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

At the end of the course the participant will understand the safety issues relating to a bed operative and to be able to carry out the operations safely:

1. 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
    

1. The importance of cleaning the work area

   • Casting area operatives should have a clear understanding of 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 PP.
    

2. Tendon patterns

   • The different types of tendon pattern.

   • Tendon drawings showing tendon positions and how to apply them.
    

3. Tendon Displacement, Bed Wiring and Pullers

   • The tendon guides should be explained in depth, covering the various patterns used for varying 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 during pulling tendons

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

   • The importance of inspection of the tendons and the potential problems.
    

4. Correct method for fitting barrels and wedges

   • Explain the common issues related to barrels and wedges to include 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 should be 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.
    

5. Fitting the Button Ends

   • 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 (provide examples of acceptable and unacceptable quality).

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

    

6. Tendon Jointing

   Where joints in the tendons are made, the following should be explained:

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

   • Points to be aware of during the jointing procedure.
    

7. Guards and Warnings

   • Relevant and adequate guards.

   • Position and type of notices.

   • Use of relevant audible warnings during Prestressing operations.
    

8. Safe Systems of Work

   • The course should make 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 providers should relate to site-specific procedures as these may differ by location and company.

Assessment

Assessment will be by observation, oral and written multiple choice questions. Relevant practical use of equipment and audits will also form part of the assessment where applicable.