clamps• presses• weights• temporary fixtures (clips, wiring)

6 Use a range of preparation and cleaning agents, to include two of the following:• detergents• solvents• petroleum products• acids

7 Produce bonded joints which comply with all of the following quality and accuracy standards:• components are dimensionally accurate and of the correct orientation• joints meet the required application standard• completed joints are clean and free from surplus adhesive• the completed joint has the required appearance

Knowledge statements:You must have knowledge and understanding of:1 The specific safety precautions to be taken when bonding engineering

materials using adhesives in a fabrication environment (general workshop andsite safety, appropriate personal protective equipment, accident procedure;statutory regulations, risk assessment procedures and COSHH regulations)

2 The personal protective clothing and equipment to be worn when carrying outbonding as part of the fabrication activities (gloves, eye protection, safetyhelmets, respiratory protection, etc)

3 The importance of good workshop practice and house keeping, ventilation andfume control equipment, first aid procedures and actions, hazardoussubstances and relevant sections of COSHH



4 The correct methods of moving or lifting sheet or plate materials5 The hazards associated with bonding fabricated components, and how they

can be minimised6 How to obtain the necessary drawings and joining specifications7 How to extract information from engineering drawings and related

specifications (to include symbols and conventions to appropriate BS or ISOstandards in relation to the work undertaken)

8 The material preparations that are required, and the equipment andconsumables that are used

9 The importance of working to organisational and bonding agent manufacturers’instructions whilst carrying out the bonding activities

10 The methods and techniques used for bonding the materials (such as gluing,impact, chemical and thermal reaction techniques)

11 The basic characteristics of the adhesives that are to be used12 The application of, and precautions to be taken when using, adhesives

and solvents13 Maintenance and care of tools and equipment14 Methods of degreasing components and producing a keying surface15 Type and suitability of adhesives; setting or curing requirements and time,

strength and appearance16 Common causes of defects associated with the bonding processes, and how to

avoid them17 The effects of the environment on the bonding process (such as temperature,

humidity, cleanliness)18 How to identify, select, use, and clean, the appropriate bonding agent holding

vessels, brushes, stirrers and spatulas, scrapers, knives, clamps and weights19 The importance of cleaning up after use, to ensure everything can be used

again and to minimise the need for replacement of equipment20 Reasons for checking that components are assembled in the correct sequence,

are positioned dimensionally accurately and to the correct orientation, inaccordance with the specifications, prior to bonding

21 How to check that completed joints are firm, sound and fit for purpose22 Procedures for cleaning off surplus adhesive and tidying up the appearance

of joints23 The extent of your own authority and whom you should report to if you have






evidence type

date

Carry out all of the following during the adhesive bonding process:

correctly prepare the materials forbonding

select the right constituents andbonding methods

check the surfaces to be bonded mateproperly to make a sound joint possible

ensure the joint is rigidly secure duringthe curing period

remove surplus material and clean upat the appropriate time

Carry out adhesive bonding activities using two of the following types of material:

metallic

non-metallic

combinations

Use two of the following types of adhesives:

impact adhesives

cold curing adhesives

rubber mastic

solvent adhesives

epoxy resins

thermally cured adhesives

Produce bonded joints in three of the following types of component:

flat and flanged joints on flat surfaces

flat and flanged joints on curvedsurfaces

vertical components

horizontal components

rectangular trunking

circular trunking



access flanges, panels and cover plates

tanks and tank covers

pipework

Use a range of bonding equipment and devices, to include four of the following:

mixing vessels

spatulas, brushes, knives

spray equipment

jigs

formers

clamps

presses

weights

temporary fixtures (clips, wiring)

Use a range of preparation and cleaning agents, to include two of the following:

detergents

solvents

petroleum products

acids

Produce bonded joints which comply with all of the following quality and accuracy standards:

components are dimensionallyaccurate and of the correct orientation

joints meet the required applicationstandard

completed joints are clean and freefrom surplus adhesive

the completed joint has the requiredappearance


Candidate Date

Assessor Date





Unit summaryThis unit identifies the competencies you need to set up and use portable, andsimple fixed spot welding machines, in accordance with approved instructions orwelding procedures. You will be expected to check that the equipment is fit forpurpose, that electrodes are correctly profiled, and that the component parts are inthe correct condition for spot welding. In preparing the equipment, you will need toset the welding current, welding and squeeze times and electrode pressure. Youmust operate the equipment safely and correctly, and make any necessaryadjustments to the equipment settings and parameters within permitted tolerances,in order to achieve a weld quality and tolerances that meet the specification.

Your responsibilities will require you to comply with organisational policy andprocedures for the welding activities undertaken, and to report any problems oradjustments to the equipment that you cannot resolve, or are outside yourpermitted authority, to the relevant people. You will be expected to work toinstructions, with a minimum of supervision, taking personal responsibility for yourown actions and for the quality and accuracy of the work that you carry out.

Your underpinning knowledge will be sufficient to provide a sound basis of yourwork, and will enable you to adopt an informed approach to applying spot weldingprocedures and instructions. You will understand how the resistance spot weldingprocess works, and will know about the equipment, materials and consumables, inadequate depth to provide a sound background to the process operation and forcarrying out the activities to the required specification.

You will understand the safety precautions required when working with theresistance spot welding equipment. You will be required to demonstrate safeworking practices throughout, and will understand the responsibility you owe toyourself and others in the workplace.

Unit 30Joining materials by resistance spot welding









You must:1 Ensure the resistance spot welding equipment is fit for purpose, by carrying out

all of the following checks:• equipment range is suitable for the operations to be performed• portable equipment power leads are undamaged and securely connected• electrodes are of the correct type, size and profile• all equipment mechanical and electrical systems operate correctly• supplies of components are adequate and suitably prepared• appropriate safety screens are available

2 Set up, check, adjust and operate one of the following resistance spot welding machines:• portable spot welding machines• fixed simple spot welding machines

3 Set up the equipment parameters in accordance with instructions and the weldingprocedure specification, to include setting all of the following:• electrode tip diameter/profile• welding current• welding and squeeze times• electrode pressure



4 Monitor the process operation and make adjustments to parameters, in order toproduce welded components covering both of the following:• two different components• two different material thicknesses

5 Produce welded components which meet all the following requirements:• achieve a weld quality as specified in the application standard• spot welds are correctly pitched out• welded components meet the required dimensional accuracy within

specified tolerance

Knowledge statements:You must have knowledge and understanding of:1 The specific safety precautions to be taken when operating resistance welding

equipment (working with machinery, the use of appropriate personal protectiveequipment; the use of safety screens; operation of machine safety devices;closing down the machine on completion of the welding activities; statutoryrequirements, risk assessment procedures and relevant requirements ofHASAWA, COSHH and Work Equipment Regulations; safe disposal of waste materials)

2 The hazards associated with resistance welding equipment (dangers from liveinternal electrical components, fumes, hot metal, expulsion of hot particles,moving parts of machines), and how they can be minimised

3 The basic principles of resistance welding; heat and pressure to form a weld;heating effect of welding current; principal features of the welded joint; heatinput; welding and pressure cycles; terminology used in welding

4 The key components and features of the equipment used (power source;welding head; power range; electrical parameters (such as arc voltage, current,electrode pressure and welding time); systems for parameter control; howvariation in the parameters influence weld features, quality and output)

5 Extracting information required from drawings and welding procedure specifications

6 Operation of the machine controls and their function; equipment care procedures

7 Monitoring the equipment during the welding process; fine tuning parametersto maintain quality; recognition of problems and action to be taken

8 Problems that can occur with the welding activities; materials and weld defects9 Self inspection of completed work10 Organisational quality systems (standards to be achieved; production records





evidence type

date

Ensure the resistance spot welding equipment is fit for purpose, by carrying out all of the following checks:

equipment range is suitable for theoperations to be performed

portable equipment power leads areundamaged and securely connected

electrodes are of the correct type, sizeand profile

all equipment mechanical and electricalsystems operate correctly

supplies of components are adequateand suitably prepared

appropriate safety screens areavailable

Set up, check, adjust and operate one of the following resistance spot welding machines:

portable spot welding machines

fixed simple spot welding machines

Set up the equipment parameters in accordance with instructions and the welding procedure specification, to include setting all of the following:

electrode tip diameter/profile

welding current

welding and squeeze times

electrode pressure

Monitor the process operation and make adjustments to parameters, in order to produce welded components covering both of the following:


two different material thicknesses







Produce welded components which meet all the following requirements:


spot welds are correctly pitched out

welded components meet the requireddimensional accuracy within specifiedtolerance


Candidate Date

Assessor Date



Unit summaryThis unit identifies the competencies you need to move loads by slinging and lifting,in accordance with approved procedures. You will be required to use correctlyspecified items of lifting gear, which will include hand, and/or power operated cranesand winches, and associated lifting accessories. You must check that the liftingequipment is within current authorisation dates, is undamaged and within thepermitted safe working load. You will be expected to correctly estimate the weight ofthe load to be moved, and attach the appropriate slings to suitable or designatedlifting points on the load in order to achieve a safe and balanced lift. You must checkthe area that the load will move through, to ensure that it is free from obstructionsand is safe for the load to be moved. You will also be expected to give the correcthand and verbal signals during the lifting activities.

Your responsibilities will require you to comply with organisational policy andprocedures for the slinging, signalling and lifting activities undertaken, and to reportany problems with the slinging and lifting equipment or the lifting activities that youcannot personally resolve, or are outside your permitted authority, to the relevantpeople. You will be expected to work with minimum supervision, taking personalresponsibility for your own actions and for the safety and integrity of the materialsbeing moved.

Your underpinning knowledge will be sufficient to provide a good understanding ofyour work, and will provide an informed approach to applying slinging, signalling andlifting procedures. You will have an understanding of the slinging, signalling andlifting techniques used, and their application, and will know about the liftingequipment and accessories for lifting, in adequate depth to provide a sound basis forcarrying out the activities to the required specification.

You will need to understand the safety precautions required when slinging and liftingcomponents, and the safeguards that are necessary for undertaking the activities.You will be required to demonstrate safe working practices throughout, and willunderstand the responsibilities you owe to yourself and others in the workplace.

Unit 31Slinging, lifting and moving materials and components



regulations and guidelinesb Position the moving equipment so that the weight of the load is evenly distributedc Attach the appropriate handling equipment securely to the load, using approved

methods to eliminate slippaged Confirm that the load is secure before movinge Move the load over the selected, suitable routef Position and release the load safely in its intended final location


You must:1 Ensure that the equipment to be used is suitable for the components being lifted,

and is in a safe and usable condition, by checking all of the following:• equipment is certified and is compliant, within current test dates• all lifting equipment registers are up to date• all slings are free from obvious defects• the lifting equipment selected is suitable and has a sufficient SWL for

the application• the identification number and SWL are clearly marked on the

equipment selected• the equipment selected is suitable for the environment of operation

2 Use two of the following lifting and moving methods and techniques:• crane• winch• powered lifting equipment• lifting appliances• pulling appliances• multi-sheaved block combinations• hand operated lifting equipment• jacks, skates and trolleys

3 Use two of the following slinging methods:• single-leg slings• two-leg slings• three- and four-leg slings



4 Move two of the following types of loads:• sheet materials• pipes, bars, joists, etc (single and in bundles)• fragile items• hot/radiant items• components with evenly distributed weight• components with uneven distributed weight• awkward shaped loads• corrosive substances/chemicals

5 Move loads safely and correctly, to be re-positioned in two of the following positions:• to differing elevations• as part of an assembly• through complex rigging operations• along the same elevation• turn a load

6 Find the weight of the materials/loads to be moved using all of the following, as applicable:• check against documentation• calculation from drawings• by estimation• by converting metric-imperial

Knowledge statements:You must have knowledge and understanding of:1 The specific safety precautions to be taken when slinging and lifting loads, and

the need for ensuring load security (general workshop and site safety,appropriate personal protective equipment, protecting other workers duringthe lifting operations; accident procedure; statutory requirements, riskassessment procedures and relevant requirements of HASAWA, COSHH andWork Equipment Regulations; safe disposal of waste materials)

2 The hazards associated with slinging and lifting of loads, and how they can be minimised

3 An understanding of ACOP for safe use of lifting equipment, and LiftingOperation & Lifting Equipment Regulations (LOLER)

4 The specific requirements for the marking of lifting equipment, and the specificmethod used in the organisation in which you are working

5 The range of equipment to be used for the lifting operations (such as hand andpower operated cranes, winches pulling equipment)

6 The lifting equipment accessories to be used (such as slings, chains, wire ropes,eye bolts)

7 Checks that should be made on the lifting equipment prior to use, and thingsthat you should look for

8 How to carry out in-service inspections of the equipment, and what to doshould any defective equipment be identified



9 How to determine the approximate weight of the load to be moved10 Factors which affect the selection of the lifting equipment and lifting

accessories (such as weight, type of load, operating environment)11 How to check that the lifting equipment is capable of lifting the load

to be moved12 How to determine the centre of gravity of the load, and how to determine

suitable slinging and lifting points13 How to plan and prepare a route for moving loads, and the things that you will

need to take into account14 The specific requirements for the organisation of lifting operations15 Signalling techniques used to communicate with crane drivers (to include both

hand signals and verbal commands)16 How lifting equipment should be stored, handled and maintained17 The extent of your own authority and whom you should report to if you have






evidence type

date

Ensure that the equipment to be used is suitable for the components being lifted, and is in a safe and usable condition, by checking all of the following:

equipment is certified and is compliant,within current test dates

all lifting equipment registers are up todate

all slings are free from obvious defects

the lifting equipment selected issuitable and has a sufficient SWL for theapplication

the identification number and SWL areclearly marked on the equipmentselected

the equipment selected is suitable forthe environment of operation

Use two of the following lifting and moving methods and techniques:

crane

winch

powered lifting equipment

lifting appliances

pulling appliances

multi-sheaved block combinations

hand operated lifting equipment

jacks, skates and trolleys

Use two of the following slinging methods:

single-leg slings

two-leg slings

three- and four-leg slings



Move two of the following types of loads:

sheet materials

pipes, bars, joists, etc (single and inbundles)

fragile items

hot/radiant items

components with evenly distributedweight

components with uneven distributedweight

awkward shaped loads

corrosive substances/chemicals

Move loads safely and correctly, to be re-positioned in two of the following positions:

to differing elevations

as part of an assembly

through complex rigging operations

along the same elevation

turn a load

Find the weight of the materials/loads to be moved using all of the following, as applicable:

check against documentation

calculation from drawings

by estimation

by converting metric-imperial


Candidate Date

Assessor Date





Unit summaryThis unit identifies the competencies you need for cutting and shaping metal plateand sections (3 mm thickness and above) for fabrications using guillotines andsection cropping machines, in accordance with approved procedures. You will berequired to select the appropriate equipment and machine settings to use, for thematerial, thickness and the accuracy to be achieved. Items to be cut and shaped mayinclude ferrous and non-ferrous materials, and will include parallel cuts, square cuts,and cuts that are at an angle. These cuts will be achieved by working to marking out,and by setting the machine’s backstop when multiple cutting is required. This will callfor care in selecting the right tools, so as to avoid damage to the materials and tools,or danger to oneself.

Your responsibilities will require you to comply with organisational policy andprocedures, seeking out relevant information for the activities undertaken, and toreport any problems with the equipment, materials or cutting activities that youcannot personally resolve, or are outside your permitted authority, to the relevantpeople. You will be expected to work to instructions, with a minimum of supervision,taking personal responsibility for your own actions and for the quality and accuracyof the work that you produce.

Your underpinning knowledge will be sufficient to provide a good understanding ofyour work, and will provide an informed approach to applying metal shearingprocedures. You will have an understanding of the shearing processes, theequipment and its application, and will know about the process in adequate depth toprovide a sound basis for carrying out the activities to the required specification.

You will understand the safety precautions required when working with shearingmachines and their associated tools and equipment. You will be required todemonstrate safe working practices throughout, and will understand theresponsibility you owe to yourself and others in the workplace.

Unit 32Cutting plate and sections using shearing machines



regulations and guidelinesb Confirm that the machine is set up and ready for the machining activities to be

carried outc Manipulate the machine tool controls safely and correctly in line with

operational proceduresd Produce components to the required quality and within the specified

dimensional accuracye Carry out quality sampling checks at suitable intervalsf Deal promptly and effectively with problems within your control and report those

that cannot be solvedg Shut down the equipment to a safe condition on conclusion of the

machining activities


You must:1 Confirm that the equipment is safe and fit for purpose by carrying out all of the

following checks:• the appropriate equipment/machine is selected for the operation

being performed• the machine guards and safety devices are in position and function correctly

2 Cut metal plate using both of the following types of shearing machine:• guillotines• section cropping machine

3 Cut materials using both of the following techniques:• to markings• using machine backstop for multiple cutting

4 Perform operations that produce straight and accurate cuts, which include bothof the following:• parallel cuts• square cuts



5 Cut plate, sections or bars for one appropriate material from the following:• black mild steel• stainless steel• aluminium• brass or copper• tin plate• other specific materials

6 Produce cut components which meet all of the following quality and accuracy standards:• dimensional accuracy is within the tolerances specified on the

drawing/specification• cut components are free from excessive distortion• cut edges are neat and free from false tool cuts and shearing slivers


environment and when working with shearing machines (general workshop andsite safety, appropriate personal protective equipment, accident procedure;statutory requirements, risk assessment procedures and relevant requirementsof HASAWA, COSHH and Work Equipment Regulations; safe disposal of waste materials)


3 Safe working practices and procedures for operating machine tools4 The correct methods of moving or lifting heavy plate, and the equipment

to be used5 The hazards associated with fabrication work and shearing operations (such as

using dangerous or badly maintained tools and equipment; lifting and handlingplate; operating machinery), and how they can be minimised

6 How to obtain the necessary drawings and specifications7 How to extract information from engineering drawings and related


8 How to interpret marking out conventions; cutting lines, centre lines, etc9 The various shearing machine cutting methods and techniques (such as cutting

to marking out; using machine backstops)10 Material handling and preparation methods (such as degreasing,

de-burring, straightening)11 The material cutting characteristics and process considerations that need to be

taken into account when shearing plate material12 The method of setting and adjusting guillotine blades for the material thickness13 Tool and equipment care and control procedures, and how to recognise when

the cutting blades require changing



14 The importance of using tools or equipment only for the purpose intended; thecare that is required when using the tools or equipment; the proper way ofpreserving tools or equipment between operations

15 The safety mechanisms and devices that are on the machine, and why theymust always be used (machine guards, interlocks, safety operating devices)

16 The things that can go wrong when shearing materials, and how these can be avoided

17 Inspection techniques that can be applied to check that shape and dimensionalaccuracy are to specification and within acceptable limits







evidence type

date

Confirm that the equipment is safe and fit for purpose by carrying out all of the following checks:

the appropriate equipment/machine isselected for the operation being performed


Cut metal plate using both of the following types of shearing machine:

guillotines

section cropping machine

Cut materials using both of the following techniques:

to markings

using machine backstop for multiplecutting

Perform operations that produce straight and accurate cuts, which include both of the following:

parallel cuts

square cuts

Cut plate, sections or bars for one appropriate material from the following:

black mild steel

stainless steel

aluminium

brass or copper

tin plate

other specific materials



Produce cut components which meet all of the following quality and accuracy standards:

dimensional accuracy is within thetolerances specified on thedrawing/specification

cut components are free fromexcessive distortion

cut edges are neat and free from falsetool cuts and shearing slivers


Candidate Date

Assessor Date





Unit summaryThis unit identifies the competencies you need for cutting and shaping plate (3mmthickness and above), rolled sections, pipe and tube for fabrications, using portablethermal cutting equipment, in accordance with approved procedures. Theequipment to be used will include hand held gas cutting equipment, plasma cuttingequipment and simple portable machines running on tracks.

You will be required to assist in assembling and setting up the appropriateequipment to be used, for the material and thickness to be cut, the type of operationto be carried out and the accuracy to be achieved. Materials to be cut and shapedmay include mild steel, stainless steel, special steels and other appropriatematerials, and will include guided cuts, external curved contours, round and squareholes and demolition work, as appropriate. This will call for care in the use of theequipment and tools, so as to avoid damage to the material and tools, and danger to oneself.

Your responsibilities will require you to comply with organisational policy andprocedures for the cutting operations undertaken, and to report any problems withthe equipment, materials, consumables or cutting activities that you cannotpersonally resolve, or are outside your permitted authority, to the relevant people.You will be expected to work to instructions, with a minimum of supervision, takingpersonal responsibility for your own actions and for the quality and accuracy of thework that you carry out.

Your underpinning knowledge will be sufficient to provide a good understanding ofyour work, and will provide an informed approach to applying thermal cuttingprocedures. You will have an understanding of the processes, and will know about theequipment and its application, the materials and consumables, in adequate depth toprovide a sound basis for carrying out the activities to the required specification.

You will understand the safety precautions required when working with the thermalcutting equipment, especially those with regard to fire and potential explosion, andthe safeguards necessary for undertaking the activities safely and correctly. You willbe expected to demonstrate safe working practices throughout, and will understandthe responsibilities you owe to yourself and others in the workplace.

Unit 33Cutting materials using hand operated thermal cutting equipment










You must:1 Confirm that the equipment is safe and fit for purpose by carrying out all of the

following checks:• regulators, hoses and valves are securely connected and free from

leaks and damage• the correct gas nozzle is fitted to the cutting torch• that a flashback arrestor is fitted to gas equipment• gas pressures are set and maintained as instructed• the correct procedure is used for lighting, adjusting and extinguishing the

cutting flame• hoses are safely routed and protected at all times• gas cylinders are handled and stored safely and correctly

2 Use one of the following thermal cutting methods:• hand held oxy-fuel gas cutting equipment• hand held plasma gas cutting equipment• simple portable track driven cutting equipment (electrical or mechanical)



3 Perform thermal cutting operations to produce four of the following features:• down-hand straight cuts (freehand)• down-hand straight cuts (track guided)• vertical cuts• square/rectangular shapes• irregular shapes• angled cuts• external curved contours• round holes• square holes• rough cutting (demolition)• weld preparations

4 Produce thermal cuts in two of the following forms of material (metal of 3mm andabove, and two different thickness):• plate• bar• rolled sections• pipe/tube• structures

5 Produce cut profiles for one type of material from the following:• mild steel• stainless steel• special steels• other appropriate metal

6 Produce thermally cut components which meet all of the following quality andaccuracy standards:• dimensional accuracy is within the tolerances specified on the

drawing/specification or within +/- 3 mm• angled cuts are within specification requirements (perpendicular/angularity)• cuts are clean and smooth with minimal drag lines

Knowledge statements:You must have knowledge and understanding of:1 The specific safety precautions to be taken when working with thermal cutting

equipment in a fabrication environment (general workshop and site safety,appropriate personal protective equipment, fire and explosion prevention,protecting other workers, safety in enclosed/confined spaces; fume control;accident procedure; statutory requirements, risk assessment procedures andrelevant requirements of HASAWA, COSHH and Work Equipment Regulations;safe disposal of waste materials)

2 The personal protective clothing and equipment that needs to be worn whenworking with fabrications and thermal cutting equipment (leather aprons andgloves, eye protection, safety helmets, etc)

3 The correct methods of moving or lifting plate materials and components



4 The hazards associated with thermal cutting (naked flames, fumes and gases,explosive gas mixtures, oxygen enrichment, spatter, hot metal, elevatedworking, enclosed spaces), and how they can be minimised

5 Safe working practices and procedures for using thermal equipment in line with British Compressed Gas Association (BCGA) codes of practice, to includesetting up procedures, permit-to-work procedures and emergency shutdown procedures

6 How to obtain the necessary drawings and thermal cutting specifications7 How to extract information from engineering drawings and related


8 The thermal cutting process (basic principles of thermal cutting and relatedequipment; the various techniques and their limitation; care of the equipmentto ensure that it is safe and ready to use)

9 The various types of thermal cutting equipment available, and typicalapplications of each type

10 The accessories that can be used with hand held thermal cutting equipment toaid cutting operations (such as guides, trammels, templates); arrangements forattaching cutting aids to the equipment

11 The gases used in thermal cutting; gas identification and colour codes; theirparticular characteristics and safety procedures

12 How to set up the thermal cutting equipment (connection of hoses, regulatorsand flashback arrestors, selection of cutting torch and nozzle size inrelationship to material thickness and operations performed)

13 Preparations prior to cutting (checking connections for leaks, setting gaspressures, setting up the material/workpiece, checking cleanliness of materials used)

14 The holding methods that are used to aid thermal cutting, and the equipmentthat can be used

15 Setting of operating conditions (flame control and the effects of mixtures andpressures associated with thermal cutting)

16 The correct procedure for lighting and extinguishing the flame, and theimportance of following the procedure

17 Procedures to be followed for cutting specific materials, and why theseprocedures must always be adhered to

18 Material thermal cutting characteristics and material preparation requirements19 The terminology used in thermal cutting in relation to the operations

being performed20 The problems that can occur with thermal cutting, and how they can be avoided;

causes of distortion during thermal cutting and methods of controlling distortion21 The effects of oil, grease, scale or dirt on the cutting process22 The causes of cutting defects, how to recognise them, and methods of

correction and prevention23 Quality requirements of the type of work being undertaken24 The extent of your own authority and whom you should report to if you have






evidence type

date

Confirm that the equipment is safe and fit for purpose by carrying out all of the following checks:

regulators, hoses and valves aresecurely connected and free from leaks and damage

the correct gas nozzle is fitted to thecutting torch

that a flashback arrestor is fitted to gasequipment

gas pressures are set and maintainedas instructed

the correct procedure is used forlighting, adjusting and extinguishingthe cutting flame

hoses are safely routed and protectedat all times

gas cylinders are handled and storedsafely and correctly

Use one of the following thermal cutting methods:

hand held oxy-fuel gas cuttingequipment

hand held plasma gas cuttingequipment

simple portable track driven cuttingequipment (electrical or mechanical)

Perform thermal cutting operations to produce four of the following features:

down-hand straight cuts (freehand)

down-hand straight cuts (track guided)

vertical cuts

square/rectangular shapes

irregular shapes

angled cuts


round holes



square holes

rough cutting (demolition)

weld preparations

Produce thermal cuts in two of the following forms of material (metal of 3mm and above, and two different thickness):

plate

bar

rolled sections

pipe/tube

structures

Produce cut profiles for one type of material from the following:

mild steel

stainless steel

special steels

other appropriate metal

Produce thermally cut components which meet all of the following quality and accuracy standards:

dimensional accuracy is within thetolerances specified on thedrawing/specification or within +/- 3 mm




Candidate Date

Assessor Date





Unit summaryThis unit identifies the competencies you need for cutting and shaping plate (3mmthickness and above), rolled sections, pipe and tube for fabrications using gascutting machines, in accordance with approved procedures. You will be required toassist in the assembling and setting up of the appropriate equipment to be used, forthe material and thickness to be cut, the type of operation to be carried out and theaccuracy to be achieved.

Materials to be cut and shaped may include mild steel, stainless steel, special steelsand other appropriate materials, and will include straight cuts, external curvedcontours, round and square holes and internal curved contours. This will call for carein the use of the equipment and tools so as to avoid damage to the material, toolsand danger to oneself.

Your responsibilities will require you to comply with organisational policy andprocedures for the thermal cutting operations undertaken, and to report anyproblems with the equipment, materials, consumables or cutting activities that youcannot personally resolve, or are outside your personal responsibilities, to therelevant authority. You will be expected to work to instructions, with a minimum ofsupervision, taking personal responsibility for your own actions and for the qualityand accuracy of the work that you carry out.

Your underpinning knowledge will be sufficient to provide a good understanding ofyour work, and will provide an informed approach to applying machine gas cuttingprocedures. You will have an understanding of the gas cutting processes, and theirapplication, and will know about the equipment, materials and consumables, inadequate depth to provide a sound basis for carrying out the activities to therequired specification.

You will understand the safety precautions required when working with the gascutting equipment, especially those with regard to fire and potential explosion, andthe safeguards necessary for undertaking the activities safely and correctly. You willbe expected to demonstrate safe working practices throughout, and will understandthe responsibilities you owe to yourself and others in the workplace.

Unit 34Cutting and shaping materials using gas cutting machines










You must:1 Confirm that the machine is safe and fit for purpose, by carrying out all of the

following checks:• hoses and equipment are securely connected and free from leaks and damage• the correct gas nozzle is fitted to the cutting torch• appropriate gas pressures are set and maintained as instructed• the correct procedure is used for lighting, adjusting and extinguishing the

cutting flame• hoses are safely routed and protected at all times• where appropriate, gas cylinders are handled and stored safely and correctly

2 Perform thermal cutting operations to produce four of the following features:• straight cuts• square/rectangular shapes• irregular shapes• angled cuts• external curved contours• round holes• square holes• internal curved contours• weld preparations



3 Produce thermal cuts in two of the following forms of material (metal of 3mm andabove, and two different thickness):• plate• bar• rolled sections• pipe/tube

4 Produce cut profiles for one type of material from the following:• mild steel• stainless steel• special steels• other appropriate metal

5 Produce cut components which meet all of the following quality and accuracy standards:• dimensional accuracy is within the tolerances specified on the

drawing/specification or within +/- 2 mm• angled cuts are within specification requirements (perpendicular/angularity)• cuts are clean and smooth with minimal drag lines

Knowledge statements:You must have knowledge and understanding of:1 The specific safety precautions to be taken when working with gas cutting

machines in a fabrication environment (general workshop and site safety,appropriate personal protective equipment, fire and explosion prevention,protecting other workers, safety in enclosed/confined spaces; fume control;accident procedure; statutory regulations)

2 The personal protective clothing and equipment that needs to be worn whenworking with fabrication materials and gas cutting equipment (leather apronsand gloves, eye protection, safety helmets, etc)

3 The correct methods of moving or lifting plate materials and components4 The hazards associated with using gas cutting machines (naked flames, fumes

and gases, explosive gas mixtures, oxygen enrichment, spatter, hot metal), andhow they can be minimised

5 Safe working practices and procedures for using gas cutting machines in linewith British Compressed Gas Association (BCGA) Codes of practice to include setting up procedures, permit-to-work procedures and emergencyshutdown procedures

6 How to obtain the necessary drawings and gas cutting specifications7 The interpretation of the drawings or sketches in first or third angle projection8 The gas cutting process (basic principles of gas cutting and related equipment,

the various techniques and their limitation, care of the equipment to ensurethat it is safe and ready to use)

9 The gases used in thermal cutting; gas identification and colour codes; theirparticular characteristics and safety procedures



10 Preparations prior to cutting (checking connections for leaks, setting gaspressures, setting up the material/workpiece, checking cleanliness of materials used)

11 The holding methods that are used to aid gas cutting, and the equipment thatcan be used

12 Setting of operating conditions; flame control and the effects of mixtures andpressures associated with gas cutting machines

13 The correct procedure for lighting and extinguishing the flame, and theimportance of following the procedure

14 Procedures for cutting specific materials, and why these procedures mustalways be adhered to

15 The terminology used in gas cutting, in relation to the operations being performed16 The problems that can occur with gas cutting, and how they can be avoided;

causes of distortion during gas cutting, and methods of controlling distortion17 The effects of oil, grease, scale or dirt on the cutting process18 The causes of cutting defects, how to recognise them, and methods of

prevention and correction19 Quality requirements for the type of work being undertaken20 The extent of your own authority and whom you should report to if you have






evidence type

date

Confirm that the machine is safe and fit for purpose, by carrying out all of the following checks:

hoses and equipment are securelyconnected and free from leaks anddamage

the correct gas nozzle is fitted to thecutting torch

appropriate gas pressures are set andmaintained as instructed

the correct procedure is used forlighting, adjusting and extinguishingthe cutting flame

hoses are safely routed and protectedat all times

where appropriate, gas cylinders arehandled and stored safely and correctly

Perform thermal cutting operations to produce four of the following features:

straight cuts

square/rectangular shapes

irregular shapes

angled cuts


round holes

square holes

internal curved contours

weld preparations

Produce thermal cuts in two of the following forms of material (metal of 3mm and above, and two different thickness):

plate

bar

rolled sections

pipe/tube



Produce cut profiles for one type of material from the following:

mild steel

stainless steel

special steels

other appropriate metal

Produce cut components which meet all of the following quality and accuracy standards:

dimensional accuracy is within thetolerances specified on thedrawing/specification or within +/- 2 mm




Candidate Date

Assessor Date





Unit summaryThis unit identifies the competencies you need to cut and shape materials usingsaws and abrasive discs, in accordance with approved procedures. You will berequired to select the appropriate equipment for the operations to be carried out,and to check that it is in a safe and usable condition. In carrying out the cutting andshaping operations, you will be expected to use both saws and abrasive discs to cutand shape the materials to the required accuracy and specification.

Your responsibilities will require you to comply with organisational policy andprocedures for the cutting activities undertaken, and to report any problems withthe equipment or the cutting activities that you cannot personally resolve, or areoutside your permitted authority, to the relevant people. You will be expected towork to instructions, with a minimum of supervision, taking personal responsibilityfor your own actions and for the quality and accuracy of the work that you carry out.

Your underpinning knowledge will be sufficient to provide a good understanding ofyour work, and will provide an informed approach to applying cutting procedureswhen using saws and abrasive discs. You will have an understanding of the suitabilityof the cutting processes, and their applications, and will know about thecharacteristics of the materials and the appropriate processes and techniques, inadequate depth to provide a sound basis for carrying out the activities to therequired specification.

You will understand the safety precautions required when carrying out the cuttingand shaping activities. You will be required to demonstrate safe working practicesthroughout, and will understand the responsibility you owe to yourself and others inthe workplace.

Unit 35Cutting materials using saws and abrasive discs










You must:1 Ensure that the equipment is fit for purpose and used safely by carrying out all of

the following:• selecting the appropriate equipment/machine for the operation

being performed• checking that machine guards and safety devices are in position and

function correctly• checking that cutting discs/blades are in a serviceable condition (sharp, and

free from damage or chips)• isolating the equipment from its power supply whilst changing blades or discs• using the equipment safely and correctly and only for its intended purpose

2 Use two of the following types of cutting equipment:• machine saw• band saw• hand held portable abrasive disc• radiac abrasive disc

3 Carry out all of the following cutting and shaping activities:• straight sawing• abrasive disc cutting• contour shaping using saws



4 Cut and shape components which contain all of the following features:• straight parallel cuts• square cuts• curved contours• angled/mitred cuts

5 Cut and shape three of the following forms of material:• flat plate• solid bar (square, round, hexagonal etc)• rolled sections (angle, channel, RSJ )• pipe/tube• rail section• non-ferrous material

6 Produce components that comply with all of the following quality and accuracy standards:• material dimensional accuracy is within specification tolerances• cuts are square, clean and free from excessive burrs• angled cuts are within specification requirements


environment and when working with power operated saws and abrasive disccutting machines (statutory requirements, risk assessment procedures andrelevant requirements of HASAWA, COSHH and Work Equipment Regulations;safe disposal of waste materials)


3 Safe working practices and procedures to be observed when working with themachines (including emergency shutdown procedures)

4 The correct methods of moving or lifting heavy plate or rolled sections5 The hazards associated with fabrication work and cutting operations (such

using dangerous or badly maintained tools and equipment; airborne particles;hot metal; burrs and sharp edges), and how they can be minimised

6 How to obtain the necessary drawings, specifications and work instructions7 How to extract information from engineering drawings and related


8 How to interpret marking out conventions (cutting lines, centre lines, etc)9 The range of machine saws available (such as power hacksaws, circular saws

and bandsaws)10 The abrasive cutting equipment available (to include hand held portable

machines and bench type radiac cutting machines)11 The selection and fitting of abrasive cutting discs; cutting disc identification

markings, and how to identify the correct type of disc for the type of materialbeing cut



12 Statutory regulations regarding the fitting and use of abrasive discs13 The material cutting characteristics and process considerations to be taken into

account when cutting materials14 The use and care of tools and equipment (such as checking that trailing leads,

plugs and sockets are in a safe and usable condition)15 The use of safety screens to protect other uses from flying sparks whilst using

abrasive cutting discs16 The importance of ensuring that machine guards are correctly fitted and

positioned before using the equipment17 How to set and adjust power saws for the various operations being performed18 The importance of using tools or equipment only for the purpose intended; the


19 The things that can go wrong when cutting materials using saws or abrasivediscs, and how these can be avoided

20 Inspection techniques that can be applied to check that shape and dimensionalaccuracy is to specification and within acceptable limits







evidence type

date

Ensure that the equipment is fit for purpose and used safely by carrying out all of the following:

selecting the appropriateequipment/machine for the operationbeing performed

checking that machine guards andsafety devices are in position andfunction correctly

checking that cutting discs/blades arein a serviceable condition (sharp, andfree from damage or chips)

isolating the equipment from its powersupply whilst changing blades or discs

using the equipment safely andcorrectly and only for its intendedpurpose

Use two of the following types of cutting equipment:

machine saw

band saw

hand held portable abrasive disc

radiac abrasive disc

Carry out all of the following cutting and shaping activities:

straight sawing

abrasive disc cutting

contour shaping using saws

Cut and shape components which contain all of the following features:

straight parallel cuts

square cuts

curved contours

angled/mitred cuts



Cut and shape three of the following forms of material:

flat plate

solid bar (square, round, hexagonal etc)

rolled sections (angle, channel, RSJ )

pipe/tube

rail section

non-ferrous material

Produce components that comply with all of the following quality and accuracy standards:

material dimensional accuracy is withinspecification tolerances

cuts are square, clean and free fromexcessive burrs

angled cuts are within specificationrequirements


Candidate Date

Assessor Date





Unit summaryThis unit identifies the competencies you need for bending and forming plate (of3mm and above) for fabrications using power operated equipment such as pressbrakes, bending machines and power presses, in accordance with approvedprocedures. You will be required to operate the appropriate bending and formingequipment, in accordance with the instructions for the operations being performed.You will need to ensure that all the required safety devices are operating correctly,and that the machine guards are in place and correctly adjusted.

Items to be bent and formed may include ferrous and non-ferrous materials, andtasks will include producing bends of various angles, setting plate ends for rollingoperations, and producing curved sections. This will call for care in selecting theright tools, so as to avoid damage to the tools and danger to oneself.

Your responsibilities will require you to comply with organisational policy andprocedures for the activities undertaken, and to report any problems with theequipment, materials, tooling or bending activities that you cannot personallyresolve, or are outside you personal authority, to the relevant people. You will beexpected to work to instructions, with a minimum of supervision, taking personalresponsibility for your own actions and for the quality and accuracy of the work thatyou carry out.

Your underpinning knowledge will be sufficient to provide a good understanding ofyour work, and will provide an informed approach to applying the power pressingprocedures required. You will have an understanding of the bending processes, andwill know about the equipment and its application, in adequate depth to provide asound basis for carrying out the activities to the required specification.

You will understand the safety precautions required when working with poweroperated presses, and the safeguards necessary for undertaking the activities safelyand correctly. You will be required to demonstrate safe working practices andprocedures throughout, and will understand the responsibilities you owe to yourselfand others in the workplace.

Unit 36Bending and forming plate using power operated machines



regulations and guidelinesb Confirm that the equipment is set up correctly and is ready for usec Manipulate the machine controls safely and correctly in line with o

perational proceduresd Produce components to the required specificatione Carry out quality sampling checks at suitable intervalsf Deal promptly and effectively with problems within your control and report those




You must:1 Confirm that the equipment is safe to use and fit for purpose, by carrying out all of

the following checks:• the appropriate machine is selected for the operation being performed• the machine guards and safety devices are in position and function correctly

2 Operate one of the following types of power-operated bending equipment:• press brakes• powered bending machine• power press

3 Perform operations that produce all of the following:• bends at 90°

• bends of various angles using various bend radii• set plate ends• box, square and rectangular sections• curved plates

4 Bend and form metal plate of 3mm or greater thickness, for one appropriatematerial and two thicknesses:• black mild steel• stainless steel• aluminium• special metals



5 Produce components that conform to all of the following quality and accuracy standards:• bend position and dimensional accuracy is within the specification tolerances• the form or sharpness of the bend conforms to best practice and or

specification, without deformation or cracking• the bend conforms to the required shape/geometry (to the template profile)

Knowledge statements:You must have knowledge and understanding of:1 The specific safety precautions to be taken when working with power-operated

bending and forming equipment such as press brakes or/and bending machinesin a fabrication environment (general workshop and site safety, appropriatepersonal protective equipment, accident procedure; statutory requirements,risk assessment procedures and relevant requirements of HASAWA, COSHHand Work Equipment Regulations; safe disposal of waste materials)

2 The correct protective clothing, and handling precautions to be taken, whenworking with heavy platework

3 The correct methods of moving or lifting sheet or plate materials4 The hazards associated with power operated bending and forming processes

(such as handling heavy sheet materials and components; operating movingequipment; using faulty or badly maintained tools and equipment), and howthey can be minimised

5 The safe working practices and procedures required for operating power-operated bending machines

6 How to obtain the necessary drawings and bending specifications7 How to extract information from engineering drawings and related


8 Marking out conventions applicable to the bending process (centre lines;bending lines)

9 The various types of power-operated bending machines that are used, and theirtypical applications

10 Ways of limiting distortion, marking and creases in the finished workpiece11 The preparations to be carried out on the materials prior to bending them12 The basic characteristics of the materials with regard to the bending

operations undertaken13 The need to take care of the bending tools and equipment; how to recognise

faulty or damaged forming tools; how bending and forming tools should be stored

14 The problems that can occur with the bending and forming activities, and howthey can be avoided

15 The organisational quality control procedures that are used, and how torecognise defects in the bends that you produce



16 How to make dimensional and forming inspection checks, and the tools andequipment that can be used

17 Accuracy and limitations of processes18 The extent of your own authority and whom you should report to if you have






evidence type

date

Confirm that the equipment is safe to use and fit for purpose, by carrying out all of the following checks:



Operate one of the following types of power-operated bending equipment:

press brakes

powered bending machine

power press

Perform operations that produce all of the following:

bends at 90°

bends of various angles using variousbend radii

set plate ends

box, square and rectangular sections

curved plates

Bend and form metal plate of 3mm or greater thickness, for one appropriate material and two thicknesses:

black mild steel

stainless steel

aluminium

special metals

Produce components that conform to all of the following quality and accuracy standards:

bend position and dimensionalaccuracy is within the specificationtolerances

the form or sharpness of the bendconforms to best practice and orspecification, without deformation orcracking



the bend conforms to the requiredshape/geometry (to the templateprofile)


Candidate Date

Assessor Date





Unit summaryThis unit identifies the competencies you need to bend and form plate forfabrications, in accordance with approved procedures, using power-operated pinchor pyramid rolls which may be hand adjusted or console controlled. You will berequired to operate the power rolling machine as instructed, based on theoperations to be performed and the thickness and size of the material to be rolled.Setting the rolls will involve setting and adjusting the gap between feed and formingrolls to suit plate thickness, positioning side roller(s) and adjusting to suit therequired radius, checking and setting parallelism of rollers, and applying suitablepressure to rollers throughout the forming operation.

You will be expected to carry out the rolling operation in a manner that ensuresmaterial is formed to the required profile without flats or deformities. You will alsoneed to ensure that all the required safety devices are operating correctly, and thatthe machine guards are in place and correctly adjusted. Items to be rolled mayinclude ferrous and non-ferrous materials, and will include operations such as rollingcylinders and cones, producing curved sections, counter-curved sections, pipesections and plate straightening. This will call for care in using the right machine forthe job, and using it in the correct way, so as to avoid damage to the tools and dangerto oneself.

Your responsibilities will require you to comply with organisational policy andprocedures for the activities undertaken, and to report any problems with theequipment, materials, or rolling activities that you cannot personally resolve, or areoutside you personal authority, to the relevant people. You will be expected to workto instructions, with a minimum of supervision, taking personal responsibility foryour own actions and for the quality and accuracy of the work that you carry out.

Your underpinning knowledge will be sufficient to provide a good understanding ofyour work, and will provide an informed approach to applying the power-rollingprocedures required. You will have an understanding of the rolling process and itsapplication, and will know about the equipment and materials, in adequate depth toprovide a sound basis for carrying out the activities to the required specification.

You will understand the safety precautions required when working with power rolls,and the safeguards necessary for undertaking the activities safely and correctly. You will be required to demonstrate safe working practices and proceduresthroughout, and will understand the responsibilities you owe to yourself and others in the workplace.

Unit 37Forming platework using power rolling machines



regulations and guidelinesb Confirm that the equipment is set up correctly and is ready for usec Manipulate the machine controls safely and correctly in line with

operational proceduresd Produce components to the required specificatione Carry out quality sampling checks at suitable intervalsf Deal promptly and effectively with problems within your control and report those





the following checks:• the rolls are appropriate for the material used and the operations being

performed• the machine guards and safety devices are in position and operating correctly• rolls are appropriate for the operation and are in a serviceable condition

(suitable diameter; free from damage)• roll settings are suitable for the material thickness and operations to be performed• equipment for supporting the plate at the start of the rolling operations is in place

2 Use one of the following types of power rolling machine:• powered rolls (hand adjusted)• powered rolls (console adjusted)• different roll sizes (diameter) and power

3 Perform rolling operations that produce three of the following:• cylinders• cones• segments of a cylindrical tank• curved section or sector of an otherwise flat plate• counter-curved sections• pipe sections• flattening or straightening plate



4 Carry out rolling operations on one type of material from the following:• carbon steel• stainless steel• aluminium• special metals

5 Produce rolled components that conform to all of the following quality andaccuracy standards:• dimensional accuracy is within the specification tolerances• the rolled section conforms to best practice and/or specification, without

deformation or cracking• the component conforms to the required shape/geometry (to the

template profile)

Knowledge statements:You must have knowledge and understanding of:1 The specific safety precautions to be taken when working with rolling machines

in a fabrication environment (general workshop and site safety, appropriatepersonal protective equipment, accident procedure; statutory requirements,risk assessment procedures and relevant requirements of HASAWA, COSHHand Work Equipment Regulations; safe disposal of waste materials)

2 Checks to be carried out to ensure that the power rolls are safe and are in a fitcondition to use

3 The personal protective clothing and equipment to be worn when working withheavy platework (gloves, eye protection, safety helmets, etc)

4 The handling precautions and correct methods of moving or lifting sheet orplate materials

5 The hazards associated with fabrication work (such as handlingsheet/fabricated components, using hot metal techniques, using dangerous orbadly maintained tools and equipment, moving parts of power rollingmachines), and how they can be minimised

6 How to obtain the necessary drawings, specifications and job instructions7 How to extract information from engineering drawings and related


8 Marking out conventions used in platework, and how to recognise the bending,forming and cutting lines

9 The basic principle of operation of the power rolling machine used, and the typeof work it can perform

10 How to set up the machine to produce the required form (cylinders, cones,curved sections, straightening plates)

11 Techniques of rolling (including pre-setting plate edges, adjusting pressurethroughout the rolling operations, checking component for parallelism or formthroughout the operations)



12 How to release the rolls and remove the workpiece when rolling cylindrical andconical sections

13 Ways of limiting distortion, marking, creases and flats in curved sections14 How the materials need to be prepared prior to rolling, and the effects of raw

material scale or burrs on the finished article15 Material characteristics with regard to forming using rolling machines16 The care and maintenance procedures to be observed to ensure the machines

are in a serviceable condition17 The organisational quality control procedures, and how to recognise

rolling defects18 The inspection checks to be carried out, and the tools and equipment

that are used19 The accuracy that can be achieved by rolling, and limitations of the

rolling processes20 The extent of your own authority and whom you should report to if you have






evidence type

date


the rolls are appropriate for thematerial used and the operations beingperformed

the machine guards and safety devicesare in position and operating correctly

rolls are appropriate for the operationand are in a serviceable condition(suitable diameter; free from damage)

roll settings are suitable for the materialthickness and operations to beperformed

equipment for supporting the plate atthe start of the rolling operations is inplace

Use one of the following types of power rolling machine:

powered rolls (hand adjusted)

powered rolls (console adjusted)

different roll sizes (diameter) and power

Perform rolling operations that produce three of the following:

cylinders

cones

segments of a cylindrical tank

curved section or sector of anotherwise flat plate

counter-curved sections

pipe sections

flattening or straightening plate



Carry out rolling operations on one type of material from the following:

carbon steel

stainless steel

aluminium

special metals

Produce rolled components that conform to all of the following quality and accuracy standards:

dimensional accuracy is within thespecification tolerances

the rolled section conforms to bestpractice and/or specification, withoutdeformation or cracking

the component conforms to therequired shape/geometry (to the template profile)


Candidate Date

Assessor Date





Unit summaryThis unit identifies the competencies you need to produce heavy platework (3mmthick plate and above) assemblies, in accordance with instructions and approvedprocedures. You will be required to interpret specifications and drawings correctly,to bring together, prepare for joining and assemble, in the right order, plateworkcomponents and sections, in order to construct completed fabricated assemblies orsub-assemblies, such as square and rectangular plate structures, covers and sideplates, tanks, pressure vessels, cylindrical sections, conical sections, reductionpieces, simple and complex boiler seatings, etc. You will be required lay out andsecure the various component parts of the structure, using mechanical fastenings,temporary tack welding, flanged and mechanically fastened or adhesive bondingtechniques, in the correct order and ensuring they are assembled in a manner that isfit for purpose.

Your responsibilities will require you to comply with organisational policy andprocedures for the platework fabrication activities to be undertaken, and to reportany problems with the activities, tools and equipment or materials that you cannotpersonally resolve, or are outside your permitted authority, to the relevant people.You will be expected to work to instructions, with a minimum of supervision, takingpersonal responsibility for your own actions and for the quality and accuracy of thework that you carry out.

Your underpinning knowledge will be sufficient to provide a good understanding ofyour work, and will provide an informed approach to applying platework fabricationtechniques and their assembly and fixing procedures. You will have anunderstanding of the assembly techniques used, the requirements of themanufacturing and assembling procedures, and their application. You will knowabout the methods of assembling the components of the required strength and thatare fit for purpose, in adequate depth to provide a sound basis for carrying out theactivities, correcting faults and ensuring the work output is produced to the requiredspecification.

You will understand the safety precautions required when working with heavyplatework components and their associated tools and equipment. You will berequired to demonstrate safe working practices throughout, and will understand theresponsibility you owe to yourself and others in the workplace.

Unit 38Producing platework assemblies



regulations and guidelinesb Follow the relevant instructions, assembly drawings and any other specificationsc Ensure that the specified components are available and that they are in a

usable conditiond Use the appropriate methods and techniques to assemble the components in





You must:1 Carry out all of the following during the platework assembly operations:

• correctly prepare and set up the components and faces to be joined• use the correct datum faces• use the specified or appropriate fixing method• correctly align the components and faces to be joined• assemble/fabricate the platework components in the correct order or manner• produce an assembly which meets the required specification

2 Produce four of the following platework assemblies:• frames• tanks• covers and side plates• square, rectangular and box sections• cylindrical• conical• reduction pieces• segmented bends• steel and composite material assemblies• simple or complicated seatings (tank or boiler seats)



3 Use four of the following types of components in the assemblies produced:• plates or covers• pre-fabricated square/rectangular components• pre-fabricated cylindrical/conical components• brackets• flanges• pipes• rolled section components (angle, channel or tee section)

4 Assemble platework components, using two of the following methods: • temporary tack welding• clamped or jigged• riveting (hot or cold)• flanged and mechanically fastened (nuts and bolts)• adhesive bonding

5 Produce platework assemblies which meet all of the following quality andaccuracy standards:• all components are correctly assembled and aligned in accordance with

the specification• overall dimensions are within specification tolerances• assemblies meet appropriate geometric tolerances (square, straight, angles,

free from twists)• where appropriate, pitches of erection holes meet specification requirements• completed assemblies have secure and firm joints, and are clean and free from

burrs or flash


environment and when producing platework assemblies (general workshopand site safety, appropriate personal protective equipment, accidentprocedure; statutory requirements, risk assessment procedures and relevantrequirements of HASAWA, COSHH and Work Equipment Regulations; safedisposal of waste materials)

2 The personal protective clothing and equipment to be worn when carrying outthe fabrication activities (leather gloves, eye protection, safety helmets, earprotection, etc)

3 Safe working practices and procedures for producing platework assemblies4 The correct methods of moving or lifting bulky and heavy fabrications5 The hazards associated with platework fabrication and assembly work (such

using dangerous or badly maintained tools and equipment; lifting and handlinglong and heavy components; cuts, slips trips and falls), and how they can be minimised

6 How to obtain the necessary drawings and joining specifications




8 How to interpret marking out conventions (cutting lines; centre lines, etc)9 The preparations to be carried out on the components prior to

assembling them10 The various methods of securing the assembled components (nuts and bolts;

tack welding methods and techniques; hot and cold riveting; adhesive bondingof components)

11 How to set up and align the various components, and the tools and equipmentto be used

12 Methods of temporarily holding the joints together to aid the assemblyactivities (jigs, clamps, rivet clamps, jacks and wedges)



15 The things that can go wrong when producing platework assemblies, and howthese can be avoided

16 Inspection techniques that can be applied to check that shape (includingstraightness) and dimensional accuracy is to specification and withinacceptable limits







evidence type

date

Carry out all of the following during the platework assembly operations:

correctly prepare and set up thecomponents and faces to be joined


use the specified or appropriate fixingmethod


assemble/fabricate the plateworkcomponents in the correct order ormanner


Produce four of the following platework assemblies:

frames

tanks

covers and side plates

square, rectangular and box sections

cylindrical

conical

reduction pieces

segmented bends

steel and composite materialassemblies

simple or complicated seatings (tank orboiler seats)

Use four of the following types of components in the assemblies produced:

plates or covers

pre-fabricated square/rectangularcomponents

pre-fabricated cylindrical/conicalcomponents



brackets

flanges

pipes

rolled section components (angle,channel or tee section)

Assemble platework components, using two of the following methods:

temporary tack welding

clamped or jigged

riveting (hot or cold)

flanged and mechanically fastened(nuts and bolts)

adhesive bonding

Produce platework assemblies which meet all of the following quality and accuracy standards:

all components are correctlyassembled and aligned in accordancewith the specification


assemblies meet appropriategeometric tolerances (square, straight,angles, free from twists)

where appropriate, pitches of erectionholes meet specification requirements

completed assemblies have secure andfirm joints, and are clean and free fromburrs or flash


Candidate Date

Assessor Date





Unit summaryThis unit identifies the competencies you need to produce holes in sheet, plate,rolled section or pipe, using drilling machines, in accordance with approvedprocedures. You will be required to select the appropriate drilling equipment to use,based on the operations to be performed and the size of the component worked on.You will be expected to use appropriate workholding methods and techniques tosecure the work piece for the drilling operations, and this will include the use of jigs,clamps, machine vice and other appropriate holding devices. In drilling the holes,you will need to position the drill bits accurately and use appropriate speeds andfeeds to drill and finish the holes to the required specification. Drilling and finishingoperations will include through holes, blind holes, counterbored holes, countersunkholes, spot facing, reaming and tapping.

Your responsibilities will require you to comply with organisational policy andprocedures for the drilling activities undertaken, and to report any problems with theequipment or drilling activities that you cannot personally resolve, or are outsideyour permitted authority, to the relevant people. You will be expected to work toinstructions, with a minimum of supervision, taking personal responsibility for yourown actions and for the quality and accuracy of the work that you carry out.

Your underpinning knowledge will be sufficient to provide a good understanding ofyour work, and will provide an informed approach to applying the drilling andfinishing procedures. You will have an understanding of the drilling equipment usedand its application, together with the material characteristics and the appropriatetooling for carrying out the drilling and finishing process. You will know about thebasic principles and requirements of securing the work piece prior to carrying outthe process, in adequate depth to provide a sound basis for carrying out the drilling activities, correcting faults and ensuring the work output meets the required specification.

You will understand the safety precautions required when carrying out the drillingand finishing activities. You will be required to demonstrate safe working practicesthroughout, and will understand the responsibility you owe to yourself and others inthe workplace.

Unit 39Producing holes using drilling machines










You must:1 Ensure that the equipment is fit for purpose and used safely, by carrying out all of

the following:• selecting the appropriate drilling equipment/machine for the operation

being performed• checking that machine guards and safety devices are in position and

function correctly• checking that drill bits and cutting tools are in a serviceable condition (sharp,

free from damage or chips)• isolating the equipment from its power supply whilst changing drill bits• securely clamping/restraining the components during the drilling operations• using the equipment safely and correctly and only for its intended purpose

2 Use two of the following drilling machines:• hand held drilling machine• pillar/bench drill• radial arm drill

3 Use two of the following workholding devices:• jigs/fixtures• machine vice• clamps



4 Carry out three of the following drilling and finishing operations:• drilling through holes• drilling holes to a depth• counterboring holes• countersinking holes• centre drilling• spot facing• trepanning holes• tapping holes• jig or template drilling• component alignment drilling

5 Produce drilled and finished components which meet all of the following qualityand accuracy standards, as applicable to the process:• dimensional and positional accuracy is within specification tolerances• drilled holes are correctly formed and free from excessive tool marks• counterbores, countersinks and spot facings meet job requirements

6 Produce drilled holes in two of the following material types:• ferrous sheet metal• stainless steel sheet metal• non-ferrous sheet metal• ferrous plate or components• stainless steel plate or components• non-ferrous plate or components• non-metallic materials• composite materials


environment and when carrying out drilling and finishing operations onmaterials used in fabrication (general workshop and site safety, appropriatepersonal protective equipment, accident procedure; statutory requirements,risk assessment procedures and relevant requirements of HASAWA, COSHHand Work Equipment Regulations; safe disposal of waste materials)


3 The correct methods of moving or lifting materials4 The safe working practices and procedures to be used when using portable

power operated tools and drilling machines (including emergency stopprocedures for the machines)

5 The hazards associated with drilling work (such as using dangerous or badlymaintained tools and equipment; insecure or poorly clamped workpieces;airborne metal particles; sharp edges and splinters), and how they can be minimised

6 How to obtain the necessary drawings, specifications and work instructions




8 How to interpret marking out conventions (cutting lines, centre lines, etc)9 The various types and application of drilling machines (including portable

power tools, bench and pedestal machines and radial arm machines)10 The range of drilling and hole finishing tools available (including twist drills,

reamers, counterbore tools, countersink tools, spot facing tools)11 The methods of holding and securing the drills and finishing tools into the

machine spindle (chucks, taper shank sleeves, collet chucks)12 The methods of holding and securing workpieces for drilling (including jigs and

fixtures, machine vices, clamps and restraining devices)13 Methods used to align the drill with the workpiece, and the use of centre drills

and pilot drills14 How to check that the drill hole is in the correct position before drilling to

the full diameter15 How to correct a drill that has been started off centre16 The selection of speeds and feeds for drilling, reaming and finishing operations17 The selection of cutting fluids and compounds for drilling18 Setting and adjusting tools and equipment (use of depth stops, etc)19 The material characteristics and process considerations to be taken into

account when carrying out drilling operations20 The care and control of tools and equipment; checking portable power tool

leads, plugs and sockets are in a safe and usable condition21 The importance of using tools or equipment only for the purpose intended; the


22 The things that can go wrong with drilling operations, and how these can be avoided

23 Inspection techniques that can be applied to check that dimensional accuracyand finish is to specification and within acceptable limits







evidence type

date

Ensure that the equipment is fit for purpose and used safely, by carrying out all of the following:

selecting the appropriate drillingequipment/machine for the operationbeing performed

checking that machine guards andsafety devices are in position andfunction correctly

checking that drill bits and cutting toolsare in a serviceable condition (sharp,free from damage or chips)

isolating the equipment from its powersupply whilst changing drill bits

securely clamping/restraining thecomponents during the drillingoperations

using the equipment safely andcorrectly and only for its intendedpurpose

Use two of the following drilling machines:

hand held drilling machine

pillar/bench drill

radial arm drill

Use two of the following workholding devices:

jigs/fixtures

machine vice

clamps

Carry out three of the following drilling and finishing operations:

drilling through holes

drilling holes to a depth

counterboring holes

countersinking holes

centre drilling

spot facing



trepanning holes

tapping holes

jig or template drilling

component alignment drilling

Produce drilled and finished components which meet all of the following quality and accuracy standards, as applicable to the process:

dimensional and positional accuracy iswithin specification tolerances

drilled holes are correctly formed andfree from excessive tool marks

counterbores, countersinks and spotfacings meet job requirements

Produce drilled holes in two of the following material types:

ferrous sheet metal

stainless steel sheet metal

non-ferrous sheet metal

ferrous plate or components

stainless steel plate or components

non-ferrous plate or components

non-metallic materials

composite materials


Candidate Date

Assessor Date





Unit summaryThis unit identifies the competencies you need to bend and form rolled sectionalmaterial using presses, bending machines and power rolls, in accordance withinstructions and approved procedures. You will be required to use the mostappropriate type and size of machine, based on the operations to be performed andthe type and section of material being used. In producing the components, you willbe required to operate the equipment safely and correctly to form the material to therequired profile without flats or deformities. The operations to be performed willinclude bending beams, curved beams, circular sections, counter curved sections,twisted beams and straightening of beams.

Your responsibilities will require you to comply with organisational policy andprocedures for the use of the machines and the process activities undertaken, and toreport any problems with the forming equipment, materials or forming activities thatyou cannot personally resolve, or are outside your permitted authority, to therelevant people. You will be expected to work to instructions, with a minimum ofsupervision, taking personal responsibility for your own actions and for the qualityand accuracy of the work that you produce.

Your underpinning knowledge will be sufficient to provide a good understanding ofyour work, and will provide an informed approach to forming structural sectionmaterial using power machine procedures. You will have an understanding of theforming equipment being used, the forming principles, and their application, and willknow about the processes involved and their limitations, in sufficient depth toprovide a sound basis for carrying out the activities, correcting any faults andensuring the work output is produced to the required specification.


Unit 40Forming structural sections using machines









the following checks:• the appropriate machine is selected for the operation being performed• the machine guards and safety devices are in position and function correctly• forming tools are appropriate and in a serviceable condition (secure, correct

shape, free from damage)• machine settings are suitable for the material thickness and operations

to be performed

2 Use one of the following types of machines:• power press• hammer machines• section bending machine• powered rolls• special-purpose machines

3 Produce formed structural sections which contain three of the following features:• right-angled bends• angular bends• curved beams• circular sections• counter-curved sections• twisted section• straightening



4 Bend and form structural components made from three of the following forms of material:• rolled steel joists (RSJ)• angle section• channel section• tee angle• structural tubes/pipes• extrusions• other specific components

5 Produce structural components which meet all of the following quality andaccuracy standards:• bend position and dimensional accuracy is within the specification tolerances• the form or sharpness of the bend conforms to best practice and/or

specification, without deformation or cracking• the bend conforms to the required shape/geometry (to the template profile)

Knowledge statements:You must have knowledge and understanding of:1 The specific safety precautions to be taken when working with power operated

bending and forming equipment (such as presses, bending machines androlling machines) in a fabrication environment

2 The general workshop and site safety requirements, statutory requirements,risk assessment procedures and relevant requirements of HASAWA, COSHHand Work Equipment Regulations; safe disposal of waste materials

3 The correct protective clothing and handling precautions to be taken whenworking with structural section materials (gloves, eye protection, safetyhelmets, ear protection)

4 The handling precautions and correct methods of moving or lifting heavystructural section (RSJs, etc)

5 The hazards associated with power-operated bending processes (such ashandling heavy structural materials and components; operating movingequipment; using faulty or badly maintained tools and equipment), and howthey can be minimised

6 The safe working practices and procedures for operating power operatedbending and forming machines

7 How to obtain the necessary structural drawings and bending procedure specifications


9 Marking out conventions applicable to the bending process (centre lines,bending lines)

10 The various types of power-operated bending machines that are used forstructural section materials, and their typical applications

11 How to prepare the machine for a range of different bends (angled bends,curved sections, twisted sections and straightening of sections)



12 The types of bending tools that are used for the various operations, and howthey are secured and set to the machine’s toolholding device

13 Ways of limiting distortion, marking and creases in the finished workpiece14 The preparations to be carried out on the materials prior to bending them15 The basic characteristics of the materials with regard to the bending

operations undertaken16 Why some materials may require a heating process before bending begins17 The need to take care of the bending tools and equipment; how to recognise

faulty or damaged forming tools; how bending and forming tools should be stored




21 Accuracy and limitations of processes22 The extent of your own authority and whom you should report to if you have






evidence type

date




forming tools are appropriate and in aserviceable condition (secure, correctshape, free from damage)

machine settings are suitable for thematerial thickness and operations to beperformed

Use one of the following types of machines:

power press

hammer machines

section bending machine

powered rolls

special-purpose machines

Produce formed structural sections which contain three of the following features:

right-angled bends

angular bends

curved beams

circular sections

counter-curved sections

twisted section

straightening

Bend and form structural components made from three of the following forms of material:

rolled steel joists (RSJ)

angle section

channel section

tee angle

structural tubes/pipes



extrusions

other specific components

Produce structural components which meet all of the following quality and accuracy standards:

bend position and dimensionalaccuracy is within the specificationtolerances

the form or sharpness of the bendconforms to best practice and/orspecification, without deformation orcracking



Candidate Date

Assessor Date





Unit summaryThis unit identifies the competencies you need to cut and shape plate or sectionmaterials to produce structural steel components such as fishplates, gussets,brackets, support pads and bed plates, in accordance with approved procedures.You will be required to interpret drawings, mark out simple shapes and holepositions, cut out and shape plate and sections, drill and prepare structuralcomponents ready for the assembly of major structural components.

Your responsibilities will require you to comply with organisational policy andprocedures for the marking out, shaping and preparation activities undertaken, andto report any problems with the interpretation, equipment used, materials ormanufacturing activities that you cannot personal resolve, or are outside yourpermitted authority, to the relevant person. You will be expected to work toinstructions, with a minimum of supervision, taking personal responsibility for yourown actions and for the quality and accuracy of the work that you carry out.

Your underpinning knowledge will be sufficient to provide a good understanding ofyour work, and will provide an informed approach to applying structural steelshaping and fabrication procedures. You will have an understanding of thefabrication processes, the equipment and its application, and will know about thematerials and how to produce structural component parts, in adequate depth toprovide a sound basis for carrying out the activities to the required specification.

You will understand the safety precautions required when working with fabricationtools and machinery. You will be required to demonstrate safe working practicesthroughout, and will understand the responsibility you owe to yourself and others inthe workplace.

Unit 41Producing structural steel ancillary components








You must:1 Ensure that you carry out all of the following during the manufacturing activities:

• use the tools and equipment safely and correctly and only for its intended purpose

• mark out the components accurately using recognised conventions• set up and hold the components firmly during the shaping operations• use approved and safe cutting and shaping methods at all times• produce the components to the correct size and shape• ensure all holes are of the correct size and are at the correct centres for fixings

2 Cut and shape material to the marked-out shape, using three of the followingmethods:• shearing/cropping• sawing• burning• drilling• bending

3 Produce structural steel components, to include three of the following:• fishplates• gussets• brackets• support pads• flanges• bed plates• tie bars• stiffening plates



4 Produce structural steel components from both of the following:• steel plate (3mm or greater thickness)• rolled steel section

5 Produce structural steel components which are cut and shaped to meet all thefollowing quality and accuracy standards:• company/customer standards requirements• dimensionally accurate (to drawing or specifications)• free from distortion• free from sharp edges, slivers or burrs


environment and when cutting plate or rolled sections to shape (generalworkshop and site safety, appropriate personal protective equipment, accidentprocedure; statutory requirements, risk assessment procedures and relevantrequirements of HASAWA, COSHH and Work Equipment Regulations; safedisposal of waste materials)


3 The correct methods of moving or lifting plate and rolled section materials4 Safe working practices and procedures to be observed when using manual and

power-operated tools5 The hazards associated with fabrication work (such as using dangerous or badly

maintained tools and equipment; operating shearing machines; handling plateand fabricated components; using hot metal techniques), and how they can be minimised

6 The procedures for obtaining the necessary drawings and specifications, andhow to check that they are the latest issue


8 The preparations to be carried out on the material prior to marking out, toenhance clarity, accuracy and safety

9 Principles of marking out, and the tools and equipment that are used10 Use of marking out conventions (datums, cutting detail, centre lines, etc)11 Ways of laying out the shapes/patterns to maximise the use of plate or

sheet materials12 Marking out and transferring information from templates, and how to transfer

information to the underside of the plate13 The tools and techniques available for cutting and shaping plate and section

materials (such as shearing machines, saws, burning equipment, drills, etc)14 The use and care of tools and equipment, including checks that need to be

made to ensure that the tools are fit for purpose (cutting tools are sharp andundamaged; plugs and cables secure and free from damage; machine guardsor safety devices operating correctly)



15 How to produce weld preparations, and the type of preparations required fordifferent joints and material thicknesses

16 Adjusting tools and equipment; use of backstops on guillotines, etc17 The importance of using tools or equipment only for the purpose intended; the


18 Safety and control procedures for shaping plate and rolled steel sections19 The things that can go wrong with cutting and shaping plate and section

materials, and how these can be avoided20 The use of machine guards and safety protection equipment21 Inspection techniques that can be applied to check that shape and dimensional

accuracy is to specification and within acceptable limits22 The extent of your own authority and whom you should report to if you have






evidence type

date

Ensure that you carry out all of the following during the manufacturing activities:

use the tools and equipment safely andcorrectly and only for its intendedpurpose

mark out the components accuratelyusing recognised conventions

set up and hold the components firmlyduring the shaping operations

use approved and safe cutting andshaping methods at all times

produce the components to the correctsize and shape

ensure all holes are of the correct sizeand are at the correct centres for fixings

Cut and shape material to the marked-out shape, using three of the following methods:

shearing/cropping

sawing

burning

drilling

bending

Produce structural steel components, to include three of the following:

fishplates

gussets

brackets

support pads

flanges

bed plates

tie bars

stiffening plates



Produce structural steel components from both of the following:

steel plate (3mm or greater thickness)

rolled steel section

Produce structural steel components which are cut and shaped to meet all the following quality and accuracy standards:

company/customer standardsrequirements

dimensionally accurate (to drawing orspecifications)

free from distortion

free from sharp edges, slivers or burrs


Candidate Date

Assessor Date





Unit summaryThis unit identifies the competencies you need to assist in the trial assembly of pre-fabricated structural steelwork, prior to its assembly and erection on site, tospecification and in accordance with approved procedures. Steelwork can includeany structural framing material, and will include such things as support structures,building frames and roofs, mezzanine platforms, rigs, access staging and platforms.

Your responsibilities will require you to comply with organisational policy andprocedures for the safe assembly of the structure and the associated assemblyactivities to be undertaken, and to report any problems with the component parts,equipment or construction activities that you cannot personally resolve, or areoutside your permitted authority, to the relevant people. You will be expected towork to instructions, with a minimum of supervision, taking personal responsibilityfor your own actions and for the quality and accuracy of the work that you carry out.

Your underpinning knowledge will be sufficient to provide a good understanding ofyour work, and will provide an informed approach to applying structural steelassembly procedures. You will have an understanding of the principles and processesassociated with the assembly of the structures, and their application. You will knowabout the ways of handling structural steelwork and the means of fixing them inposition, as well as the care and use of the tools and equipment, in adequate depth toprovide a sound basis for carrying out the activities to the required specification.

You will understand the safety precautions required when assembling the structuralcomponents and when using the associated tools and equipment. You will berequired to demonstrate safe working practices throughout, and will understand theresponsibility you owe to yourself and others in the workplace.

Unit 42Assembling structural steelwork



regulations and guidelinesb Determine what has to be done and how this will be achievedc Select the appropriate construction elements and check that they are in a

usable conditiond Position and secure the construction elements in line with the specificatione Securely fix any necessary temporary support facilitiesf Take appropriate measures to protect the finished constructiong Deal promptly and effectively with problems within your control and report those



You must:1 Carry out all of the following during the structural assembly operations:

• comply with health and safety and site regulations at all times• use safety and personal equipment (such as hard hat, footwear and gloves)• use the correct construction drawings and interpret them correctly• correctly prepare the components and faces to be erected and assembled• use the correct datum faces• assemble the structural components in the correct order and manner• correctly align the components and faces to be joined• use the specified or appropriate fixing method, and ensure all bolts are

tightened to the required torque• produce an assembly which meets the required specification

2 Assemble structural steelwork for one of the following:• building frames and roofs• support structures• mezzanine platforms• rigs• access staging and platforms



3 Use four of the following types of components in the assemblies produced:• columns• beams• roof trusses• frames• bed plates• staircases• bulkheads• roof sheeting/cladding• fishplates• brackets• support plates• guards and hand rails• safety cages• platforms and ladders

4 Use all of the following during the assembly activities: • hand tools and equipment (podger, crow bar, spanners, torque wrenches)• assembly and alignment techniques and procedures (levels, plumb lines,

laser equipment)• mechanical fastening techniques and procedures (bolted, riveted)• slinging and lifting techniques (ropes, chains, cranes)• temporary staging or mobile platforms

5 Produce assemblies which meet all of the following quality and accuracy standards:• all components are correctly assembled and aligned, in accordance with

the specification• overall dimensions are within specification tolerances• assemblies meet appropriate geometric tolerances (square, straight, angles,

free from twists)• completed assemblies meet specification

Knowledge statements:You must have knowledge and understanding of:1 The specific safety precautions to be taken when working in a steel

construction environment and when assembling structural components(general site safety, appropriate personal protective equipment, accidentprocedure; working at height and statutory regulations relating to it, riskassessment procedures and relevant requirements of HASAWA, COSHH andWork Equipment Regulations; safe disposal of waste materials)

2 The personal protective clothing and equipment to be worn when carrying outthe assembly activities (leather gloves, eye protection, safety helmets, earprotection, safety harness, etc)

3 Safe working practices and procedures for assembling structural components4 The correct methods of moving or lifting heavy structural sections



5 The hazards associated with assembling structural components (such as usingdangerous or badly maintained tools and equipment, lifting and handling longand heavy components, working at height, slips trips and falls), and how theycan be minimised

6 How to obtain the necessary construction and site drawings and joining specifications


8 The preparations to be carried out on the components prior to assembling them

9 Equipment and temporary installations that may be required to support thestructure during the assembly activities

10 The various methods of securing the assembled components (the range of nutsand bolts used, including close-tolerance location bolts; temporary tackwelding methods and techniques)

11 How to set up and align the various components, and the tools and equipmentthat is used for this



14 The things that can go wrong when producing structuralcomponents/assemblies, and how these can be avoided

15 Inspection techniques that can be applied to check that the construction is tospecification and within acceptable limits

16 The extent of your own authority and whom you should report to if you haveproblems that you cannot solve






evidence type

date

Carry out all of the following during the structural assembly operations:

comply with health and safety and siteregulations at all times

use safety and personal equipment(such as hard hat, footwear and gloves)

use the correct construction drawingsand interpret them correctly

correctly prepare the components andfaces to be erected and assembled


assemble the structural components inthe correct order and manner


use the specified or appropriate fixingmethod, and ensure all bolts aretightened to the required torque


Assemble structural steelwork for one of the following:

building frames and roofs

support structures

mezzanine platforms

rigs

access staging and platforms

Use four of the following types of components in the assemblies produced:

columns

beams

roof trusses

frames

bed plates

staircases



bulkheads

roof sheeting/cladding

fishplates

brackets

support plates

guards and hand rails

safety cages

platforms and ladders

Use all of the following during the assembly activities:

hand tools and equipment (podger,crow bar, spanners, torque wrenches)

assembly and alignment techniquesand procedures (levels, plumb lines,laser equipment)

mechanical fastening techniques andprocedures (bolted, riveted)

slinging and lifting techniques (ropes,chains, cranes)

temporary staging or mobile platforms

Produce assemblies which meet all of the following quality and accuracy standards:

all components are correctlyassembled and aligned, in accordancewith the specification


assemblies meet appropriategeometric tolerances (square, straight,angles, free from twists)

completed assemblies meetspecification


Candidate Date

Assessor Date





Unit summaryThis unit identifies the competencies you need to bend and form pipes using pipebending machines, in accordance with approved procedures. You will be required towork to instruction with the appropriate type and size of machine and former, basedon the pipe type, size and operations to be performed. In producing thecomponents, you will be required to operate the equipment safely and correctly, orto direct operations for their effective use, and to bend and form the pipe to therequired profile without flats or deformations. The pipe bending and formingoperations will include bending at right angles, bending to other angles, producingoffsets, bridge sets, curved sections and expansion loops.

Your responsibilities will require you to comply with organisational policy andprocedures for the use of the machines and the process activities undertaken, and toreport any problems with the pipe forming equipment, materials or formingactivities that you cannot personally resolve, or are outside your permitted authority,to the relevant people. You will be expected to work to instructions, with a minimumof supervision, taking personal responsibility for your own actions and for the qualityand accuracy of the work that you carry out.

Your underpinning knowledge will be sufficient to provide a good understanding ofyour work, and will provide an informed approach to forming pipework usingmachine procedures. You will have an understanding of the characteristics of theequipment being used, the forming principles, and their application, and will knowabout the processes involved and their limitations, in sufficient depth to provide asound basis for carrying out the activities, correcting any faults and ensuring thework output is produced to the required specification.


Unit 43Forming pipework by machine bending









the following checks:• the appropriate machine is selected for the operation being performed• the machine guards and safety devices are in position and function correctly• forming tools are appropriate and in a serviceable condition (secure, correct

diameter, free of damage)• machine settings are suitable for the pipe diameter, material thickness and

operations to be performed

2 Use one of the following types of pipe bending machines:• hand operated manual bending machines (small diameter pipe)• hydraulically operated bending machines• powered pipe bending machines• CNC bending machines• power press with different former radii and sizes (pipe diameter)

3 Bend and form one of the following types of pipework:• heavy duty pipes• small bore lubrication/fuel piping• cable ducting pipework• structural pipes• high pressure pipes



4 Produce pipework forms that include three of the following:• right-angled bends• angular bends• offsets• bridge sets• expansion loops• curved sections

5 Bend and form pipes made from one of the following types of material:• ferrous steel• non-ferrous• special metals

6 Produce pipe bends and forms which comply with all of the following quality andaccuracy standards, as applicable:• meet drawing, specification, template or job requirements• meet customer requirements• have the required dimensional accuracy within specified tolerances• the form or sharpness of the bend conforms to best practice and or

specification without deformation or cracking• the bend conforms to the required shape/geometry (to the template profile)

Knowledge statements:You must have knowledge and understanding of:1 The specific safety precautions to be taken when working with pipe bending

equipment/bending machines in a fabrication environment2 The general workshop and site safety requirements (statutory requirements,

risk assessment procedures and relevant requirements of HASAWA, COSHHand Work Equipment Regulations; safe disposal of waste materials)

3 The safe working practices and procedures for operating power-operatedbending and forming machines

4 The specific personal protective equipment to be worn when carrying out thepipe bending activities (gloves, eye protection, safety helmets, ear protection, etc)

5 The handling precautions and correct methods of moving or lifting long lengthsor heavy pipes

6 The hazards associated with the pipe bending activities (handling long pipelengths; using power operated bending equipment; using dangerous or badlymaintained tools and equipment; using heating equipment), and how they canbe minimised


8 Principles and methods of marking out pipework, and the type of equipmentused (direct marking; use of templates; use of set wires; marking outconventions applicable to the bending process (centre lines, bending lines)



9 How to prepare the pipes in readiness for the bending and forming activities(visually checking for defects, cleaning the materials, removing burrs and sharp edges)

10 The characteristics of the various materials used, with regard to the bendingoperations and why some materials may require the addition of heat to aid thebending process

11 The various types of machines used to bend and form the pipe (including theuse of hand bending machines, hydraulic bending equipment, power-operatedequipment and heating methods)

12 How to prepare and set up the machine for a range of different bends (angledbends, curved sections, twisted sections and straightening of sections)

13 How to produce the various bends required (such as angled bends, dog-legsets, bridge sets and expansion loops)

14 Ways of limiting distortion, wrinkles, marking and creases in the finished workpiece










evidence type

date




forming tools are appropriate and in aserviceable condition (secure, correctdiameter, free of damage)

machine settings are suitable for thepipe diameter, material thickness andoperations to be performed

Use one of the following types of pipe bending machines:

hand operated manual bendingmachines (small diameter pipe)

hydraulically operated bendingmachines

powered pipe bending machines

CNC bending machines

power press with different former radiiand sizes (pipe diameter)

Bend and form one of the following types of pipework:

heavy duty pipes

small bore lubrication/fuel piping

cable ducting pipework

structural pipes

high pressure pipes

Produce pipework forms that include three of the following:

right-angled bends

angular bends

offsets

bridge sets

expansion loops

curved sections



Bend and form pipes made from one of the following types of material:

ferrous steel

non-ferrous

special metals

Produce pipe bends and forms which comply with all of the following quality and accuracy standards, as applicable:

meet drawing, specification, templateor job requirements

meet customer requirements

have the required dimensionalaccuracy within specified tolerances

the form or sharpness of the bendconforms to best practice and orspecification without deformation orcracking



Candidate Date

Assessor Date





Unit summaryThis unit identifies the competencies you need to produce socket and flange filletwelded joints in pipe, using a manual welding process such as manual metal arc(MMA), MIG, MAG, TIG, flux cored wire, plasma or gas welding equipment, inaccordance with instructions and/or approved welding procedures. You will berequired to check that all the workholding equipment and manipulating devicesrequired are available and in a usable condition. You will be expected to check thewelding equipment to ensure that all the leads/cables, hoses and wire feedmechanisms are securely connected and free from damage.

In preparing to weld, you will need to set and adjust the welding conditions, in linewith the instructions or welding procedure specification. You must operate theequipment safely and correctly and make any necessary adjustments to settings, inline with your permitted authority, in order to produce the welded joints to therequired specification. You will be required to demonstrate your capability toproduce the fillet welds to the required quality, and this could be through testsaccording to BS 4872 or EN 287.

Your responsibilities will require you to comply with organisational policy andprocedures for the welding activities undertaken, and to report any problems withthe welding equipment or welding activities that you cannot resolve, or are outsideyour permitted authority, to the relevant people. You will be expected to work toinstructions, with a minimum of supervision, taking personal responsibility for yourown actions and for the quality and accuracy of the work that you produce.

Your underpinning knowledge will be sufficient to provide a sound basis for yourwork, and will provide an understanding of how the particular welding processworks. You will know about the equipment, materials and consumables, in adequatedepth to provide a sound background for the welding operations to be performed,and for ensuring the work output is produced to the required specification.

You will understand the safety precautions required when working with the weldingequipment. You will be required to demonstrate safe working practices throughout,and will understand the responsibility you owe to yourself and others in the workplace.

Unit 44Producing socket and flange fillet welded joints in pipeusing a manual welding process









following welding processes:• Manual Metal Arc• MIG/MAG• TIG• Cored wire• Plasma• Gas welding

2 Use consumables appropriate to the material and application, to include either ofthe following:two types of electrode from:• rutile• basic• cellulosic• nickel alloy• aluminiumOR• two types of filler wire from different material groups

3 Produce socket and flange fillet welded joints in one of the following:• small bore pipe (50mm outside diameter or less)• large bore pipe (above 50mm outside diameter)



4 Weld joints, in good access situations, in four of the following BS EN287 positions:• Flat (PA) rotating• Horizontal vertical (PB) fixed• Horizontal vertical (PB) rotating• Vertical upwards (PF) fixed• Vertical down (PG) fixed• Horizontal overhead (PD) fixed

5 Produce welded pipes which:• meet the required dimensional accuracy within specified tolerance• achieve minimum weld quality requirements applicable to fillet welds,

equivalent to those given in the relevant European/International standards (eg,EN 25817 / ISO 5187 and EN 30042 / ISO 10042), as required by the applicationstandard or specification


the selected welding equipment (general workshop and site safety, appropriatepersonal protective equipment, fire prevention, protecting other workers fromarc eye, safety in enclosed/confined spaces; fume control; accident procedure;statutory regulations, risk assessment procedures and relevant requirementsof HASAWA, COSHH and Work Equipment Regulations; safe disposal of waste materials)


3 The hazards associated with the selected welding process (live electricalcomponents, poor earthing, arc radiation, fumes and gases, gas supply leaks,spatter, hot slag and metal, elevated working, enclosed spaces, slips, trips andfalls), and how they can be minimised

4 The manual welding process selected, and an awareness of the different typesof welding equipment (basic principles of fusion welding, AC and DC powersources, ancillary equipment, power ranges, care of equipment, terminologyused in welding, flame setting)

5 Extracting information required from drawings and welding procedurespecifications (interpretation of welding symbols, scope, content andapplication of the welding procedure specification)

6 The consumables associated with the chosen welding process (types ofelectrodes and/or filler metal and application, types of shielding gas and theirapplication, gas supply and control, correct storage and drying of electrodesand filler wire)

7 The types and features of welded joints in pipe (fillet and butt welds, single andmulti-run welds, welding positions, weld quality)



8 Methods of setting up and restraining the joint to achieve correct location ofcomponents and control of distortion (edge preparation, use of jigs andfixtures, manipulators and positioners, tack welding size and spacing inrelationship to material thickness and component size, use of temporaryattachments, pre-setting)

9 Preparing the welding equipment, and checks that need to be made to ensurethat it is safe and ready to use (electrical connections, earthing arrangements;equipment calibration, setting welding parameters)

10 The techniques of operating the welding equipment to produce a range ofjoints in the various joint positions (fine tuning parameters, correctmanipulation of the welding gun or electrode, safe closing down of the welding equipment)


12 Problems that can occur with the welding activities, and how these can beovercome (causes of distortion and methods of control, effects of welding onmaterials and sources of weld defects; methods of prevention)

13 The organisational quality systems used; weld standards to be achieved; weld inspection and test procedures used (including visual and non-destructive tests)

14 Personal approval tests, and their applicability to your work15 The extent of your own authority and whom you should report to if you have






evidence type

date

Set up, check, adjust and use welding and related equipment for one of the following welding processes:

Manual Metal Arc

MIG/MAG

TIG

Cored wire

Plasma

Gas welding

Use consumables appropriate to the material and application, to include either of the following:

two types of electrode from:

rutile

basic

cellulosic

nickel alloy

aluminium

OR


Produce socket and flange fillet welded joints in one of the following:

small bore pipe (50mm outsidediameter or less)

large bore pipe (above 50mm outsidediameter)

Weld joints, in good access situations, in four of the following BS EN287 positions:

Flat (PA) rotating

Horizontal vertical (PB) fixed

Horizontal vertical (PB) rotating

Vertical upwards (PF) fixed

Vertical down (PG) fixed

Horizontal overhead (PD) fixed



Produce welded pipes which:


achieve minimum weld qualityrequirements applicable to fillet welds,equivalent to those given in therelevant European/Internationalstandards (eg, EN 25817 / ISO 5187 andEN 30042 / ISO 10042), as required bythe application standard orspecification


Candidate Date

Assessor Date





Unit summaryThis unit identifies the competencies you need to produce composite mouldingsusing wet lay-up techniques, in accordance with approved procedures. You will berequired to follow the appropriate instructions, drawings, specifications anddocumentation to produce the composite mouldings, using the correct wet lay-upproduction techniques.

You will produce a range of composite mouldings, incorporating a variety of featuresand using a range of techniques and processes. Mouldings produced will includelaminates and sandwich structures, using a range of resin, fibre and core materials.

Your responsibilities will require you to comply with organisational policy andprocedures for the composite moulding activities undertaken, and to report anyproblems with the moulding activities, equipment or materials that you cannotpersonally resolve, or are outside your permitted authority, to the relevant people.You will be expected to work to instructions, with a minimum of supervision, takingpersonal responsibility for your own actions and for the quality and accuracy of thework that you carry out.

Your underpinning knowledge will be sufficient to provide a good understanding ofyour work, and will provide an informed approach to applying composite mouldingwet lay-up techniques and procedures. You will have an understanding of theproduction techniques used, and their application, in adequate depth to provide asound basis for carrying out the activities, recognising faults, and ensuring the workoutput is to the required specification.

You will understand the safety precautions required when carrying out the wet lay-up moulding activities and when using the associated tools and equipment. You willbe required to demonstrate safe working practices throughout, and will understandthe responsibility you owe to yourself and others in the workplace.

Unit 45Producing composite mouldings using wet lay-up techniques



regulations and guidelinesb Follow the correct component drawing or any other related specifications for the

component to be producedc Determine what has to be done and how this will be achievedd Obtain and prepare the appropriate tools, equipment and materialse Carry out the moulding or laying-up activities using the correct methods

and techniquesf Produce components to the required specificationg Check that all the required operations have been completed to specificationh Deal promptly and effectively with problems within your control and report those



You must:1 Carry out all of the following during the moulding activities:

• use the correct issue of production documentation (instructions, drawings, job cards)

• use relevant health and safety documentation (material data sheets, COSHH sheets)

• use the correct tools and equipment for the activity and ensure they are safe to use

• use the correct materials and consumables, as specified in the production documentation

• apply safe and appropriate wet lay-up working practices and procedures at all times

• keep the work area in a safe condition

2 Prepare moulds and materials for production activities, to include all of the following:• cleaning of tooling and removal of resin build-ups• checking of tooling for surface defects• correctly applying sealants/release agents• dispensing and applying the correct measure and mix of resin/catalyst



3 Produce a range of mouldings, using two of the following application techniques:• spray application of fibre/resin• application of a gel coat• brush application of fibre/resin• roller application of fibre/resin• removal of voids and air pockets• use of vacuum bagging• use of bleed plies

4 Produce a range of mouldings incorporating one of the following in the lay-up:• feathered joins• overlap joins• orientated plies• inserts• fixtures• butt joins

5 Produce a range of mouldings, incorporating two of the following shape features:• internal corner• external corner• double curvature• concave surface• convex surface• vertical surface

6 Produce a range of mouldings using all the following:• resin (such as polyester, epoxy, phenolic, vinyl ester)• fibre (such as glass, carbon, polyethylene, aramid)• reinforcement (such as braids, roving, tapes, chopped strand, continuous

filament, woven)• core material (such as wood, coremat, structural foam, honeycomb)

7 Produce a range of mouldings which comply with one or more of the following standards:• ISO 9000 quality assurance procedures• customer standards and requirements• company standards and procedures

Knowledge statements:You must have knowledge and understanding of:1 Health and safety precautions to be taken, and procedures used in the

specific work area, when working with composite materials, consumables,tools and equipment

2 The hazards associated with working with composite materials, consumables,tools and equipment, and how to minimise these in the work area

3 The protective equipment that is needed for personal protection and, whererequired, the protection of others



4 The application of COSHH regulations in relation to the storage, use anddisposal of composite materials and consumables

5 How to use and extract information from engineering drawings and relatedspecifications (to include symbols and conventions to appropriate BS or ISOstandards in relation to work undertaken)

6 How to interpret and use imperial and metric systems of measurement7 Quality procedures used in the workplace to ensure production control (in

relation to currency, issue, meeting specification, etc)8 Conventions and terminology used for wet lay-up techniques (eg, resin and

fibre weights/volumes, material orientation, material identification, materialtailoring, mixing ratios, gel times, exotherm, bleed plies, etc)

9 The type of resin, fibres and reinforcement used, and their applications10 The visual identification of both raw and finished composite materials11 Methods of preparation for patterns, moulds and tooling (including the correct

use of surface sealers and release agents)12 Mixing ratios for gel coats, resins and catalysts, and their associated

working times13 The methods used in the application of the resin/fibre during the lay-up activity14 Tools and equipment used in the lay-up activities, and their care, preparation

and control procedures15 How to recognise faults that can occur during the lay-up process16 Procedures and methods used for removing mouldings from production tooling17 The identification of defects in the composite moulding (such as de-lamination,

voids, contaminants, etc)18 The care and safe handling of production tooling and composite mouldings

throughout the production cycle19 The production controls used in the work area, and actions to be taken for

unaccounted items20 The extent of your own authority and whom you should report to if you have






evidence type

date

Carry out all of the following during the moulding activities:

use the correct issue of productiondocumentation (instructions, drawings,job cards)

use relevant health and safetydocumentation (material data sheets,COSHH sheets)

use the correct tools and equipment forthe activity and ensure they are safe touse

use the correct materials andconsumables, as specified in theproduction documentation

apply safe and appropriate wet lay-upworking practices and procedures at alltimes

keep the work area in a safe condition

Prepare moulds and materials for production activities, to include all of the following:

cleaning of tooling and removal of resinbuild-ups

checking of tooling for surface defects

correctly applying sealants/releaseagents

dispensing and applying the correctmeasure and mix of resin/catalyst

Produce a range of mouldings, using two of the following application techniques:

spray application of fibre/resin

application of a gel coat

brush application of fibre/resin

roller application of fibre/resin

removal of voids and air pockets

use of vacuum bagging

use of bleed plies



Produce a range of mouldings incorporating one of the following in the lay-up:

feathered joins

overlap joins

orientated plies

inserts

fixtures

butt joins

Produce a range of mouldings, incorporating two of the following shape features:

internal corner

external corner

double curvature

concave surface

convex surface

vertical surface

Produce a range of mouldings using all the following:

resin (such as polyester, epoxy,phenolic, vinyl ester)

fibre (such as glass, carbon,polyethylene, aramid)

reinforcement (such as braids, roving,tapes, chopped strand, continuousfilament, woven)

core material (such as wood, coremat,structural foam, honeycomb)

Produce a range of mouldings which comply with one or more of the following standards:

ISO 9000 quality assurance procedures

customer standards and requirements

company standards and procedures


Candidate Date

Assessor Date





Unit summaryThis unit identifies the competencies you need to produce composite mouldingsusing pre-preg laminating techniques, in accordance with approved procedures. Youwill be required to follow the appropriate instructions, drawings, specifications anddocumentation to produce the various mouldings, using the correct pre-preglaminating production techniques.

You will produce a range of composite mouldings, incorporating a variety of featuresand using a range of techniques and processes. Mouldings produced will includelaminates and sandwich structures, using a range of resin, fibre and core materials.

Your responsibilities will require you to comply with organisational policy andprocedures for the pre-preg laminating activities undertaken, and to report anyproblems with the production activities, equipment or materials that you cannotpersonally resolve, or are outside your permitted authority, to the relevant people.You will be expected to work to instructions, with a minimum of supervision, takingpersonal responsibility for your own actions and for the quality and accuracy of thework that you carry out.

Your underpinning knowledge will be sufficient to provide a good understanding ofyour work, and will provide an informed approach to applying pre-preg laminatingtechniques and procedures. You will have an understanding of the pre-preglaminating production techniques used, and their application, in adequate depth toprovide a sound basis for carrying out the activities, recognising faults, and ensuringthe work output is to the required specification.

You will understand the safety precautions required when carrying out the pre-preglaminating activities and when using the associated tools and equipment. You will berequired to demonstrate safe working practices throughout, and will understand theresponsibility you owe to yourself and others in the workplace.

Unit 46Producing composite mouldings using pre-preg laminating techniques









• use the correct issue of production documentation (instructions, drawings, job cards)

• use relevant health and safety documentation (material data sheets, COSHHsheets, risk assessments)

• use the correct tools and equipment for the activity, and ensure they are safe to use

• use the correct materials as specified in the production documentation• apply safe and appropriate pre-preg laminating working practices and

procedures at all times• keep the work area in a safe condition

2 Prepare moulds and materials for production activities, to include carrying out allof the following:• cleaning of tooling and removal of resin build ups• checking of tooling for surface defects• correctly applying sealants/release agents• cutting materials to correct shape and orientation (where applicable)



3 Produce a range of mouldings, using techniques for two of the following types ofproduction tools:• metal• wet lay-up• glass pre-preg• tooling block• carbon pre-preg• female tooling• male tooling• multi-part tools• matched tooling• closed tooling

4 Produce composite fabrications, incorporating one of the following in the lay-up:• butt joins• overlap joins• staggered joins• orientated plies• inverted plies• inserts

5 Produce composite fabrications, incorporating three of the following features:• internal corners• external corners• double curvature• concave surface• convex surfaces• return surfaces• joggle details• nett edges

6 Use all of the following in the lay-up activities:• resin (such as epoxy, phenolic, bismaleimide, cyanate ester)• fibre (such as glass, polyethylene, aramid, carbon)• reinforcement (such as continuous, uni-directional, braids, woven,

multi-axis, tapes)• core materials (such as wood, syntactic core, expanding core, foam,

honeycomb)

7 Use one of the following for applying temperature during the cure cycle:• oven• heated tools/moulds• autoclave• heated press



8 Use one of the following for applying pressure during the cure cycle:• pressure bags• vacuum bags• thermal mould expansion• fibre tensioning

9 Produce a range of mouldings which comply with one of the following standards:• ISO 9000 quality assurance procedures• customer standards and requirements• company standards and procedures

Knowledge statements:You must have knowledge and understanding of:1 Health and safety precautions to be taken, and procedures used in the specific

work area, when working with composite materials, consumables, tools and equipment


3 Protective equipment that is needed for personal protection and, whererequired, the protection of others



6 How to interpret imperial and metric systems of measurement7 Quality procedures used in the workplace to ensure production control (in

relation to currency, issue, meeting specification, etc)8 Conventions and terminology used for pre-preg laminating techniques (eg,

material orientation, material identification, material templates, ply lay-up,pressure plates, vacuum bagging, cure cycles, exotherm, etc)

9 The type of resin systems, fibres and reinforcements used, and their applications

10 The core, insert and filler materials used, and their applications11 The visual identification of both raw and finished composite materials12 Methods used in the application of pre-preg materials to tooling surfaces

(including methods of tailoring and cutting)13 Correct methods of storage and handling of ancillary and consumable materials14 Tools and equipment used in the pre-preg laminating activities, and their care,

preparation and control procedures15 How to recognise faults that can occur during the moulding process16 The importance of adhering to the cure cycle17 Procedures and methods used for removing mouldings from production tooling



18 The care and safe handling of production tooling and composite mouldingsthroughout the production cycle

19 The production controls used in the work area, and actions to be taken forunaccounted items




evidence type

date


use the correct issue of productiondocumentation (instructions, drawings, job cards)

use relevant health and safetydocumentation (material data sheets,COSHH sheets, risk assessments)

use the correct tools and equipment forthe activity, and ensure they are safe to use

use the correct materials as specified inthe production documentation

apply safe and appropriate pre-preglaminating working practices andprocedures at all times


Prepare moulds and materials for production activities, to include carrying out all of the following:

cleaning of tooling and removal of resinbuild ups

checking of tooling for surface defects

correctly applying sealants/releaseagents

cutting materials to correct shape andorientation (where applicable)

Produce a range of mouldings, using techniques for two of the following types of production tools:

metal

wet lay-up

glass pre-preg

tooling block

carbon pre-preg

female tooling

male tooling

multi-part tools







matched tooling

closed tooling

Produce composite fabrications, incorporating one of the following in the lay-up:

butt joins

overlap joins

staggered joins

orientated plies

inverted plies

inserts

Produce composite fabrications, incorporating three of the following features:

internal corners

external corners

double curvature

concave surface

convex surfaces

return surfaces

joggle details

nett edges

Use all of the following in the lay-up activities:

resin (such as epoxy, phenolic,bismaleimide, cyanate ester)

fibre (such as glass, polyethylene,aramid, carbon)

reinforcement (such as continuous, uni-directional, braids, woven, multi-axis,tapes)

core materials (such as wood, syntacticcore, expanding core, foam,honeycomb)

Use one of the following for applying temperature during the cure cycle:

oven

heated tools/moulds

autoclave

heated press



Use one of the following for applying pressure during the cure cycle:

pressure bags

vacuum bags

thermal mould expansion

fibre tensioning

Produce a range of mouldings which comply with one of the following standards:





Candidate Date

Assessor Date





Unit summaryThis unit identifies the competencies you need to produce components by acrylicmoulding, in accordance with approved procedures. You will be required to followthe appropriate instructions, drawings, specifications and documentation toproduce the various types of components. You will be expected to produce theacrylic components using the specified moulding process and techniques. This willinvolve using equipment such as air circulating ovens, presses, trimming andautomated cutting equipment. The products produced will include deep drawn,double curvature, convex and concave shapes.

Your responsibilities will require you to comply with organisational policy andprocedures for the acrylic moulding activities undertaken, and to report anyproblems with the moulding activities, equipment or materials that you cannotpersonally resolve, or are outside your permitted authority, to the relevant people.You will be expected to work to instructions, with a minimum of supervision, takingpersonal responsibility for your own actions and for the quality and accuracy of thework that you carry out.

Your underpinning knowledge will be sufficient to provide a good understanding ofyour work, and will provide an informed approach to applying acrylic mouldingtechniques and procedures. You will have an understanding of the productiontechniques used, and their application, in adequate depth to provide a sound basisfor carrying out the activities, recognising faults, and ensuring the work output is tothe required specification.

You will understand the safety precautions required when carrying out the acrylicmoulding activities and when using the associated tools and equipment. You will berequired to demonstrate safe working practices throughout, and will understand theresponsibility you owe to yourself and others in the workplace.

Unit 47Produce components by acrylic moulding









• use the correct issue production documentation (work instructions, drawings,job cards)

• use relevant health and safety documentation (material data sheets, COSHH sheets)


• use the correct materials and consumables, as specified in the production documentation

• apply safe and appropriate acrylic moulding practices and procedures at all times


2 Carry out one of the following moulding methods and techniques:• vacuum moulding• deep drawing• shape clamping• positive pressure shaping• stress relieving



3 Carry out three of the following operations during the moulding process:• tool/equipment preparation• sheet preparation• trimming• setting and controlling temperatures• stress relieving• sheet forming• de-moulding

4 Produce a range of components with two of the following features:• box sections• cylindrical section• convex shapes• concave shapes• single curvatures• double curvatures

5 Produce a range of mouldings which comply with one or more of the following standards:• ISO 9000 quality assurance procedures• customer standards and requirements• company standards and procedures

Knowledge statements:You must have knowledge and understanding of:1 The specific safety practices and procedures that you need to observe when

working with acrylics, including any specific legislation, regulations/codes ofpractice for the activities, equipment or materials used

2 The health and safety requirements of the work area where you are carrying outthe activities, and the responsibility these requirements place on you

3 The protective equipment that you need to use for both personal protectionand, where appropriate, protection of others

4 The hazards associated with moulding acrylic materials, and with the tools andequipment used, and how they can be minimised

5 The interpretation of drawings, standards, quality control procedures andspecifications used for the moulding activity, and the currency/issue checks ofthe documents you are working with

6 The principles of deep drawing, concave/convex moulding, positive pressuremoulding and stress relieving

7 The different methods of heating materials, and the temperature control methods8 The sheet profiling procedures, and material trimming methods/procedures9 The supply of acrylic sheet (such as colour, thickness, sheet size, surface

texture, material protection)10 The use of forming aids11 The methods of sheet trimming and sheet cleaning prior to moulding



12 The preparation methods and procedures applied to the moulding surface13 The material cleaning methods and procedures to be applied14 The quality control procedures to followed during the moulding operations15 The methods and techniques for lifting, handling and supporting the

components/equipment/materials during the moulding activities16 Recognition of moulding defects (such as misalignment, distortion, damage,

contamination and surface defects)17 The tools and equipment used in the moulding activities, and their calibration,

care, preparation and control procedures18 The problems that can occur with the moulding operations, and how these can

be overcome19 The recording documentation to be completed for the moulding

activities undertaken20 The extent of your own authority and whom you should report to if you have






evidence type

date


use the correct issue productiondocumentation (work instructions,drawings, job cards)

use relevant health and safetydocumentation (material data sheets,COSHH sheets)

use the correct tools and equipment forthe activity, and ensure they are safe touse

use the correct materials andconsumables, as specified in theproduction documentation

apply safe and appropriate acrylicmoulding practices and procedures atall times


Carry out one of the following moulding methods and techniques:

vacuum moulding

deep drawing

shape clamping

positive pressure shaping

stress relieving

Carry out three of the following operations during the moulding process:

tool/equipment preparation

sheet preparation

trimming

setting and controlling temperatures

stress relieving

sheet forming

de-moulding



Produce a range of components with two of the following features:

box sections

cylindrical section

convex shapes

concave shapes

single curvatures

double curvatures

Produce a range of mouldings which comply with one or more of the following standards:





Candidate Date

Assessor Date





Unit summaryThis unit identifies the competencies you need to vacuum form components, inaccordance with approved procedures. You will be required to follow theappropriate instructions, drawings and specifications, to produce the various typesof components from thermoplastic sheet, fibre reinforced thermoplastic sheet andstructural foam. This will require you to use a range of air circulating ovens, vacuumforming machines, trimming equipment and various types of tooling. Thecomponents produced will have a range of features, including male shapes, femaleshapes, double curvatures and stiffened mouldings.

Your responsibilities will require you to comply with organisational policy andprocedures for the vacuum forming activities undertaken, and to report anyproblems with the vacuum forming activities, equipment, materials or consumablesthat you cannot personally resolve, or are outside your permitted authority, to therelevant people. You will be expected to work to instructions, with a minimum ofsupervision, taking personal responsibility for your own actions and for the qualityand accuracy of the work that you carry out.

Your underpinning knowledge will be sufficient to provide an understanding of yourwork, and will provide an informed approach to applying vacuum formingprocedures. You will have an understanding of the vacuum forming proceduresused, and their application, and will know about the vacuum forming techniques,materials, tooling and consumables used, in adequate depth to provide a soundbasis for carrying out the activities, recognising faults and ensuring the work outputis to the required specification.

You will understand the safety precautions required when carrying out the vacuumforming operations and when using the associated tools and equipment. You will berequired to demonstrate safe working practices throughout, and will understand theresponsibility you owe to yourself and others in the workplace.

Unit 48Vacuum forming composite materials








You must:1 Carry out all of the following during the vacuum forming activities:

• use the correct issue of production documentation (job instructions, drawings, specifications)

• use relevant health and safety documentation (material data sheets, relevantCOSHH sheets, risk assessments)

• use the correct materials and consumables as specified in the productiondocumentation (colour, size, composition)

• use the correct tools and equipment for the activity and check they are fit for purpose

• apply safe and appropriate vacuum forming techniques and working practicesat all times

• leave the work area in a safe condition

2 Use two of the following types of equipment:• air circulating ovens• vacuum forming machines• tufnol tooling• metal tooling• wood tooling• trimming equipment• composite tooling



3 Carry out three of the following operations:• bubble blowing to minimize webbing• positioning of robbers• cleaning tooling• temperature control• trimming techniques• drying of sheet• use of intensifiers• sheet cleaning

4 Produce a range of components with two of the following features:• double curvatures• male shapes• female shapes• stiffened mouldings

5 Produce a range of components using one the following materials:• thermoplastic sheet (such as polycarbonate, polysulphone, acrylic,

polyvinyl chloride, ABS)• fibre-reinforced thermoplastic sheet• structural foams (polyvinyl chloride (PVC), polymethate (Rohacell), etc)

6 Produce components which comply with one or more of the following standards:• ISO 9000 series and procedures• customer standards and requirements• company standards and procedures

Knowledge statements:You must have knowledge and understanding of:1 The specific safety practices and procedures that you need to observe when

working with vacuum forming equipment (including any specific legislation,regulations/codes of practice for the activities, equipment or materials)

2 The health and safety requirements of the work area where you are carrying outthe activities, and the responsibility these requirements place on you

3 The protective equipment that you need to use for both personal protectionand, where appropriate, protection of others

4 The hazards associated with carrying out vacuum forming activities, and withthe tools and equipment used, and how they can be minimised

5 The application of COSHH regulations in relation to the storage, use anddisposal of materials and consumables used in the vacuum forming process

6 How to extract information from engineering drawings, and relatedspecifications (to include symbols and conventions to appropriate BS or ISOstandards in relation to the work undertaken)

7 How to interpret imperial and metric systems of measurement8 The methods of sheet trimming and sheet cleaning, prior to forming9 The preparation methods and procedures applied to the moulding surface10 The identification of the correct male/female mould tooling



11 The methods and techniques of loading and aligning materials into the mould tooling

12 The methods and techniques for carrying out the de-moulding procedures13 How to recognise vacuum forming defects (such as misalignment, distortion,

damage, contamination and surface defects)14 The importance of adhering to the vacuum forming cycle15 The quality control procedures to followed during the vacuum

forming operations16 The tools and equipment used in the vacuum forming activities, and their care,

preparation and control procedures17 The problems that can occur with the vacuum forming operations, and how

these can be overcome18 The production documentation to be completed for the vacuum forming

activities undertaken19 The extent of your own authority and whom you should report to if you have






evidence type

date

Carry out all of the following during the vacuum forming activities:

use the correct issue of productiondocumentation (job instructions,drawings, specifications)

use relevant health and safetydocumentation (material data sheets,relevant COSHH sheets, riskassessments)

use the correct materials andconsumables as specified in theproduction documentation (colour,size, composition)

use the correct tools and equipment forthe activity and check they are fit forpurpose

apply safe and appropriate vacuumforming techniques and workingpractices at all times

leave the work area in a safe condition

Use two of the following types of equipment:

air circulating ovens

vacuum forming machines

tufnol tooling

metal tooling

wood tooling

trimming equipment

composite tooling

Carry out three of the following operations:

bubble blowing to minimize webbing

positioning of robbers

cleaning tooling

temperature control

trimming techniques



drying of sheet

use of intensifiers

sheet cleaning

Produce a range of components with two of the following features:

double curvatures

male shapes

female shapes

stiffened mouldings

Produce a range of components using one the following materials:

thermoplastic sheet (such aspolycarbonate, polysulphone, acrylic,polyvinyl chloride, ABS)

fibre-reinforced thermoplastic sheet

structural foams (polyvinyl chloride(PVC), polymethate (Rohacell), etc)

Produce components which comply with one or more of the following standards:

ISO 9000 series and procedures




Candidate Date

Assessor Date





Unit summaryThis unit identifies the competencies you need to trim composite mouldings usinghand tools, in accordance with approved procedures. You will be required to followthe appropriate instructions, drawings, specifications and documentation to trimvarious composite mouldings, using the correct trimming techniques.

You will be expected to select and use the correct tools and equipment for thetrimming activity. You will trim a range of composite mouldings, incorporating avariety of features, by using cutting, sanding, drilling and polishing techniques andprocesses. Mouldings to be trimmed will include a range of resin and fibre materials.

Your responsibilities will require you to comply with organisational policy andprocedures for the trimming activities undertaken, and to report any problems withthe trimming activities, equipment or materials that you cannot personally resolve,or are outside your permitted authority, to the relevant people. You will be expectedto work to instructions, with a minimum of supervision, taking personalresponsibility for your own actions and for the quality and accuracy of the work thatyou carry out.

Your underpinning knowledge will be sufficient to provide a good understanding ofyour work, and will provide an informed approach to applying composite mouldingtrimming techniques and procedures. You will have an understanding of thetrimming techniques used, and their application, in adequate depth to provide asound basis for carrying out the activities, recognising faults and ensuring thetrimmed mouldings are to the required specification.

You will understand the safety precautions required when carrying out the trimmingactivities and when using the associated tools and equipment. You will be requiredto demonstrate safe working practices throughout, and will understand theresponsibility you owe to yourself and others in the workplace.

Unit 49Trimming composite mouldings using hand tools








You must:1 Carry out all of the following during the trimming activities:

• use the correct issue of production documentation (job instructions, drawings, specifications)

• use relevant health and safety documentation (material data sheets, relevantCOSHH sheets, risk assessments)

• use the correct tools and equipment for the activity, and ensure they are safeto use and suitably stored

• apply safe and appropriate trimming techniques and working practices at all times


2 Carry out all the following when preparing for the trimming activity:• check moulding is correct and complete• check for any defects in the moulding• identify and protect the moulding in the work area

3 Mark out the mouldings using four of the following methods:• scriber• height gauge• moulded scribe lines• centre punch• trimming templates



4 Cut mouldings using two the following methods:• cutting wheels/discs• saws• routers• trim jigs

5 Sand mouldings using three of the following methods:• rubbing blocks• diamond files• pencil grinders• disc sanders• belt sanders

6 Use a hand drill or pedestal drill to drill mouldings, using three of the following methods:• drill jigs• hole saws• counterbores• countersinks• drill bits

7 Polish mouldings using three of the following methods:• wet sanding• cutting compound• polishing compound• rubbing block• orbital sander• polisher

8 Trim mouldings using techniques for both of the following:• resins (such as polyester, vinyl ester, epoxy, phenolic, bismaleimide,

cyanate ester )• fibres (such as polyethylene, glass, aramid, carbon)



9 Trim mouldings that require, or incorporate, eight of the following features:• straight edges• curved edges• flat surfaces• polished surfaces• shaped surfaces• radius corners• returns• nett edges• joggle details• removal of join lines• holes• multiple hole sizes• countersinks• counterbores• further lay-up stages• inserts to be drilled• inserts to be tapped• solid cores• honeycomb cores• edge filling

10 Trim a range of fabrications which comply with one of the following standards:• ISO 9000 quality assurance procedures• customer standards and requirements• company standards and procedures

Knowledge statements:You must have knowledge and understanding of:1 Health and safety precautions to be taken and procedures used when

working with composite materials, consumables, tools and equipment in the specific work area

2 The hazards associated with trimming composite materials, consumables,tools and equipment, and how to minimise these in the work area




6 How to interpret drawings, imperial and metric systems of measurement,workpiece reference points and system of tolerancing

7 How to prepare for the trimming activities, and how to mark out the mouldingsfor the material that needs to be removed

8 Quality procedures used in the workplace to ensure production control (inrelation to currency, issue, meeting specification, etc)



9 Conventions and terminology used for trimming activities (eg, scribe lines,sanding grades, types of cutting tools, speeds)

10 The different types of manual and power tools used in composite trimming operations

11 The different types of cutting tools and abrasives used in trimming compositematerials, and their application

12 The visual identification of cured composite materials13 The identification of defects in composite mouldings14 The methods used in the trimming of composite mouldings15 The care and safe handling of composite mouldings throughout the

trimming cycle16 The extent of your own authority and whom you should report to if you have




evidence type

date

Carry out all of the following during the trimming activities:

use the correct issue of productiondocumentation (job instructions,drawings, specifications)

use relevant health and safetydocumentation (material data sheets,relevant COSHH sheets, riskassessments)

use the correct tools and equipment forthe activity, and ensure they are safe touse and suitably stored

apply safe and appropriate trimmingtechniques and working practices at alltimes


Carry out all the following when preparing for the trimming activity:

check moulding is correct andcomplete

check for any defects in the moulding

identify and protect the moulding in thework area

Mark out the mouldings using four of the following methods:

scriber

height gauge

moulded scribe lines

centre punch

trimming templates

Cut mouldings using two the following methods:

cutting wheels/discs

saws

routers

trim jigs







Sand mouldings using three of the following methods:

rubbing blocks

diamond files

pencil grinders

disc sanders

belt sanders

Use a hand drill or pedestal drill to drill mouldings, using three of the following methods:

drill jigs

hole saws

counterbores

countersinks

drill bits

Polish mouldings using three of the following methods:

wet sanding

cutting compound

polishing compound

rubbing block

orbital sander

polisher

Trim mouldings using techniques for both of the following:

resins (such as polyester, vinyl ester,epoxy, phenolic, bismaleimide, cyanateester )

fibres (such as polyethylene, glass,aramid, carbon)

Trim mouldings that require, or incorporate, eight of the following features:

straight edges

curved edges

flat surfaces

polished surfaces

shaped surfaces

radius corners



returns

nett edges

joggle details

removal of join lines

holes

multiple hole sizes

countersinks

counterbores

further lay-up stages

inserts to be drilled

inserts to be tapped

solid cores

honeycomb cores

edge filling

Trim a range of fabrications which comply with one of the following standards:





Candidate Date

Assessor Date





Unit summaryThis unit identifies the competencies you need to identify and deal with defects incomposite mouldings (moulds, panels, components, jigs), in accordance withapproved procedures. You will be required to use appropriate drawings,specifications and documentation to identify and deal with defects in composites mouldings.

You will be able to identify a range of defects in composite mouldings, using variousmethods and techniques. Defects will be identified in a range of mouldings with avariety of resin and fibre materials.

Your responsibilities will require you to comply with organisational policy andprocedures for the activities undertaken, and to report any problems with theactivities that you cannot personally resolve, or are outside your permitted authority,to the relevant people. You will be expected to work to instructions, with a minimumof supervision, taking personal responsibility for your own actions and for the qualityand accuracy of the work you carry out.

Your underpinning knowledge will be sufficient to provide a good understanding ofyour work, and will provide an informed approach to identifying defects incomposite mouldings. You will have an understanding of composite materials, andtheir application, and will know about the associated defects, in adequate depth toprovide a sound basis for identifying the defects in line with organisation practiceand procedures.

You will understand the safety precautions required when working with thecomposite mouldings and when using associated tools and equipment. You will berequired to demonstrate safe working practices throughout, and will understand theresponsibility you owe to yourself and others in the workplace.

Unit 50Identifying defects in composite mouldings



regulations and guidelinesb Identify defects with regard to the product or asset specificationc Assess the defects and determine action required to return the products and

assets to specified conditiond Report recommendations for action to the appropriate people promptly and in

accordance with organisational procedurese Record details of defects in accordance with quality assurance and control

systems and procedures


You must:1 Carry out all of the following during the inspection activities:

• use the correct issue production documentation (drawings, manuals,specifications, job cards)

• use relevant health and safety documentation (material data sheets, COSHHsheets, risk assessments)



2 Identify defects in composite mouldings using four of the following methods:• touch• sound• visual• measurement• mechanical tests• CMM• NDT• stage inspection



3 Identify defects in six of the following types of composite mouldings:• trim• closing panels• housings• body panels• tubes• sections• sandwich panels• structural• aerodynamic• moulds• jigs

4 Identify defects applicable to two of the following resin types:• polyester• vinyl ester• epoxy• phenolic• bismaleimide• cyanate ester

5 Identify defects applicable to two of the following fibre types:• polyethylene• glass• aramid• carbon



6 Identify eight of the following types of defect in composite mouldings:• incomplete curing• dimensional• tolerances• ply orientation• wrong join type• surface finish• distortion• blisters• bridging• de-lamination• wrinkles• broken fibres• splintering• voids• dents or ‘dings’• dis-bonds• resin rich areas• incorrect material• excessive adhesive• damaged cores• wrong inserts• insert positions• impact damage

7 Ensure that inspected mouldings comply with one of the following standards:• ISO 9000 quality assurance procedures• customer standards and requirements• company standards and procedures

Knowledge statements:You must have knowledge and understanding of:1 Health and safety precautions to be taken and procedures used when working

with composite materials, consumables, tools and equipment in the specificwork area





6 How to use imperial and metric systems of measurement, workpiece referencepoints and system of tolerancing



7 Quality procedures used in the workplace to ensure production control (inrelation to currency, issue, meeting specification, etc) and the completion ofsuch documents

8 Conventions and terminology used when identifying and rectifying defects (eg, dis-bonds, de-lamination, resin injection, resin voids, core potting, repair patches)

9 Failure modes for various composite mouldings, and what can contribute to these

10 Correct methods of storage and handling of composite materials11 Tools and equipment used for checking the various composite mouldings12 The extent of your own authority and whom you should report to if you have




evidence type

date

Carry out all of the following during the inspection activities:

use the correct issue productiondocumentation (drawings, manuals,specifications, job cards)

use relevant health and safetydocumentation (material data sheets,COSHH sheets, risk assessments)

use the correct tools and equipment forthe activity, and ensure they are safe touse


Identify defects in composite mouldings using four of the following methods:

touch

sound

visual

measurement

mechanical tests

CMM

NDT

stage inspection

Identify defects in six of the following types of composite mouldings:

trim

closing panels

housings

body panels

tubes

sections

sandwich panels

structural

aerodynamic

moulds

jigs







Identify defects applicable to two of the following resin types:

polyester

vinyl ester

epoxy

phenolic

bismaleimide

cyanate ester

Identify defects applicable to two of the following fibre types:

polyethylene

glass

aramid

carbon

Identify eight of the following types of defect in composite mouldings:

incomplete curing

dimensional

tolerances

ply orientation

wrong join type

surface finish

distortion

blisters

bridging

de-lamination

wrinkles

broken fibres

splintering

voids

dents or ‘dings’

dis-bonds

resin rich areas

incorrect material



excessive adhesive

damaged cores

wrong inserts

insert positions

impact damage

Ensure that inspected mouldings comply with one of the following standards:





Candidate Date

Assessor Date





The Level 2 award in Fabrication and Welding has been contextualised by SEMTA from the NationalEngineering Competency Standards (ECS). The following table lists the opportunities for generation of KeySkills evidence for each unit in the award and also gives reference to the ECS unit it has been derived from.

Fabrication and Welding Unit ECS Unit Key Skills Reference

Communication Application of Problem SolvingNumber

Unit 1: Complying with Statutory N/ARegulations and Organisational Safety Requirements

Unit 2: Using and Interpreting 1.13 C2.1a N2.1 PS1.1Engineering Drawings and C2.2 PS1.2Documents PS1.3

Unit 3: Working Efficiently and N/AEffectively in Engineering

Unit 4: Joining Materials by the 3.09 C1.1 PS1.1Manual Metal Arc Welding Process C2.2 PS1.2

PS1.3

Unit 5: Joining Materials by Manual 3.09 C1.1 PS1.1MIG/MAG and other Continuous C2.2 PS1.2Wire Welding Processes PS1.3

Unit 6: Joining Materials by Manual 3.09 C1.1 PS1.1TIG and Plasma Arc Welding C2.2 PS1.2Processes PS1.3

Unit 7: Joining Materials by the 3.09 C1.1 PS1.1Manual Gas Welding Process C2.2 PS1.2

PS1.3

Unit 8: Producing Fillet Welded 3.09 C1.1 PS1.1Joints using a Manual C2.2 PS1.2Welding Process PS1.3

Unit 9: Welding Materials with 3.10 C1.1 PS1.1Mechanised Arc Welding C2.2 PS1.2Equipment PS1.3

Unit 10: Welding Materials using 3.10 C1.1 PS1.1Resistance Spot, Seam and C2.2 PS1.2Projection Welding Machines PS1.3

Unit 11: Welding Materials using 3.10 C1.1 PS1.1Laser Welding Machines C2.2 PS1.2

PS1.3

Level 2 NVQ on Fabrication and Welding Level 2Opportunities for generation of Key Skills evidence




Unit 12 Welding Materials using 3.10 C1.1 PS1.1Electron Beam Welding Machines C2.2 PS1.2

PS1.3

Unit 13: Welding Materials using 3.10 C1.1 PS1.1Friction Welding Machines C2.2 PS1.2

PS1.3

Unit 14: Joining Rails using the 3.09 C1.1 PS1.1Aluminothermic Welding Process C2.2 PS1.2

PS1.3

Unit 15: Restore Rails to Operational 5.06 C1.3Condition using an Arc Welding C2.2Process

Unit 16: Welding Rails using Flash 3.10 C1.1 PS1.1Welding Equipment C2.2 PS1.2

PS1.3

Unit 17: Joining Materials by Manual 3.09 C1.1 PS1.1Torch Brazing and Soldering C2.2 PS1.2

PS1.3

Unit 18: Joining Materials using 3.10 C1.1 PS1.1Brazing Machines C2.2 PS1.2

PS1.3

Unit 19: Joining Plastics using 3.09 3.09 C1.1Manual Welding Processes C2.2

Unit 20: Joining Materials using 3.10 C1.1 PS1.1Plastics Welding Machines C2.2 PS1.2

PS1.3

Unit 21: Marking Out Components 3.04 C1.1 N2.1 PS1.1for Fabrication C2.1 PS1.2

PS1.3

Unit 22: Cutting Sheet Metal to 3.03 C1.1 N2.1 PS1.1Shape using Hand and Machine C2.1 PS1.2Tools PS1.3

Unit 23: Forming Sheet Metal using 3.16 C1.1 N2.1 PS1.1Hand and Machine tools C2.1 PS1.2

PS1.3





Unit 24 Producing Sheet Metal 3.12 C1.1 N2.1 PS1.1Assemblies C2.1 PS1.2

PS1.3

Unit 25: Heat Treating Materials for 3.15 C1.1 PS1.1Fabrication Activities C2.1 PS1.2

PS1.3

Unit 26: Cutting and Shaping 3.01 C1.1 PS1.1Materials using NC/CNC Laser C2.1 PS1.2Profiling Machines PS1.3

Unit 27: Cutting and Shaping using 3.01 C1.1 PS1.1NC/CNC Plasma or Gas Cutting C2.1 PS1.2Machines PS1.3

Unit 28: Assembling Components 3.12 C1.1 N2.1 PS1.1using Mechanical Fasteners C2.1 PS1.2

PS1.3

Unit 29: Bonding Engineering 3.11 C1.1 PS1.1Materials using Adhesives C2.2 PS1.2

PS1.3

Unit 30: Joining Materials by 3.10 C1.1 PS1.1Resistance Spot Welding C2.2 PS1.2

PS1.3

Unit 31: Slinging, Lifting and Moving 4.08 PS2.1Materials and Components PS2.2

PS2.3

Unit 32: Cutting Plate and Sections 3.04 C1.1 N2.1 PS1.1using Shearing Machines C2.2 PS1.2

PS1.3

Unit 33: Cutting Materials using 3.04 C1.1 N2.1 PS1.1Hand Operated Thermal Cutting C2.2 PS1.2Equipment PS1.3

Unit 34: Cutting and Shaping 3.04 C1.1 N2.1 PS1.1Materials using Gas Cutting C2.2 PS1.2Machines PS1.3

Unit 35: Cutting Materials using 3.04 C1.1 N2.1 PS1.1Saws and Abrasive Discs C2.2 PS1.2

PS1.3





Unit 36: Bending and Forming Plate 3.06 C1.1 N2.1 PS1.1using Power Operated Machines C2.2 PS1.2

PS1.3

Unit 37: Forming Platework using 3.06 C1.1 N2.1 PS1.1Power Rolling Machines C2.2 PS1.2

PS1.3

Unit 38: Producing Platework 3.12 C1.1 N2.1 PS1.1Assemblies C2.2 PS1.2

PS1.3

Unit 39: Producing Holes using 3.04 C1.1 N2.1 PS1.1Drilling Machines C2.1 PS1.2

PS1.3

Unit 40: Forming of Structural 3.06 C1.1 N2.1 PS1.1Sections using Machines C2.2 PS1.2

PS1.3

Unit 41: Producing Structural Steel 3.03 C1.1 N2.1 PS1.1Ancillary Components C2.2 PS1.2

PS1.3

Unit 42: Assembling Structural 4.05 C2.1a PS2.1Steelwork C2.3 PS2.2

PS2.3

Unit 43: Forming Pipework by 3.06 C1.1 N2.1 PS1.1Machine Bending C2.2 PS1.2

PS1.3

Unit 44: Producing Socket and 3.09 C1.1 PS1.1Flange Fillet Welded Joints in Pipe C2.2 PS1.2using a Manual Welding Process PS1.3

Unit 45: Producing Composite 3.05 C1.1 N2.1 PS1.1Mouldings using Wet Lay-up C2.2 PS1.2Techniques PS1.3

Unit 46: Producing Composite 3.05 C1.1 N2.1 PS1.1Mouldings using Pre-Preg C2.2 PS1.2Laminating Techniques PS1.3

Unit 47: Producing Components by 3.05 C1.1 N2.1 PS1.1Acrylic Moulding C2.2 PS1.2

PS1.3





Unit 48: Vacuum Forming 3.06 C1.1 N2.1 PS1.1Composite Materials C2.1 PS1.2

PS1.3

Unit 49: Trimming Composite 3.03 C1.1 N2.1 PS1.1Mouldings using Hand Tools C2.1 PS1.2

PS1.3

Unit 50: Identifying Defects in 5.07 C2.1a N2.1 PS1.1Composite Mouldings C2.2 PS1.2

C2.3

Unit 51: Applying Surface Finishes 3.14 C1.1 PS1.1to Composite Mouldings C2.1 PS1.2

PS1.3

Unit 52: Bonding Composite 3.11 C1.1 PS1.1Mouldings C2.1 PS1.2

PS1.3

Unit 53: Producing Composite 3.12 C1.1 N2.1 PS1.1Assemblies C2.1 PS1.2

PS1.3



Further information regarding centre/scheme approval or any aspect of assessmentof the NVQs should be referred to the relevant City & Guilds regional/national office:

Region Telephone Facsimile

City & Guilds Scotland 0131 226 1556 0131 226 1558

City & Guilds North East 0191 402 5100 0191 402 5101

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SP-02-1681

Level 2 NVQ in Fabrication and Welding (1681) · 4 Brazing and/or Soldering ... Level 2 NVQ in...

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Transcript of Level 2 NVQ in Fabrication and Welding (1681) · 4 Brazing and/or Soldering ... Level 2 NVQ in...