PMC557096A
Specify and monitor the installation of block_precast refractories

This unit of competency covers developing the specification for installing block or precast refractories and then monitoring that installation to ensure it complies with the specification. It is intended for refractory experts who will most likely also have some management responsibility.

Application

This unit of competency requires the application of knowledge of refractory installation techniques to ensure the installation meets the requirements of the refractory. It covers the following types of refractory:

block

brick

precast.

This unit does NOT cover the installation of monolithic/castable refractories, refer to PMC557095A Specify and monitor the installation of monolithic/castable refractories. While blocks/precast may also be used to make repairs, this unit may be used to include repairs using these techniques. The specification of the repair technique is covered in PMC557097A Specify and monitor repairs to refractory installations.

This unit applies to individuals who may design a refractory installation and may also monitor the installation of refractory, or they may be installation specialists. They may be working in liaison with other refractory specialists or they may be the sole refractory specialist for this job/in their organisation. They will typically be liaising with a range of other technical experts as well as management and maybe accounts.

This unit may apply to individuals working for an organisation which supplies and installs refractories, is a refractory consulting organisation or a client organisation which buys and uses the refractory.


Elements and Performance Criteria

ELEMENT

PERFORMANCE CRITERIA

1. Confirm design specification

1.1. Check design specification against agreed set of requirements for the refractory

1.2. Identify discrepancies or conflicts in requirements

1.3. Confirm installation requirements and specifications

2. Design installation process

2.1. Determine refractory materials to be installed

2.2. Determine bond form to be used

2.3. Determine junctions and piers

2.4. Determine mortar requirements

2.5. Determine installation equipment requirements

2.6. Determine anchor requirements

2.7. Determine laying requirements

2.8. Design scaffolding or other internal access needs if required

2.9. Design external access/egress means if required

2.10. Identify installation health, safety and environment (HSE) hazards

2.11. Determine appropriate hazard controls

2.12. Check for discrepancies or conflicts in the designs and take appropriate action

3. Prepare for installation

3.1. Specify installation procedure

3.2. Liaise with relevant stakeholders

3.3. Modify specification if needed

3.4. Ensure correct ordering of requirements

3.5. Identify time critical items for the installation

3.6. Identify other items critical to the success of the project

3.7. Identify or develop measures to monitor all critical items

3.8. Prepare installation specification

4. Monitor installation

4.1. Ensure requirements meet specification/contract

4.2. Ensure hazard controls are in place and effective

4.3. Monitor work to installation specification

4.4. Take appropriate action on non-conformances as required

4.5. Report during project as required

4.6. Complete end of project documentation on completion

Required Skills

Required skills

Required skills include:

solving problems

communicating at all levels

using organisation knowledge system

investigating

analysing

interpreting data

negotiating

technical reporting

Required knowledge

Required knowledge includes:

properties of all common refractory materials

block/precast installation methods

installing for:

straight walls

corners

curves

roofs

arches

anchors and anchoring systems

installation equipment such as lifting and placement aids

post placement requirements for different mortars

scaffolding design and construction

relevant terms

relevant calculations

project planning and management

Evidence Required

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

Assessment of this unit should include demonstrated competence in a workplace based project or a simulated workplace project.

Access should be available to all normally accessed tables, data etc which would be available to and used by a competent refractory specialist performing this assignment.

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

Competence must be demonstrated in the ability to select an appropriate material and write the required specification.

Context of and specific resources for assessment

Assessment may occur on the job or in an appropriately simulated environment. Access is required to real or appropriately simulated situations, including work areas, materials and equipment, and to information on workplace practices and OHS practices.

Where applicable, reasonable adjustment must be made to work environments and training situations to accommodate ethnicity, age, gender, demographics and disability.

Access must be provided to appropriate learning and/or assessment support when required. Where applicable, physical resources should include equipment modified for people with disabilities.

Method of assessment

Assessment must satisfy the endorsed assessment guidelines of the Manufactured Mineral Products Training Package.

Assessment methods must confirm consistency and accuracy of performance (over time and in a range of workplace relevant contexts) together with application of underpinning knowledge.

Assessment methods which include direct observation of tasks should also include questioning on underpinning knowledge to ensure its correct interpretation and application.

Assessment may be applied under project related conditions (real or simulated) and require evidence of process.

Assessment must confirm a reasonable inference that competency is able not only to be satisfied under the particular circumstance, but is able to be transferred to other circumstances.

Assessment may be in conjunction with assessment of other units of competency where required.

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.


Range Statement

The range statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. 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.

Refractory materials

Refractory materials may include one or more of:

cementitious refractories

clay refractories

other refractories

Bond forms

Bond forms include:

stretcher bond

header bond

English bond

English garden wall bond

reverse bond

broken bond

Junctions and piers

Junctions include:

tie brick

special brick

squint brick

Piers may be:

attached

detached

not needed

Note: feather edge refractory bricks are not normally included

Mortar

Mortar includes:

hydraulic setting dry mixes

air setting dry mixes

heat setting dry mixes

and may be:

clay

fireclay

chamotte

mortar

Installation equipment

Installation equipment may include one or more of:

equipment for lifting and placing precast blocks

temporary support for roofs and arches

spreader jacks

Anchors

Types of anchors may include:

anchor bolts

anchor mesh

retention clips

Post laying requirements

Post laying requirements may include:

drying

control of moisture and or temperature

removal of scaffolding or other access/egress provisions

HSE hazards

HSE hazards may include:

exposure to heat

exposure to dust

exposure to refractory materials

confined space entry

working with equipment

working at heights

ultra-violet (UV) and other welding hazards

disposal of waste, scrap and excess materials

manual handling hazards

Hazard control

Appropriate hazard control should be determined by:

applying the hierarchy of control

Stakeholders

Stakeholders may include:

customer representatives

technical experts

regulators

refractory designer

materials and equipment suppliers

contractors

Requirements

Requirements include:

materials

equipment

contractors

Time critical items

Time critical items are those items which if not completed on time will cause the project to run overtime and may be determined from:

critical path analysis

long lead time items

other techniques

Installation specification

Installation specification should include:

technical specification

hazard controls and residual hazards

installation schedule

measures monitoring critical items

End of project documentation

End of project documentation may include:

operating and/or maintenance procedures

technical specification

routine monitoring requirements

project review report:

what was intended

what was achieved

achieved costs

achieved timing

significant project issues

possible improvements


Sectors

Unit sector

Operational/technical


Employability Skills

This unit contains employability skills.


Licensing Information

Not applicable.