1 Determine job requirements

1.1 New welds and weld repairs are located

1.2 Corrugations on the rail are identified

1.3 Appropriate equipment is selected

1.4 Appropriate repair method and/or profile is selected to ensure completed work will meet specifications

1.5 Site is cleared of obstructions and combustible material

2 Grind weld repair

2.1 Rail and check rail are ground to profile using approved equipment in accordance with workplace procedures

2.2 Grinding equipment is operated safely in accordance with occupational health and safety (OH&S) and environmental requirements

2.3 Rail profile and vertical and horizontal alignment are measured to ensure compliance with acceptance standards

2.5 Rail surface condition is assessed for compliance with acceptance standards

3 Grind rail to repair corrugations

3.1 Rail is ground using approved equipment in accordance with workplace procedures

3.2 Grinding equipment is operated safely in accordance with OH&S and environmental requirements

3.3 Finished surface is checked to ensure compliance with specification

4 Re-profile rail

4.1 Rail is re-profiled using approved equipment in accordance with workplace procedures

4.2 Equipment is operated safely in accordance with OH&S and environmental requirements

4.3 Finished surface is checked to ensure ground profile complies with organisational requirements and specifications

5 Complete documentation

5.1 Documentation is completed in accordance with organisational requirements

This section describes the knowledge and skills required for this unit.

Required knowledge:

Acceptance standards for rail profile and surface condition

Authorisation/approval processes and procedures

Documentation and recordkeeping requirements

Grinding methods and results

Hazards that may exist when grinding rail and welds, and ways of controlling the risks involved

Problems that may occur when grinding rail and welds, and action that can be taken to report or resolve the problems

Relevant communication systems and procedures

Relevant safety, OH&S and environmental procedures and regulations

Workplace procedures for grinding rail and welds

Required skills:

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

Communicate effectively with others when grinding rail and welds

Complete documentation related to grinding rail and welds

Interpret and follow operational instructions and prioritise work when grinding rail and welds

Modify activities depending on operational contingencies, risk situations and environments

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

Read and interpret technical data, drawings, instructions and manuals relevant to grinding rail and welds

Report and/or rectify any identified problems, faults or malfunctions that may occur when grinding rail and welds in accordance with regulatory requirements and workplace procedures

Select and use hand tools, power tools and equipment

Select and use required personal protective equipment

Work collaboratively with others when grinding rail and welds

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

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 required 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:

identifying job requirements

operating grinding equipment safely

grinding welds and weld repairs using appropriate grinding wheel speed and rate of metal removal

grinding rail to repair surface defects

completing documentation correctly

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

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

Practical assessment must occur:

through activities in an appropriately simulated environment, and/or

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.

Type and rate of grinding may vary according to:

location

purpose of grinding

Equipment may include:

hand held grinders

rail profile grinders

ride on rail profile grinders

hand tools

gauges

electronic rail profiler

Measuring equipment may include:

straight edge

electronic straight edge

profile gauge

Materials may include:

grinding wheels

Liaison may include:

internal or external personnel from other work areas (e.g. signallers/controllers, electricians)

Communication equipment systems may include:

two-way radios

telephones/mobile phones

agreed audible or hand signal

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

high visibility clothing

hearing protection

gloves

sunscreen

sunglasses

safety glasses

insect repellent

safety headwear

fire retardant clothing and overgear (aprons, spats etc.)

face shields

safety footwear

portable radios/mobile phones

hand lamps

flags

safety devices

Information/documents may include:

operational instructions, policies and workplace procedures

local authority regulations and procedures

information provided by other workplace personnel

track inspection reports

work orders

technical instructions

manufacturer or workplace equipment instructions and operation manuals

two-way radio/mobile phone operation procedures

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

Applicable procedures and codes may include:

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

relevant state/territory OH&S and environmental protection legislation