This unit formS the core of the training and is suitable for Casting, Specials and Unit Handling

 

The risks and hazards associated with the operations

• Housekeeping

• The machinery used during the manufacturing process

• Other non-machinery hazards

• Working on or around tendons with live loads i.e. tying rebar
   

The importance of cleaning the work area

• Operatives will understand the importance of cleaning the casting area in preparation for the process

• The use of work area cleaning tools e.g. squeegee mops

• The use of releasing agents and the issues relating to COSHH and PPE
   

Tendon patterns

• The different types of tendon patterns

• Tendon drawings showing tendon positions and how to apply them
   

Tendon Displacement, Bed Wiring and Pullers

• The tendon guides are explained in depth, covering the various patterns used for different product designs

• The positioning of tendons along the casting area and preparation for the stressing operation to take place

• The correct systems for coupling the tendons to the ‘dead-end’ and the ‘live-end’ of the casting area

• The correct method for pulling the tendon from the coil and the directional issues

• The importance of continual visual checks on the tendon coils

• The points and dangers to be aware of when pulling tendons

• The positioning of tendon safety restraint systems and reasons for their use

• The importance of inspecting the tendons and the potential problems
   

Correct method for fitting Barrels and Wedges

• We explain the common issues related to barrels and wedges, including typical faults and related hazards

• Correct storage methods for barrels and wedges

• The correct use of barrels and wedges and the different types of tendon connectors

• The importance of inspection for each component and awareness of the relevant problems (practical examples of both acceptable and unacceptable quality are used)

• The methods used for the separation of unacceptable components

• The use of grip release spray and the reasons for using it

• The use of double-ended couplers
   

Fitting the Button Ends

• We explain the relevant faults and issues regarding button-ends

• The storage methods for ferrules and their use

• The inspection of button-ending equipment and test requirements

• Know how to inspect the button-end and the qualities required showing examples of acceptable and unacceptable quality

• The correct methods of cropping tendons before proceeding with the manufacture of the button end
   

Tendon Jointing

• Where joints in the tendons are made, the following is explained:

• The correct operation of the tendon jointer (practical demonstration is given) including essential safety requirements

• Points to be aware of during the jointing procedure
   

Guards and Warnings

• Relevant and adequate guards

• Position and type of notices

• Use of relevant audible warnings during Pre-stressing operations
   

Safe Systems of Work

• The course makes specific reference at all times to the procedures set out in the relevant Safe System of Work as authorised by the Factory Manager

• The above elements of the course are subject to discussion and change. The course will be tailored to your site-specific procedures as these may differ by location and company

 

This module is assessed through a multiple-choice questionnaire