SAQA All qualifications and part qualifications registered on the National Qualifications Framework are public property. Thus the only payment that can be made for them is for service and reproduction. It is illegal to sell this material for profit. If the material is reproduced or quoted, the South African Qualifications Authority (SAQA) should be acknowledged as the source.
SOUTH AFRICAN QUALIFICATIONS AUTHORITY 
REGISTERED UNIT STANDARD THAT HAS PASSED THE END DATE: 

Join rails by means of the exothermic welding process 
SAQA US ID UNIT STANDARD TITLE
120451  Join rails by means of the exothermic welding process 
ORIGINATOR
SGB Manufacturing and Assembly Processes 
PRIMARY OR DELEGATED QUALITY ASSURANCE FUNCTIONARY
-  
FIELD SUBFIELD
Field 06 - Manufacturing, Engineering and Technology Engineering and Related Design 
ABET BAND UNIT STANDARD TYPE PRE-2009 NQF LEVEL NQF LEVEL CREDITS
Undefined  Regular  Level 3  NQF Level 03  40 
REGISTRATION STATUS REGISTRATION START DATE REGISTRATION END DATE SAQA DECISION NUMBER
Passed the End Date -
Status was "Reregistered" 		 2018-07-01  2023-06-30  SAQA 06120/18 
LAST DATE FOR ENROLMENT LAST DATE FOR ACHIEVEMENT
2024-06-30   2027-06-30  

In all of the tables in this document, both the pre-2009 NQF Level and the NQF Level is shown. In the text (purpose statements, qualification rules, etc), any references to NQF Levels are to the pre-2009 levels unless specifically stated otherwise.  

This unit standard does not replace any other unit standard and is not replaced by any other unit standard. 

PURPOSE OF THE UNIT STANDARD 
This unit standard is for a learner within the fabrication and welding fields. Learners credited with this unit standard will be able to join rails of various profiles by means of the exothermic welding process safely and to a high degree of accuracy in accordance with required quality specifications and standards.

The qualifying learner is capable of:
  • Obtaining the correct equipment, tools, consumables and human resources.
  • Testing the operation of equipment.
  • Applying safe working procedures and instructions related to the exothermic welding process.
  • Executing none destructive test on rails.
  • Casting of rails.
  • Shearing of rails.
  • Grinding of rails.
  • Removing equipment from rail in accordance with company and manufacturer's instructions. 
    		•

    LEARNING ASSUMED TO BE IN PLACE AND RECOGNITION OF PRIOR LEARNING 
    It is assumed that learners are already competent in:
  • Communication and Mathematical Literacy at NQF Level 2.

    The following unit standards at NQF Level 2:
  • "Care for, select and use hand and measuring tools".
  • "Operate rail disc cutting equipment".
  • "Operate rail-grinding equipment".
  • "Grind rails with rail grinding equipment".
  • "Cut rails of various profiles and grades".
  • "Operate hydraulic rail shearing machine".
  • "Shear rails". 
    		•

    UNIT STANDARD RANGE 
    The level assigned to this unit standard is appropriate because, performance may be carried out:
  • In different weather conditions.
  • During day and night time.
  • In different yard layouts/mainline/siding/shed/workshop (might or might not include overhead traction).
  • Within a specific time-span.
  • Under hazardous conditions.
  • This unit standard is inclusive of chrome-manganese rails, rail-bound and rail-manufactured frogs.
  • This unit standard is exclusive of mono block frogs. 
    		•

    Specific Outcomes and Assessment Criteria: 

    SPECIFIC OUTCOME 1 
    Plan and prepare machines, equipment and resources prior to the exothermic welding of rails. 
    OUTCOME RANGE 
  • Rail shearing machine.
  • Rail grinding machine.
  • Rail disc cutting machine. 
    		•

    ASSESSMENT CRITERIA     

    ASSESSMENT CRITERION 1 
    Equipment, tools, consumables and correct fire-fighting equipment required for joining rails are obtained, verified, loaded and off-loaded in accordance with Permanent way welding specifications. 

    ASSESSMENT CRITERION 2 
    The correct personal protective equipment is identified, obtained and used at all times as required. 

    ASSESSMENT CRITERION 3 
    The necessary precautions are taken to prevent injuries of personnel when working with Perway and welding equipment according to Permanent way specifications. 

    ASSESSMENT CRITERION 4 
    Vehicle inspection is done in accordance with company procedures and instructions. 
    ASSESSMENT CRITERION RANGE 
    Road Transport Act.
     

    ASSESSMENT CRITERION 5 
    Equipment inspection is done in accordance with company procedures and instructions. 

    SPECIFIC OUTCOME 2 
    Plan and prepare for the exothermic welding process of rails in accordance with company procedures and specifications. 

    ASSESSMENT CRITERIA     

    ASSESSMENT CRITERION 1 
    Fire hazards are identified, limited or removed in accordance with the company's and legislative requirements. 

    ASSESSMENT CRITERION 2 
    Applicable fire fighting equipment is off loaded and placed in the work area safely and correctly according to company policies, procedures and specifications. 

    ASSESSMENT CRITERION 3 
    On-track protection is placed correctly and timeously according to Permanent way specifications. 

    ASSESSMENT CRITERION 4 
    Rail ends are cleaned and checked for cracks by means of non-destructive tests. 

    ASSESSMENT CRITERION 5 
    Preparatory work is done in accordance with Permanent way specifications. 
    ASSESSMENT CRITERION RANGE 
    Grinding/pre-stressing.
     

    SPECIFIC OUTCOME 3 
    Join rails by means of the exothermic welding process safely and correctly in accordance with laid down procedures and specifications. 

    ASSESSMENT CRITERIA     

    ASSESSMENT CRITERION 1 
    Preheating process is performed safely and correctly according to company procedures and specifications. 

    ASSESSMENT CRITERION 2 
    Exothermic welding procedure is performed safely and correctly according to company procedures and specifications. 

    ASSESSMENT CRITERION 3 
    Shearing process is performed safely and correctly according to company specifications and procedures. 

    ASSESSMENT CRITERION 4 
    Grinding process is performed safely and correctly according to company specifications and procedures. 

    ASSESSMENT CRITERION 5 
    Measurements are taken to ensure that the exothermic weld conforms to specified tolerances as per company specifications. 

    ASSESSMENT CRITERION 6 
    Equipment, tools, consumables and debri are removed from track safely and correctly in accordance with company and legislative safety policies, procedures and specifications. 

    ASSESSMENT CRITERION 7 
    Non-destructive testing is performed correctly and in accordance with specified welding procedures and specifications. 

    ASSESSMENT CRITERION 8 
    Information regarding the exothermic joint is recorded correctly and timeously according to company procedures. 

    SPECIFIC OUTCOME 4 
    Complete the relevant technical documentation. 

    ASSESSMENT CRITERIA     

    ASSESSMENT CRITERION 1 
    Work orders and instructions are interpreted and understood in accordance with company's policies and procedures. 

    ASSESSMENT CRITERION 2 
    Information is reported to the relevant parties in line with the set standards. 

    ASSESSMENT CRITERION 3 
    The completed documentation is administered in accordance with company's policies and procedures. 


    UNIT STANDARD ACCREDITATION AND MODERATION OPTIONS 
  • Anyone assessing a learner or moderating the assessment of a learner against this unit standard must be registered as an assessor with the relevant Education, Training, Quality, Assurance (ETQA) Body, or with an ETQA that has a Memorandum of Understanding with the relevant ETQA.
  • Any institution offering learning that will enable the achievement of this unit standard must be accredited as a provider with the relevant Education, Training, Quality, Assurance (ETQA) Body, or with an ETQA that has a Memorandum of Understanding with the relevant ETQA.
  • Assessment and moderation of assessment will be overseen by the relevant Education, Training, Quality, Assurance (ETQA) Body, or by an ETQA that has a Memorandum of Understanding with the relevant ETQA, according to the ETQA's policies and guidelines for assessment and moderation.
  • Moderation must include both internal and external moderation of assessments, unless ETQA policies specify otherwise. Moderation should also encompass achievement of the competence described in the Unit Standard.
  • Anyone wishing to be assessed against this unit standard may apply to be assessed by any assessment agency, assessor or provider institution that is accredited by the relevant ETQA. 
    		•

    UNIT STANDARD ESSENTIAL EMBEDDED KNOWLEDGE 
    The purpose, function and use of measuring equipment.
  • District asset diagram reading.
  • The purpose, function and operation of tools and equipment.
  • The purpose, function, identification and use of consumables.
  • Act 85 related to applicable equipment and machines used.
  • Lifting equipment (Code of Practice No 29 & 30).
  • The stowage of equipment.
  • Track maintenance instructions and specifications related to exothermic welding.
  • Track welding specifications related to exothermic welding process.
  • The safe work procedures related to the exothermic welding process.
  • Basic electricity.
  • The purpose, function and use of personal protective equipment.
  • Rails identification (Roll marks).
  • The parameters of limits as stated in specification for the length and depth of defects.
  • Crack detection by non-destructive test.
  • The identification, purpose and use of specific fastenings.
  • The pre-heating process and procedures for different rail types.
  • The exothermic welding process, procedures and specifications.
  • Stencilling.
  • Coding. 
    		•

    UNIT STANDARD DEVELOPMENTAL OUTCOME 
    N/A 

    UNIT STANDARD LINKAGES 
    N/A 


    Critical Cross-field Outcomes (CCFO): 

    UNIT STANDARD CCFO IDENTIFYING 
    Problem solving
    Learners have the generic ability to identify and solve problems with regard to:
  • Equipment failures.
  • Weather conditions.
  • Deviances in rail heights that exceeds specified limits.
  • Correctness, quantity and quality of material. 
    		•

    UNIT STANDARD CCFO WORKING 
    Learners can work effectively in teams when:
  • Preparing for and performing the exothermic welding process of rails.
  • Working with cross-functional disciplines. 
    		•

    UNIT STANDARD CCFO ORGANISING 
    Self-organisation and - management
    Learners can organise and manage one-self by:
  • Observing and assessing the work area to limit hazards and ensure safe working conditions for fellow employees.
  • Planning and organising of various activities related to exothermic welding. 
    		•

    UNIT STANDARD CCFO COLLECTING 
    Information evaluation
    Learners can evaluate information:
  • Whilst measuring defects on the rail to determine specific process to be applied.
  • By analysing the cause and effect of defects in the joint which affect the wheel/rail interaction. 
    		•

    UNIT STANDARD CCFO COMMUNICATING 
    Learners can communicate effectively:
  • By means of verbal and written reports.
  • By receiving and giving instructions verbally and in writing.
  • With relevant parties for example sub-ordinates, technical personnel, etc. 
    		•

    UNIT STANDARD CCFO SCIENCE 
    Learners can use science and technology by:
  • Performing various non-destructive tests.
  • Performing heat treatment in order to maintain an acceptable metallurgical structure in the weld deposit as well, as in the parent rail.
  • Controlling the heat input during welding thus controlling the size and metallurgic structure of the heat affective zone. 
    		•

    UNIT STANDARD CCFO DEMONSTRATING 
    Interrelatedness of systems
  • Learners can understand that, by eliminating the dynamic effects on the track, the life span of the component and track structure is enhanced, thus contributing to the safe passage of rail traffic. 
    		•

    UNIT STANDARD CCFO CONTRIBUTING 
    Learner and societal development
    Learners can understand the importance of:
  • Safety rules and guidelines in the usage of electrical/gas equipment and appliances.
  • Working and living in a multi-cultural environment. 
    		•

    UNIT STANDARD ASSESSOR CRITERIA 
    N/A 

    REREGISTRATION HISTORY 
    As per the SAQA Board decision/s at that time, this unit standard was Reregistered in 2012; 2015. 

    UNIT STANDARD NOTES 
    Values
  • Safety conscientiousness.
  • Time conscientiousness.
  • Sobriety.
  • Reliability.
  • Trustworthy.
  • Responsibility towards assets and equipment.
  • Integrity.
  • Quality conscientiousness.

    Supplementary information
  • Rail vehicles include all trains and other on-track inspection and maintenance vehicles capable of travelling on railway track. 
    		•

    QUALIFICATIONS UTILISING THIS UNIT STANDARD: 
      ID QUALIFICATION TITLE PRE-2009 NQF LEVEL NQF LEVEL STATUS END DATE PRIMARY OR DELEGATED QA FUNCTIONARY
    Elective  49795   National Certificate: Rail Construction and Maintenance  Level 3  NQF Level 03  Passed the End Date -
    Status was "Reregistered"     		 2023-06-30  TETA 


    PROVIDERS CURRENTLY ACCREDITED TO OFFER THIS UNIT STANDARD: 
    This information shows the current accreditations (i.e. those not past their accreditation end dates), and is the most complete record available to SAQA as of today. Some Primary or Delegated Quality Assurance Functionaries have a lag in their recording systems for provider accreditation, in turn leading to a lag in notifying SAQA of all the providers that they have accredited to offer qualifications and unit standards, as well as any extensions to accreditation end dates. The relevant Primary or Delegated Quality Assurance Functionary should be notified if a record appears to be missing from here.
     
    1. R and H Rail (Pty) Ltd 


    All qualifications and part qualifications registered on the National Qualifications Framework are public property. Thus the only payment that can be made for them is for service and reproduction. It is illegal to sell this material for profit. If the material is reproduced or quoted, the South African Qualifications Authority (SAQA) should be acknowledged as the source.