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

MEM05027 Mapping and Delivery Guide
Perform aluminothermic welding

Version 1.0
Issue Date: May 2024


Qualification -
Unit of Competency MEM05027 - Perform aluminothermic welding
Description
Employability Skills
Learning Outcomes and Application This unit of competency defines the skills and knowledge required to weld using the aluminothermic welding process. It includes planning and preparing the welding method, preparing materials and the site for aluminothermic welding, carrying out the welding process in accordance with safe working/regulatory requirements and workplace procedures, checking weld conformance and completing all required documentation.This unit applies in a maintenance or site environment where the weld quality is not required to meet an Australian Standard. The aluminothermic welding process (commonly referred to as the CADWELD process) is pre-engineered and is used to make welded connections of copper to copper or copper to steel or other metals. It is also used for header cable taps, conductor splices and terminations, and ground rod connections, or for attaching cathodic protection leads to pipes (steel or cast iron), tanks and structures in which no outside source of heat or power is required. A common use is to join copper cables (wire) for use in direct burial (grounding/earthing) applications.Where the interpretation of technical drawings is required unit MEM09002 Interpret technical drawing should also be selected.Where the selection and use of engineering measurement is required unit MEM12023 Perform engineering measurements should also be selected.Where the selection and use of tools is required unit MEM18001 Use hand tools and unit MEM18002 Use power tools/hand held operations, should also be selected as appropriate.Work may be undertaken in the field/on-site (as distinct from a production/manufacturing facility) and may be undertaken in a trench. In those situations, MSMOPS363 Organise on-site work, for work on site and MSMPER205 Enter confined space, for work in a trench should also be selected as appropriate. Work will often be undertaken under a permit to work system in which case MSMPER200 Work in accordance with an issued permit and possibly other related permit units should also be selected as appropriate.Where the aluminothermic welding process is required for rail track welding, TLIW3015 Weld rail using aluminothermic welding process should be selected from the TLI Transport and Logistics Training Package.No licensing, legislative or certification requirements apply to this unit at the time of publication.Band: AUnit Weight: 2
Duration and Setting X weeks, nominally xx hours, delivered in a classroom/online/blended learning setting.
Prerequisites/co-requisites
Competency Field Fabrication
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: Determine job requirements
  • Follow standard operating procedures (SOPs)
       
Element: Comply with work health and safety (WHS) requirements at all times
       
Element: Use appropriate personal protective equipment (PPE) in accordance with SOPs
       
Element: Identify job requirements from specifications, sketches, job sheets or work instructions
       
Element: Prepare and plan for welding
  • Identify weld requirements from job instructions
       
Element: Obtain permits and other required authorities
       
Element: Identify site and job hazards and implement appropriate hazard control measures
       
Element: Complete pre-site preparations
       
Element: Identify the locations of welds and assess in accordance with SOPs and specifications
       
Element: Clean and prepare surfaces ready for welding
       
Element: Clear site of obstructions and combustible material to minimise risk of accidents and fire
       
Element: Prepare equipment for welding
  • Set up welding equipment
       
Element: Select consumables to suit application
       
Element: Perform aluminothermic welding
  • Apply safe welding practices
       
Element: Ensure moulds are fitted and shimmed, sleeved or sealed, as required
       
Element: Pre-heat materials to standard
       
Element: Ensure materials are welded using aluminothermic method in accordance with approved procedures
       
Element: Clean and inspect mould
       
Element: Complete documentation
  • Assess weld conformance in accordance with specifications
       
Element: Complete required reports, documentation and/or records in accordance with workplace requirements
       

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.

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.

Work environment includes one (1) or more of the following:

restricted spaces

exposed conditions

controlled or open environments

Pre-site preparations include one (1) or more of the following:

checking all required equipment and materials

identifying required personal protective equipment

loading all requirements for the job

Materials to be joined include one (1) or more of the following:

common steel

copper-clad steel

Columbium

Niobium

brass

wrought iron

stainless steel

cast iron

galvanised and bethanised steel

bronze

silicon bronze

Assessment of weld locations include one (1) or more of the following:

proximity to existing welds or repairs

substrate integrity issues

preparation of pre-qualification samples

Weld consumables include one (1) or more of the following:

aluminothermic powder

starting powder

metallic disc

Equipment includes one (1) or more of the following:

mould

lute (sealant)

ignition source

handle clamps

wire brush

mould scraper

gas pre-heating/cutting equipment

PPE includes one or more of the following:

high visibility clothing

fire retardant overalls or long sleeved shirts and long pants

hearing protection

gauntlet type gloves

welding goggles

safety glasses

safety headwear

safety footwear

portable radios/mobile phones

other safety devices

Procedures and codes include one (1) or more of the following:

relevant state/territory WHS legislation together with any nationally approved compliance codes and/or guidelines

relevant state/territory environmental protection requirements

legislation

relevant fire regulations

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
Follow standard operating procedures (SOPs) 
 
 
 
Identify weld requirements from job instructions 
 
 
 
 
 
 
Set up welding equipment 
 
Apply safe welding practices 
 
 
 
 
Assess weld conformance in accordance with specifications 
 

Forms

Assessment Cover Sheet

MEM05027 - Perform aluminothermic welding
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

MEM05027 - Perform aluminothermic welding

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: