Persons achieving competence in this unit will need to fulfil the applicable legislated rail safety requirements including acts and regulations from each state and territory together with any nationally approved compliance codes and/or guidelines.

Work is performed under some supervision, generally within a team environment. It involves the application of routine operational principles and procedures to weld rail using the aluminothermic welding technique as part of workplace activities across a variety of operational contexts within the Australian rail system.

Operators of mechanised equipment must have undertaken training and, where appropriate, hold the relevant licence, permit or certificate and be recognised as competent for the class of machinery being used.

ELEMENT

PERFORMANCE CRITERIA

1Prepare and plan welding method

1.1 Work requirements are determined to identify scope of work and resources required

1.2 Welding equipment and consumables are prepared and checked for serviceability

1.3 Site is cleared of obstructions and combustible material to minimise risk of accidents and fire

1.4 Fire fighting and other safety equipment is organised, checked and located in accordance with required regulations

1.5 Personnel are briefed about safety precautions specific to aluminothermic welding as required to minimise risk of injury

2Prepare rail for welding

2.1 Location of weld is identified and assessed in accordance with standards and procedures

2.2 Track is prepared for welding in accordance with workplace standards and procedures

2.3 Rail is prepared for welding in accordance with workplace standards and procedures

3Carry out welding process

3.1 Moulds are fitted and luted to standard to prevent leakage of the molten reaction

3.2 Rails are pre-heated to standard to prevent heat loss

3.3 Rails are welded using aluminothermic method in accordance with approved procedures

3.4 Welding equipment is removed according to approved procedures

3.5 Excess material is removed from weld in accordance with workplace procedures

3.6 Rail profile is restored to standard using rail profile grinder in accordance with workplace procedures

3.7 Arrangements are made for track to be restored

4Check weld conformance

4.1 Finish ground weld area is visually inspected for surface finish and defects

4.2 Finish ground weld area is checked for conformance to rail profile and geometry acceptance standards

5Complete documentation

5.1 Required documentation and/or records are completed in accordance with workplace requirements

REQUIRED KNOWLEDGE AND SKILLS

This describes the essential knowledge and skills and their level required for this unit.

Required knowledge:

Relevant safety, OH&S and environmental procedures and regulations

Workplace procedures for the welding of rail using the aluminothermic technique

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

Hazards that may exist during the welding of rail using the aluminothermic technique, and ways of controlling the risks involved

Contents of relevant workplace 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

Required skills:

Communicate effectively with others when welding rail using the aluminothermic process

Read and interpret technical data, drawings, instructions and manuals relevant to the welding of rail using the aluminothermic process

Interpret and follow operational instructions and prioritise work when welding rail using the aluminothermic process

Complete documentation related to the welding of rail using the aluminothermic process

Operate electronic communication equipment to required protocol

Work collaboratively with others when welding rail using the aluminothermic process

Promptly report and/or rectify any identified problems, faults or malfunctions that may occur when welding rail using the aluminothermic process in accordance with regulatory requirements and workplace procedures

Plan own work including predicting consequences and identifying improvements

Apply precautions and required action to minimise, control or eliminate hazards that may exist during work activities

Monitor work activities in terms of planned schedule

Modify activities depending on differing operational contingencies, risk situations and environments

Work systematically with required attention to detail without injury to self or others, or damage to equipment

Carry out required welding operations

Operate and adapt to differences in equipment in accordance with standard operating procedures

Check compliance between work and job specifications

Implement fire control procedures

Select and use required personal protective equipment

Identify, select and use hand and portable power tools

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

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

The evidence required to demonstrate competency in this unit must be relevant to and satisfy all of the requirements of the elements and performance criteria of this unit and include demonstration of applying:

the underpinning knowledge and skills

relevant legislation and workplace procedures

other relevant aspects of the range statement

Assessment must include exercises which demonstrate competent performance of the following in a range of situations:

planning and preparing for welding method

preparing rail for welding

using appropriate type or types of welding processes

checking weld for conformance

completing documentation correctly

successfully performing a minimum of 10 welds

Context of and specific resources for assessment

Performance is demonstrated consistently over a period of time and in a suitable range of contexts

Resources for assessment include:

a range of relevant exercises, case studies and/or other simulated practical and knowledge assessment, and/or

access to an appropriate range of relevant operational situations in the workplace

In both real and simulated environments, access is required to:

relevant and appropriate materials and equipment, and

applicable documentation including workplace procedures, regulations, codes of practice and operation manuals

Method of assessment

Assessment of this unit must be undertaken by a registered training organisation

As a minimum, assessment of knowledge must be conducted through appropriate written/oral tests

Practical assessment must occur:

in an appropriate range of situations in the workplace

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

Operations may be conducted:

by day or night

in all weather conditions

Work may be conducted in:

restricted spaces

exposed conditions

controlled or open environments

Work may involve:

hazards to eyes

heat hazards

exposure to chemicals, and dangerous or hazardous substances

movements of equipment, goods and vehicles

Resources may include:

rail tensor

hand tools (hot axe, hammer)

wedges

straight edge

rail shears

rail friction saw

rail profile grinder, angle grinder

welding equipment

electric generator

gas heating/cutting equipment

Welding processes may include:

Thermit Australia welding processes (i.e. SkV-Elite, SKVF, SMWF, SKVL)

Railtech welding processes (i.e. PLK CJ, WG68 X CJ)

other approved welding processes

Weld types may include:

standard gap (short preheat)

standard gap (long preheat)

wide gap

junction

Consumables may include:

welding materials as required

rail jewellery (plates, dogspikes, etc.)

gases (oxy, acetylene, propane)

closure rails

Safety hazards may include:

fire risk

poor weather

eye damage

burns

rail tensor failure (broken pins etc.)

welding rail in electrified territory

Depending on the type of organisation concerned and the local terminology used, workplace procedures may include:

company procedures

enterprise procedures

organisational procedures

established procedures

Liaison may include:

internal or external personnel from other work areas (e.g. train controllers, other track gangs)

Communications systems may include:

two-way radios

telephones/mobile phones

agreed audible or hand signals

Depending on the work context, safety and personal protective equipment may include:

high visibility clothing

fire retardant overalls or long sleeved shirts and long pants

hearing protection

gauntlet type gloves

sunscreen

sunglasses

welding goggles

safety glasses

insect repellent

safety headwear

safety footwear

portable radios/mobile phones

hand lamps

flags

safety devices

Information may be provided:

electronically

in writing, via forms/documents

orally, via face-to-face communications

Information/documents may include:

operational instructions, policies and workplace procedures

local authority regulations and procedures

welding records

track inspection reports

timekeeping records

incident reporting data

maintenance specifications

technical instructions

manufacturers or workplace equipment instructions and operation manuals

emergency procedure manuals

two-way radio/mobile phone operation procedures

QA plans, data and document control

conditions of service, legislation and industrial agreements including workplace agreements and awards

Applicable procedures and codes may include:

legislated rail safety requirements including acts and regulations from each applicable state and territory together with any nationally approved compliance codes and/or guidelines

relevant Australian Standards and related requirements, including AS 4292

relevant state/territory OH&S legislation

relevant state/territory environmental protection legislation

electrified territory regulations

relevant fire regulations

This unit contains employability skills.