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

PMC553051 Mapping and Delivery Guide
Produce structural precast concrete

Version 1.0
Issue Date: May 2024


Qualification -
Unit of Competency PMC553051 - Produce structural precast concrete
Description
Employability Skills
Learning Outcomes and Application This unit of competency covers the skills and knowledge required to produce structural precast and pre-stressed concrete products, such as beams and girders.This unit of competency applies to operators who are required to assemble moulds and reinforcement; mould, cure and strip the product; control quality and solve problems within area of responsibility. This unit of competency applies to an experienced operator demonstrating theoretical and technical knowledge and well developed skills in situations that require some discretion and judgement. The experienced operator may work alone or as a member of a team or group and will work in liaison with other shift team members, team leader, supervisor and engineers, as appropriate. No licensing, legislative or certification requirements apply to this unit at the time of publication.
Duration and Setting X weeks, nominally xx hours, delivered in a classroom/online/blended learning setting.

The unit should be assessed holistically and the judgement of competence shall be based on a holistic assessment of the evidence.

The collection of performance evidence:

should occur over a range of situations which include typical disruptions to normal, smooth operation of an operating plant

will typically include a supervisor/third-party report or other evidence, focussing on consistent performance and problem recognition and solving. A supervisor/third-party report must be prepared by someone who has a direct, relevant, current relationship with the person being assessed and who is in a position to form a judgement on workplace performance relevant to the unit of competency

must include the use of an appropriate industrial item/s of equipment requiring demonstration of operation, start-up and shutdown procedures and responding to problems

may use industry-based simulation for all or part of the unit particularly where safety, lack of opportunity or significant cost is an issue.

Assessment should occur in operational workplace situations. Where this is not possible or where personal safety or environmental damage are limiting factors assessment must occur in a sufficiently rigorous simulated environment that reflects realistic operational workplace conditions. This must cover all aspects of workplace performance, including environment, task skills, task management skills, contingency management skills and job role environment skills.

Assessment in a simulated environment should use evidence collected from demonstration of skills and one or more of:

walk-throughs

pilot plant operation

industry-based case studies/scenarios

‘what ifs’.

Knowledge evidence may be collected concurrently with performance evidence (provided a record is kept) or through an independent process such as workbooks, written assessments or interviews (provided a record is kept).

Assessment processes and techniques must be appropriate to the language, literacy and numeracy requirements of the work being performed and the needs of the candidate.

Conditions for assessment must include access to all tools, equipment, materials and documentation required, including relevant workplace procedures, product and manufacturing specifications associated with this unit.

The regulatory framework will be reflected in workplace policies and procedures and is not required to be independently assessed.

Foundation skills are integral to competent performance of the unit and should not be assessed separately.

Assessors must satisfy the assessor competency requirements that are in place at the time of the assessment as set by the VET regulator.

In addition the assessor or anyone acting in subject matter expert role in assessment shall demonstrate both technical competency and currency. If the assessor cannot demonstrate technical competency and currency they shall assess with a subject matter expert who does meet these requirements.

Technical competence can be demonstrated through one or more of:

relevant VET or other qualification/Statement of Attainment

appropriate workplace experience undertaking the type of work being assessed under routine and non-routine conditions

appropriate workplace experience supervising/evaluating the type of work being assessed under routine and non-routine conditions

Currency can be demonstrated through one or more of:

being currently employed undertaking the type of work being assessed

being employed by the organisation undertaking the type of work being assessed and having maintained currency in accordance with that organisation’s policies and procedures

having consulted/had contact with an organisation undertaking the type of work being assessed within the last twelve months, the consultation/contact being related to assessment

conducting on the job training/assessments of the type of work being assessed

being an active member of a relevant professional body and participating in activities relevant to the assessment of this type of work.
Prerequisites/co-requisites
Competency Field Operations
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 mould for casting
  • Check casting schedule and job specification
  • Clean and oil moulds according to requirements
  • Check for mould damage and repair as necessary
       
Element: Assemble reinforcement cage
  • Lift preassembled reinforcing sections into mould using good work health and safety (WHS) practice
  • Assemble additional steel to complete cage to drawings and job specification
  • Fit additional items, such as base plates, tie plates and lifting devices, according to work instructions
  • Fit hold-ups and hold-downs as appropriate
  • Place voids or ducts according to work specifications
  • Run pre-stressing strands through reinforcing cages as required
  • Set up guards and comply with WHS requirements for stressing
  • Tension strands to extension dimensions and/or gauge readings according to works or engineer instructions
  • Recheck reinforcing cage is in correct position and adjust as necessary
       
Element: Close mould and test vibrators
  • Lift mould sides and additional parts into position and secure to specification
  • Fit any additional items as required
  • Fit vibrators to start positions
  • Test run before casting commences
       
Element: Pour concrete
  • Begin casting in accordance with work instructions
  • Move vibrators and time vibration as required
  • Screed top surface flat in preparation for final finish if required
  • Patch product as required
  • Clean mould and worksite in accordance with WHS requirements
       
Element: Control concrete quality
  • Test raw materials as required
  • Prepare test cylinders and samples as required
  • Monitor and control concrete mix to keep within specifications
  • Update all records and file all records and supplier certificates in appropriate place
  • Raise non-conformance reports as required
       
Element: Cure product
  • Cover and cure mould and test cylinders in accordance with standard procedures and work instructions
  • Monitor curing to achieve specified stripping strength
       
Element: Strip and store product
  • Test samples to ensure specific strength has been achieved
  • Remove mould sides and store ready for cleaning
  • If applicable, de-stress in accordance with work procedures and sequences
  • Ensure unit is lifted according to work instructions and moved to store, supported only on points designated on the drawings
       
Element: Respond to problems
  • Identify possible routine and non-routine problems in the equipment or process
  • Determine problems needing action
  • Determine possible fault causes
  • Rectify problem using appropriate solution within area of responsibility
  • Report problems outside area of responsibility to designated person
       
Element: Control hazards
  • Identify hazards from the job to be done
  • Identify other hazards in the work area
  • Assess the risks arising from those hazards
  • Implement measures to control those risks in line with procedures
       


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.

Elements describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element.

1

Prepare mould for casting

1.1

Check casting schedule and job specification

1.2

Clean and oil moulds according to requirements

1.3

Check for mould damage and repair as necessary

2

Assemble reinforcement cage

2.1

Lift preassembled reinforcing sections into mould using good work health and safety (WHS) practice

2.2

Assemble additional steel to complete cage to drawings and job specification

2.3

Fit additional items, such as base plates, tie plates and lifting devices, according to work instructions

2.4

Fit hold-ups and hold-downs as appropriate

2.5

Place voids or ducts according to work specifications

2.6

Run pre-stressing strands through reinforcing cages as required

2.7

Set up guards and comply with WHS requirements for stressing

2.8

Tension strands to extension dimensions and/or gauge readings according to works or engineer instructions

2.9

Recheck reinforcing cage is in correct position and adjust as necessary

3

Close mould and test vibrators

3.1

Lift mould sides and additional parts into position and secure to specification

3.2

Fit any additional items as required

3.3

Seal mould

3.4

Fit vibrators to start positions

3.5

Test run before casting commences

4

Pour concrete

4.1

Begin casting in accordance with work instructions

4.2

Move vibrators and time vibration as required

4.3

Screed top surface flat in preparation for final finish if required

4.4

Patch product as required

4.5

Clean mould and worksite in accordance with WHS requirements

5

Control concrete quality

5.1

Test raw materials as required

5.2

Prepare test cylinders and samples as required

5.3

Monitor and control concrete mix to keep within specifications

5.4

Update all records and file all records and supplier certificates in appropriate place

5.5

Raise non-conformance reports as required

6

Cure product

6.1

Cover and cure mould and test cylinders in accordance with standard procedures and work instructions

6.2

Monitor curing to achieve specified stripping strength

7

Strip and store product

7.1

Test samples to ensure specific strength has been achieved

7.2

Remove mould sides and store ready for cleaning

7.3

If applicable, de-stress in accordance with work procedures and sequences

7.4

Ensure unit is lifted according to work instructions and moved to store, supported only on points designated on the drawings

8

Respond to problems

8.1

Identify possible routine and non-routine problems in the equipment or process

8.2

Determine problems needing action

8.3

Determine possible fault causes

8.4

Rectify problem using appropriate solution within area of responsibility

8.5

Report problems outside area of responsibility to designated person

9

Control hazards

9.1

Identify hazards from the job to be done

9.2

Identify other hazards in the work area

9.3

Assess the risks arising from those hazards

9.4

Implement measures to control those risks in line with procedures

Evidence required to demonstrate competence in this unit must be relevant to and satisfy the requirements of the elements and performance criteria and demonstrate the ability to:

read and interpret plans/steel drawings, test results, product specifications, casting schedules, job sheets, procedures, material labels and safety information

check and prepare/position/assemble materials, moulds, formwork/specialised formwork, fittings, reinforcement and equipment to meet specifications

apply tension to strands

cast the product, test raw materials and take samples

cure, strip, destress and store product

monitor key variables, including:

mould condition

amount and consistency of concrete mix

placement and anchorage of reinforcement and fittings

placement of voids and ducts

tension of reinforcement

concrete cover

compaction/vibration

curing conditions

curing time/rate

stripping strength

product integrity and conformance to specification

make adjustments to meet product quality and production output specifications

identify hazards and apply relevant hazard controls

apply safety procedures

· apply housekeeping procedures

· recognise out of specification products, process problems and materials faults

recognise routine and non-routine problems

identify when the operator is able to rectify problems, when assistance is required and who is the appropriate source for assistance

take action to resolve problems or report them to appropriate personnel

distinguish between possible causes of routine problems, including:

raw material/mix variations

mould anomalies

casting/operating conditions

reinforcement abnormalities

process errors

communicate effectively with team/work group and supervisors

complete workplace records

do basic arithmetical manipulations, including additions, subtractions, divisions, fractions and percentages.

Must provide evidence that demonstrates knowledge relevant to their job sufficient to operate independently and to solve routine and non-routine problems, including knowledge of:

principles of casting process

significance to structural concrete products of key factors, including:

concrete cover

role of reinforcement

placement and anchorage of reinforcement and fittings

stressing/destressing

curing

compaction and vibration

formwork/specialised formwork (e.g. voids and ducts)

mould design

mould condition/wear

water-cement ratio

concrete finishing

methods of curing

compaction methods

fabrication methodologies

concrete sampling and testing procedures

physics and chemistry relevant to the equipment/process/materials

the potential effects of variations in raw materials and equipment operation/processes in relation to quality of product

factors which may affect product quality or production output and appropriate remedies

quality requirements at each stage of production

common adjustments in variables and their impact on product quality and production output

routine problems, their probable causes and relevant corrective actions

organisation procedures relevant to the work environment/job role

hazards from critical stages of pre-stressing reinforcement (placement, stressing, de-stressing, cutting, etc)

hierarchy of control

hazards that may arise in the job/work environment and:

their possible causes

potential consequences

appropriate risk controls.

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.

Elements describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element.

1

Prepare mould for casting

1.1

Check casting schedule and job specification

1.2

Clean and oil moulds according to requirements

1.3

Check for mould damage and repair as necessary

2

Assemble reinforcement cage

2.1

Lift preassembled reinforcing sections into mould using good work health and safety (WHS) practice

2.2

Assemble additional steel to complete cage to drawings and job specification

2.3

Fit additional items, such as base plates, tie plates and lifting devices, according to work instructions

2.4

Fit hold-ups and hold-downs as appropriate

2.5

Place voids or ducts according to work specifications

2.6

Run pre-stressing strands through reinforcing cages as required

2.7

Set up guards and comply with WHS requirements for stressing

2.8

Tension strands to extension dimensions and/or gauge readings according to works or engineer instructions

2.9

Recheck reinforcing cage is in correct position and adjust as necessary

3

Close mould and test vibrators

3.1

Lift mould sides and additional parts into position and secure to specification

3.2

Fit any additional items as required

3.3

Seal mould

3.4

Fit vibrators to start positions

3.5

Test run before casting commences

4

Pour concrete

4.1

Begin casting in accordance with work instructions

4.2

Move vibrators and time vibration as required

4.3

Screed top surface flat in preparation for final finish if required

4.4

Patch product as required

4.5

Clean mould and worksite in accordance with WHS requirements

5

Control concrete quality

5.1

Test raw materials as required

5.2

Prepare test cylinders and samples as required

5.3

Monitor and control concrete mix to keep within specifications

5.4

Update all records and file all records and supplier certificates in appropriate place

5.5

Raise non-conformance reports as required

6

Cure product

6.1

Cover and cure mould and test cylinders in accordance with standard procedures and work instructions

6.2

Monitor curing to achieve specified stripping strength

7

Strip and store product

7.1

Test samples to ensure specific strength has been achieved

7.2

Remove mould sides and store ready for cleaning

7.3

If applicable, de-stress in accordance with work procedures and sequences

7.4

Ensure unit is lifted according to work instructions and moved to store, supported only on points designated on the drawings

8

Respond to problems

8.1

Identify possible routine and non-routine problems in the equipment or process

8.2

Determine problems needing action

8.3

Determine possible fault causes

8.4

Rectify problem using appropriate solution within area of responsibility

8.5

Report problems outside area of responsibility to designated person

9

Control hazards

9.1

Identify hazards from the job to be done

9.2

Identify other hazards in the work area

9.3

Assess the risks arising from those hazards

9.4

Implement measures to control those risks in line with procedures

This field allows for different work environments and conditions that may affect performance. Essential operating conditions that may be present (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) are included.

Regulatory framework

The latest version of all legislation, regulations, industry codes of practice and Australian/international standards, or the version specified by the local regulatory authority, must be used.

Applicable legislation, regulations, standards and codes of practice include:

health, safety and environmental (HSE) legislation, regulations and codes of practice relevant to the workplace, equipment and production processes and hazardous materials

Australian/international standards relevant to the materials being used and products being made

any relevant licence and certification requirements.

All operations to which this unit applies are subject to stringent HSE requirements, which may be imposed through state/territory or federal legislation, and these must not be compromised at any time. Where there is an apparent conflict between performance criteria and such requirements the legislative requirements take precedence.

Procedures

All operations must be performed in accordance with relevant procedures.

Procedures are written, verbal, visual, computer-based or in some other form, and include one or any combination of:

manufacturer's technical information

job cards

drawings

emergency procedures

work instructions

standard operating procedures (SOPs)

safe work method statements (SWMS)

formulas/recipes

batch sheets

temporary instructions

any similar instructions provided for the smooth running of the plant.

Hazards

Hazards must be identified and controlled. Identifying hazards requires consideration of:

heat, smoke, dust, vapours or other atmospheric hazards

weight, shape, volume of materials to be handled

hazardous products and materials

sharp edges, protrusions or obstructions

slippery surfaces, spills or leaks

electricity

gas

gases and liquids under pressure

noise

rotational equipment or vibration

plant services (steam, condensate, cooling water, etc)

structural hazards

equipment failures

machinery, equipment and product mass

limited head spaces or overhangs

working at heights

working in restricted or confined spaces

other hazards that might arise.

Problems

Routine and non-routine problems must be resolved.

Routine problems are predictable and have known solutions and include one or more of:

slippage, breaking of tensioned strands

mould problems

compaction in areas with high reinforcement content (end blocks and haunches)

compact product with tight bends/clearances

polystyrene blocks (which may be used in formwork to lighten products) may float to surface on vibration

polystyrene blocks may move sideways undetected, reducing wall thickness

variations in cement/water ratio

raw materials supply

product quality problems.

Non-routine problems are unexpected problems or variations of previous problems.

Non-routine problems must be resolved by applying operational knowledge to develop new solutions, either individually or in collaboration with relevant experts, to:

determine problems needing action

determine possible fault causes

develop solutions to problems which do not have a known solution

follow through items initiated until final resolution has occurred

report problems outside area of responsibility to designated person.

Operational knowledge includes one or more of:

procedures

training

technical information, such as journals and engineering specifications

remembered experience

relevant knowledge obtained from appropriate people.

Records and reports

Records include one or more of:

log books/sheets

electronic records

job/work sheets

other records used for the smooth running of the plant.

Reports include one or more of:

paper or electronic-based logs and reports

verbal/radio reports

reporting items found which require action.

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
Check casting schedule and job specification 
Clean and oil moulds according to requirements 
Check for mould damage and repair as necessary 
Lift preassembled reinforcing sections into mould using good work health and safety (WHS) practice 
Assemble additional steel to complete cage to drawings and job specification 
Fit additional items, such as base plates, tie plates and lifting devices, according to work instructions 
Fit hold-ups and hold-downs as appropriate 
Place voids or ducts according to work specifications 
Run pre-stressing strands through reinforcing cages as required 
Set up guards and comply with WHS requirements for stressing 
Tension strands to extension dimensions and/or gauge readings according to works or engineer instructions 
Recheck reinforcing cage is in correct position and adjust as necessary 
Lift mould sides and additional parts into position and secure to specification 
Fit any additional items as required 
Fit vibrators to start positions 
Test run before casting commences 
Begin casting in accordance with work instructions 
Move vibrators and time vibration as required 
Screed top surface flat in preparation for final finish if required 
Patch product as required 
Clean mould and worksite in accordance with WHS requirements 
Test raw materials as required 
Prepare test cylinders and samples as required 
Monitor and control concrete mix to keep within specifications 
Update all records and file all records and supplier certificates in appropriate place 
Raise non-conformance reports as required 
Cover and cure mould and test cylinders in accordance with standard procedures and work instructions 
Monitor curing to achieve specified stripping strength 
Test samples to ensure specific strength has been achieved 
Remove mould sides and store ready for cleaning 
If applicable, de-stress in accordance with work procedures and sequences 
Ensure unit is lifted according to work instructions and moved to store, supported only on points designated on the drawings 
Identify possible routine and non-routine problems in the equipment or process 
Determine problems needing action 
Determine possible fault causes 
Rectify problem using appropriate solution within area of responsibility 
Report problems outside area of responsibility to designated person 
Identify hazards from the job to be done 
Identify other hazards in the work area 
Assess the risks arising from those hazards 
Implement measures to control those risks in line with procedures 

Forms

Assessment Cover Sheet

PMC553051 - Produce structural precast concrete
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

PMC553051 - Produce structural precast concrete

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: