Unit of Competency Mapping – Information for Teachers/Assessors – Information for Learners

MEM05027A Mapping and Delivery Guide
Perform aluminothermic welding

Version 1.0
Issue Date: May 2024


Qualification -
Unit of Competency MEM05027A - Perform aluminothermic welding
Description This unit of competency covers the skills and knowledge required to weld using the aluminothermic welding process. It includes planning and preparing the welding method, preparing materials and the site for aluminothermic welding, carrying out the welding process in accordance with safe working/regulatory requirements and workplace procedures, checking weld conformance, and completing all required documentation.
Employability Skills This unit contains employability skills.
Learning Outcomes and Application This unit applies in a maintenance or site environment where the weld quality is not required to meet an Australian Standard. The aluminothermic welding process (commonly referred to as the CADWELD process) is pre-engineered and can be used to make welded connections of copper to copper or copper to steel or other metals. It is also used for header cable taps, conductor splices and terminations, and ground rod connections, or for attaching cathodic protection leads to pipes (steel or cast iron), tanks and structures in which no outside source of heat or power is required. A common use is to join copper cables (wire) for use in direct burial (grounding/earthing) applications.Work may be undertaken in the field/on site (as distinct from a production/manufacturing facility) and may be undertaken in a trench. In those situations, it may be appropriate to also access MSAPMOPS363A Organise on site work for work on site and MSAPMPER205C Enter confined space for work in a trench. Work will often be undertaken under a permit to work system in which case it may also be appropriate to access MSAPMPER200C Work in accordance with an issued permit and possibly other related permit units.Where the aluminothermic welding process is required for rail track welding, TLIW3015A Weld rail using aluminothermic welding process should be selected from the TLI10 Transport and Logistics Training Package.Band: AUnit Weight: 2
Duration and Setting X weeks, nominally xx hours, delivered in a classroom/online/blended learning setting.
Prerequisites/co-requisites Not applicable.
Competency Field
Development and validation strategy and guide for assessors and learners Student Learning Resources Handouts
Activities 		Slides
PPT 		Assessment 1 Assessment 2 Assessment 3 Assessment 4
Elements of Competency Performance Criteria              
Element: Prepare and plan for welding
  • Weld requirements are identified from job instructions
  • Permits and other required authorities are obtained
       
Element: Site and job hazards are identified and appropriate hazard controls implemented
  • Pre-site preparations are completed
  • The locations of welds are identified and assessed in accordance with standard operating procedures and specifications
  • Surfaces are cleaned and prepared ready for welding
  • Site is cleared of obstructions and combustible material to minimise risk of accidents and fire
       
Element: Prepare equipment for welding
  • Welding equipment is set up correctly
  • Consumables are selected to suit application
       
Element: Perform aluminothermic welding
  • Safe welding practices are applied
  • Moulds are fitted and shimmed, sleeved or sealed, as required
  • Materials are pre-heated to standard
  • Materials are welded using aluminothermic method in accordance with approved procedures
  • Welds are cleaned to standard operating procedures
  • Mould is cleaned and inspected to standard operating procedures
       
Element: Check weld conformance
  • Weld conformance is assessed in accordance with standard operating procedures and specifications
       
Element: Complete documentation
  • Required reports, documentation and/or records are completed in accordance with workplace requirements
       


Evidence Required

List the assessment methods to be used and the context and resources required for assessment. Copy and paste the relevant sections from the evidence guide below and then re-write these in plain English.

The evidence guide provides advice on assessment and must be read in conjunction with the performance criteria, required skills and knowledge, range statement and the Assessment Guidelines for the Training Package.

Overview of assessment

A person who demonstrates competency in this unit must be able to carry out and apply the principles of the aluminothermic welding process and associated equipment, applications and procedures, outlining the main phases and operations, including safety aspects.

Critical aspects for assessment and evidence required to demonstrate competency in this unit

Assessors must be satisfied that the candidate can competently and consistently perform all elements of the unit as specified by the criteria, including required knowledge, and be capable of applying the competency in new and different situations and contexts.

Assessors should gather a range of evidence that is valid, sufficient, current and authentic. Evidence can be gathered through a variety of ways, including direct observation, supervisor’s reports, project work, samples and questioning. Questioning techniques should not require language, literacy and numeracy skills beyond those required in this unit of competency.

Context of and specific resources for assessment

This unit may be assessed on the job, off the job, or a combination of both on and off the job. Where assessment occurs off the job, that is the candidate is not in productive work, then an appropriate simulation must be used where the range of conditions reflects realistic workplace situations. The competencies covered by this unit would be demonstrated by an individual working alone or as part of a team. The assessment environment should not disadvantage the candidate.

The candidate must have access to all tools, equipment, materials and documentation required. The candidate must be permitted to refer to any relevant workplace procedures, product and manufacturing specifications, codes, standards, manuals and reference materials.

Method of assessment

This unit could be assessed in conjunction with any other units addressing the safety, quality, communication, materials handling, recording and reporting associated with carrying out aluminothermic welding or other units requiring the exercise of the skills and knowledge covered by this unit

Guidance information for assessment

Assessment processes and techniques must be culturally appropriate and appropriate to the language and literacy capacity of the candidate and the work being performed.

Submission Requirements

List each assessment task's title, type (eg project, observation/demonstration, essay, assignment, checklist) and due date here

Assessment task 1: [title]      Due date:

(add new lines for each of the assessment tasks)

Assessment Tasks

Copy and paste from the following data to produce each assessment task. Write these in plain English and spell out how, when and where the task is to be carried out, under what conditions, and what resources are needed. Include guidelines about how well the candidate has to perform a task for it to be judged satisfactory.

Required skills

Required skills include:

communicating effectively with others

reading and interpreting technical data, drawings, procedures, instructions and manuals

working collaboratively with others when welding materials using the aluminothermic process

planning and monitoring own work, including predicting consequences and identifying improvements

selection and use of required personal protective equipment

implementing fire control procedures

selecting appropriate welding tools and equipment

applying precautions and required action to minimise, control or eliminate hazards that may exist during work activities without injury to self or others, or damage to equipment

reporting and/or rectifying any identified problems, faults or malfunctions that may occur in accordance with regulatory requirements and workplace procedures

applying defect acceptance criteria and identifying actions to be taken after rejections of welds

checking compliance between work and job specifications

completing reports, records and documentation

Required knowledge

Required knowledge includes:

relevant safety, occupational health and safety (OHS) and environmental procedures and regulations

principles of the aluminothermic welding process chemical reaction

common types of welding imperfections and defects and their causes (e.g. cracks, porosities, mould off centre, stresses in materials, pre-heating offset, sand inclusions and moisture)

workplace procedures for the welding of materials using the aluminothermic technique

problems that may occur during the welding of materials using the aluminothermic technique and action that can be taken to report or resolve the problems

hazards that may exist during the welding of materials using the aluminothermic technique and ways of controlling the risks involved

contents of relevant technical manuals and instructions

characteristics of plant and equipment, hardware and components used in welding activities

impact on work activities of regulatory requirements

impact of other work activities on welding integrity

workplace documentation requirements

site inspection techniques

The range statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. Bold italicised wording, if used in the performance criteria, is detailed below. Essential operating conditions that may be present with training and assessment (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) may also be included.

Work environment

Work environment may include, but is not limited to:

restricted spaces

exposed conditions

controlled or open environments

Pre-site preparations

Pre-site preparations may include, but are not limited to:

checking all required equipment and materials

identifying required personal protective equipment

loading all requirements for the job

Materials to be joined

Materials to be joined may include, but are not limited to:

common steel

copper-clad steel

Columbium

Niobium

brass

wrought iron

stainless steel

cast iron

galvanised and bethanised steel

bronze

silicon bronze

Assessment of weld locations

Assessment of weld locations may include, but are not limited to:

proximity to existing welds or repairs

substrate integrity issues

preparation of pre-qualification samples

Weld consumables

Weld consumables may include, but are not limited to:

aluminothermic powder

starting powder

metallic disc

Equipment

Equipment may include, but is not limited to:

mould

lute (sealant)

ignition source

handle clamps

wire brush

mould scraper

gas pre-heating/cutting equipment

Personal protective equipment

Personal protective equipment may include, but is not limited to:

high visibility clothing

fire retardant overalls or long sleeved shirts and long pants

hearing protection

gauntlet type gloves

welding goggles

safety glasses

safety headwear

safety footwear

portable radios/mobile phones

other safety devices

Procedures and codes

Procedures and codes may include, but are not limited to:

relevant state/territory OHS legislation together with any nationally approved compliance codes and/or guidelines

relevant state/territory environmental protection requirements

legislation

relevant fire regulations

Copy and paste from the following performance criteria to create an observation checklist for each task. When you have finished writing your assessment tool every one of these must have been addressed, preferably several times in a variety of contexts. To ensure this occurs download the assessment matrix for the unit; enter each assessment task as a column header and place check marks against each performance criteria that task addresses.

Observation Checklist

Tasks to be observed according to workplace/college/TAFE policy and procedures, relevant legislation and Codes of Practice Yes No Comments/feedback
Weld requirements are identified from job instructions 
Permits and other required authorities are obtained 
 
Pre-site preparations are completed 
The locations of welds are identified and assessed in accordance with standard operating procedures and specifications 
Surfaces are cleaned and prepared ready for welding 
Site is cleared of obstructions and combustible material to minimise risk of accidents and fire 
Welding equipment is set up correctly 
Consumables are selected to suit application 
Safe welding practices are applied 
Moulds are fitted and shimmed, sleeved or sealed, as required 
Materials are pre-heated to standard 
Materials are welded using aluminothermic method in accordance with approved procedures 
Welds are cleaned to standard operating procedures 
Mould is cleaned and inspected to standard operating procedures 
Weld conformance is assessed in accordance with standard operating procedures and specifications 
Required reports, documentation and/or records are completed in accordance with workplace requirements 

Forms

Assessment Cover Sheet

MEM05027A - Perform aluminothermic welding
Assessment task 1: [title]

Student name:

Student ID:

I declare that the assessment tasks submitted for this unit are my own work.

Student signature:

Result: Competent Not yet competent

Feedback to student

 

 

 

 

 

 

 

 

Assessor name:

Signature:

Date:

Assessment Record Sheet

MEM05027A - Perform aluminothermic welding

Student name:

Student ID:

Assessment task 1: [title] Result: Competent Not yet competent

(add lines for each task)

Feedback to student:

 

 

 

 

 

 

 

 

Overall assessment result: Competent Not yet competent

Assessor name:

Signature:

Date:

Student signature:

Date: