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: A
Unit Weight: 2
Elements and Performance Criteria
Elements describe the essential outcomes. | Performance criteria describe the performance needed to demonstrate achievement of the element. | ||
1 | Determine job requirements | 1.1 | Follow standard operating procedures (SOPs) |
1.2 | Comply with work health and safety (WHS) requirements at all times | ||
1.3 | Use appropriate personal protective equipment (PPE) in accordance with SOPs | ||
1.4 | Identify job requirements from specifications, sketches, job sheets or work instructions | ||
2 | Prepare and plan for welding | 2.1 | Identify weld requirements from job instructions |
2.2 | Obtain permits and other required authorities | ||
2.3 | Identify site and job hazards and implement appropriate hazard control measures | ||
2.4 | Complete pre-site preparations | ||
2.5 | Identify the locations of welds and assess in accordance with SOPs and specifications | ||
2.6 | Clean and prepare surfaces ready for welding | ||
2.7 | Clear site of obstructions and combustible material to minimise risk of accidents and fire | ||
3 | Prepare equipment for welding | 3.1 | Set up welding equipment |
3.2 | Select consumables to suit application | ||
4 | Perform aluminothermic welding | 4.1 | Apply safe welding practices |
4.2 | Ensure moulds are fitted and shimmed, sleeved or sealed, as required | ||
4.3 | Pre-heat materials to standard | ||
4.4 | Ensure materials are welded using aluminothermic method in accordance with approved procedures | ||
4.5 | Clean welds | ||
4.6 | Clean and inspect mould | ||
5 | Complete documentation | 5.1 | Assess weld conformance in accordance with specifications |
5.2 | Complete required reports, documentation and/or records in accordance with workplace requirements | ||
Foundation Skills
This section describes those required skills (reading, writing, oral communication and numeracy) that are essential to workplace performance in this unit of competency.
Foundation skills essential to performance are explicit in the performance criteria of this unit of competency.
Range Statement
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 |
Competency Field
Fabrication