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Elements and Performance Criteria

1. Plan and prepare for casting operations
   • Access, interpret and apply smelting documentation and ensure the work activity is compliant
   • Receive, interpret and clarify shift change over details
   • Select and wear appropriate personal protective equipment
   • Select and use appropriate plant, tools and equipment for the work activity
   • Perform plant, tools and equipment pre-start checks
   • Carry out start-up procedures
   • Identify, address and report potential risks, hazards and environmental issues and implement control measures
   • Communicate with other equipment operators
   • Access, interpret and adhere to emergency procedures
   • Ensure area is well ventilated
   • Adjust mould, launder and ladle system for work activity
2. Prepare moulds/launder system
   • Dress moulds/launder system
   • Check for faults or defects
   • Prepare moulding pit
   • Dry product
   • Strip and cleanout moulding pit, where required
   • Check cooling system is fit for operation
3. Cast metal
   • Teem/tap liquid metal into ladles and/or launder system, where required
   • Cast liquid metal into moulds
   • Test temperature and obtain a sample of the liquid
   • Identify variances and adjust the composition with additives
   • Monitor cast during work activity
4. Remove cast metal
   • Knock off mould plates when mould has been bumped out
   • Identify faults to launders, report and repair
   • Identify and remove damaged and faulty moulds
   • Remove slides from ladles, identify faults, repair and reposition slides
   • Inspect for quality, chips and marks
   • Prepare ingots, anodes or bullion for transport and storage
5. Shutdown in sequence and/or isolate equipment
   • Shutdown and/or isolate equipment
   • Perform post shutdown and/or isolation checks
6. Conduct housekeeping activities
   • Clean, check, maintain and store plant, tools and equipment
   • Report issues identified with plant, tools and equipment
7. Plan and prepare for casting operations
   • Access, interpret and apply smelting documentation and ensure the work activity is compliant
   • Receive, interpret and clarify shift change over details
   • Select and wear appropriate personal protective equipment
   • Select and use appropriate plant, tools and equipment for the work activity
   • Perform plant, tools and equipment pre-start checks
   • Carry out start-up procedures
   • Identify, address and report potential risks, hazards and environmental issues and implement control measures
   • Communicate with other equipment operators
   • Access, interpret and adhere to emergency procedures
   • Ensure area is well ventilated
   • Adjust mould, launder and ladle system for work activity
8. Prepare moulds/launder system
   • Dress moulds/launder system
   • Check for faults or defects
   • Prepare moulding pit
   • Dry product
   • Strip and cleanout moulding pit, where required
   • Check cooling system is fit for operation
   • Teem/tap liquid metal into ladles and/or launder system, where required
   • Cast liquid metal into moulds
   • Test temperature and obtain a sample of the liquid
   • Identify variances and adjust the composition with additives
   • Monitor cast during work activity
9. Remove cast metal
   • Knock off mould plates when mould has been bumped out
   • Identify faults to launders, report and repair
   • Identify and remove damaged and faulty moulds
   • Remove slides from ladles, identify faults, repair and reposition slides
   • Inspect for quality, chips and marks
   • Prepare ingots, anodes or bullion for transport and storage
10. Shutdown in sequence and/or isolate equipment
    • Shutdown and/or isolate equipment
    • Perform post shutdown and/or isolation checks
11. Conduct housekeeping activities
    • Clean, check, maintain and store plant, tools and equipment
    • Report issues identified with plant, tools and equipment

Performance Evidence

Evidence is required to be collected that demonstrates a candidate’s competency in this unit. Evidence must be relevant to the roles within this sector’s work operations and satisfy all of the requirements of the performance criteria of this unit and include evidence that the candidate:

locates and applies relevant documentation, policies and procedures

implements the requirements, procedures and techniques for the safe, effective and efficient completion of casting ingots including:

handling additives safely

works effectively with others to undertake and complete the casting of ingots that meets all of the required outcomes including:

complying with written and verbal reporting requirements and procedures

communicating clearly and concisely with others to receive and clarify work instructions and coordinate work activities

demonstrates completion of the casting of ingots that safely, effectively and efficiently meets all of the required outcomes on more than one (1) occasion including:

conducting equipment pre-start checks and start-up procedures

preparing, stripping out and cleaning moulding pit

casting liquid metal to moulds

taking temperature and obtaining samples of the liquid

repairing launders

shutting down and/or isolating equipment

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Knowledge Evidence

The candidate must demonstrate knowledge in applying the cast ingots through:

identifying potential dangers inherent in specific plant and equipment

identifying specifications of moulds, bottom plates, trumpets, ingots, anodes, bullion

applying the process to different base metals

identifying ingot, anode and bullion weight and markers relationship

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