Assemble And Fit Small Steelwork To Overhead Track Equipment Steel Structures Under Isolated And Earthed Conditions Training

Objectives:
• Understand the scope and application of overhead track equipment in industrial settings.
• Identify different types of steel structures used in overhead track systems.
• Recognize safety requirements for working with steel structures.
• Explain the role of earthing and isolation in electrical safety.

Topics:
• Overview of overhead track equipment and steel structures
• Types of steel: mild steel, high-strength steel, and galvanised steel
• Basic principles of load-bearing structures
• Introduction to earthing and isolation concepts
• Safety standards and regulations (OHS Act, SANS 10089)
• Personal protective equipment (PPE) requirements
• Site safety and hazard identification
• Documentation and quality control basics

Objectives:
• Interpret engineering drawings and specifications for steelwork assembly.
• Identify symbols, dimensions, and tolerances relevant to overhead track equipment.
• Apply basic measurement techniques using appropriate tools.
• Understand the importance of accuracy in assembly.

Topics:
• Types of drawings: general arrangement, detail, and assembly drawings
• Reading dimensions, weld symbols, and surface finish marks
• Using measuring tools: tape measure, callipers, spirit level
• Tolerances and fit requirements for steelwork
• Bill of materials and part identification
• Practical exercise: interpreting a sample drawing
• Common errors in reading drawings
• Quality checks for dimensional accuracy

Objectives:
• Select and inspect steel materials for defects and suitability.
• Perform cutting, drilling, and grinding operations safely.
• Prepare surfaces for welding and assembly.
• Apply material handling techniques to prevent damage.

Topics:
• Material selection: profiles, plates, and fasteners
• Inspection for rust, cracks, and dimensional deviations
• Cutting methods: oxy-fuel, plasma, and mechanical cutting
• Drilling and tapping for bolted connections
• Grinding and edge preparation for welding
• Handling and storage of steel components
• Practical exercise: cutting and drilling steel sections
• Safety precautions during material preparation

Objectives:
• Assemble steel components using bolted connections.
• Apply correct torque and tightening sequences.
• Perform temporary assembly for alignment and fit-up.
• Inspect bolted joints for compliance.

Topics:
• Types of bolts: high-strength, structural, and anchor bolts
• Torque specifications and tightening methods
• Use of washers, nuts, and locking devices
• Temporary assembly techniques: tack welding and clamps
• Alignment checks using plumb bobs and levels
• Practical exercise: bolting a simple steel frame
• Inspection criteria for bolted connections
• Documentation of assembly steps

Objectives:
• Describe welding processes suitable for structural steel.
• Set up welding equipment and select appropriate consumables.
• Perform basic fillet and butt welds.
• Inspect welds for common defects.

Topics:
• Welding processes: MMAW, GMAW, FCAW for structural steel
• Welding parameters: current, voltage, travel speed
• Electrode and filler metal selection
• Welding positions: flat, horizontal, vertical, overhead
• Practical exercise: fillet weld on a T-joint
• Weld defect identification: porosity, cracks, undercut
• Weld inspection methods: visual and dye penetrant
• Safety in welding: fumes, fire, and electrical hazards

Objectives:
• Assemble steel structures for overhead track equipment following drawings.
• Align and level components accurately.
• Integrate track rails and supports.
• Apply temporary bracing for stability.

Topics:
• Sequence of assembly: columns, beams, brackets
• Levelling and alignment techniques using laser levels
• Installation of track rails and joint plates
• Temporary bracing for structural stability
• Practical exercise: assembling a gantry structure
• Checking for squareness and plumb
• Adjustments and rework procedures
• Safety during assembly at height

Objectives:
• Explain earthing principles for overhead track equipment.
• Install earthing conductors and connections.
• Apply isolation procedures for electrical safety.
• Test earthing continuity and resistance.

Topics:
• Earthing systems: TN, TT, IT for steel structures
• Earthing conductors: copper, steel, and connections
• Isolation of track sections: insulated joints and gaps
• Practical exercise: installing earthing bonds
• Testing earth resistance using a clamp-on meter
• Isolation verification and lockout/tagout
• Compliance with SANS 10142-1 and OHS Act
• Documentation of earthing and isolation

Objectives:
• Inspect assembled steelwork for compliance with specifications.
• Perform non-destructive testing (NDT) on welds.
• Conduct load testing on overhead track structures.
• Complete quality control documentation.

Topics:
• Visual inspection checklist for steelwork
• NDT methods: magnetic particle and ultrasonic testing
• Load testing procedures: static and dynamic
• Interpretation of test results
• Practical exercise: inspecting a completed assembly
• Filling out inspection reports and test certificates
• Non-conformance reporting and corrective actions
• Final quality review

Objectives:
• Demonstrate competence in assembling and fitting steelwork.
• Integrate all aspects: drawing reading, assembly, welding, earthing.
• Complete a full assembly project under supervision.
• Pass the final assessment covering theory and practical.

Topics:
• Full assembly project: from drawing to completed structure
• Application of earthing and isolation in the project
• Time management and work planning
• Final practical assessment: assemble and fit steelwork
• Written assessment: multiple choice and short questions
• Feedback and review of performance
• Certification requirements and next steps
• Course evaluation and closure