This unit of competency applies to operators who install and/or repair refractory bricks and blocks. Cast refractory may be the total requirements for the job, or it may need to join to moulded or brick/block refractory.

This unit does NOT cover the installation of brick/block or mouldable refractory, refer to PMC552091B Prepare for, install and repair refractory brickwork/blockwork or PMC552092B Prepare for and install mouldable refractory materials.

This unit includes the mixing of castable refractory.

This competency will typically be performed by a team of operators working under direction and to a specification and/or procedures.

ELEMENT

PERFORMANCE CRITERIA

1. Establish the suitability of resources

1.1. Check all information conforms with resources

1.2. Record discrepancies in information

1.3. Report any inaccuracies in information to the person in charge

1.4. Identify and select materials, components, tools and equipment

2. Mix, place and compact refractory concrete

2.1. Mix refractory concrete

2.2. Place and compact refractory concrete

2.3. Vibrate refractory concrete

2.4. Remove and reinstate damaged refractory concrete

2.5. Provide and remove temporary supports/formwork

2.6. Maintain tools and equipment

3. Contribute to controlling hazards in work area

3.1. Identify hazards in work area

3.2. Assess risks arising from those hazards

3.3. Take appropriate action to control risks in accordance with procedures and duty of care

Required skills

Required skills include:

observing and monitoring work procedures

adjusting/correcting/responding to sources of information

identifying and solving problems

manual skills

physical handling skills

using tools and equipment correctly and safely

working in a team or individually, as required

reading and numeracy to interpret workplace documents and technical information

Required knowledge

Required knowledge includes:

methods of preparing background surfaces

types, uses and operation of tools and equipment

methods of compacting materials by hand and with vibration equipment

correct selection and use of anchors

types and methods of finishing the surface of the concrete

reasons for, and timing of, dedicated curing and heat-up programs and the consequences for the installed concrete if the program is not correctly followed

types and uses of temporary support/formwork

methods of protecting work during installation

reasons for, and methods of, providing test panels

methods of cutting

safeguards to take during reinstatement

methods of removing damaged refractory

methods of keying and bonding new to existing refactories

reasons for, and methods of, obtaining seals between new and existing refractory

materials sources

materials types/categorisation

methods of production

familiarity with installation techniques

familiarity with principles of selection

familiarity with variety of applications

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

The unit will be assessed in as holistic a manner as is practical and may be integrated with the assessment of other relevant units of competency.

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

Competence must be demonstrated in the operation of all ancillary equipment to the level required for this unit of competency.

Competence must be demonstrated in the ability to recognise and analyse potential situations requiring action and then in implementing appropriate corrective action.

Consistent performance should be demonstrated. In particular look to see that:

refractory cement has the required degree of compaction (neither too little nor too much) and that the casting conforms to requirements

all OHS requirements are followed.

Context of and specific resources for assessment

Assessment will require access to an operating plant over an extended period of time, or a suitable method of gathering evidence of operating ability over a range of situations.

Assessment will occur over a range of situations which will include disruptions to normal, smooth operation.

Simulation or case studies/scenarios may be required to allow for timely assessment of parts of this unit of competency. Simulation should be based on the actual plant and will include 'walk-throughs' of the relevant competency components. A bank of scenarios/case studies/what ifs and questions will be required to probe the reasoning behind observable actions.

Method of assessment

In all plants it may be appropriate to assess this unit concurrently with relevant teamwork and communication units.

It may be appropriate to assess this unit concurrently with other relevant units.

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.

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.

Procedures

All operations are performed in accordance with standard procedures and work instructions

Tools and equipment

Tools and equipment include:

mixers

pumps

vibrators

lifting equipment

equipment allowing access

Installation

Installation includes:

correct thickness

conforming to required curves and angles

maintaining cover

tying to structure

keying to existing refractory

Occupational health and safety (OHS)

All operations are subject to stringent OHS requirements and these must not be compromised at any time. Where there is an apparent conflict between performance criteria and OHS requirements, the OHS requirements take precedence.

Unit sector

Operational/technical

This unit contains employability skills.