Select Use And Maintain Perway Tools And Equipment Training

Objectives:
• Understand the scope and importance of Permanent Way (Perway) maintenance.
• Identify common perway tools and equipment used in rail infrastructure.
• Explain safety protocols and legislative requirements (OHS Act).
• Describe the role of a perway worker in tool selection and maintenance.

Topics:
• Overview of rail infrastructure and perway components.
• Categories of perway tools: hand tools, power tools, and heavy equipment.
• Introduction to relevant standards: SANS, SAQA, and unit standard 120035.
• Basic safety principles: PPE, tool inspection, and hazard identification.
• Tool inventory and documentation procedures.

Objectives:
• Identify and describe the use of common hand tools (spanners, hammers, crowbars, etc.).
• Demonstrate correct handling and ergonomic techniques.
• Explain the importance of tool condition and cleanliness.
• Apply basic maintenance procedures for hand tools.

Topics:
• Detailed look at track-specific hand tools: rail tongs, claw bars, track gauges.
• Proper gripping, swinging, and leverage techniques.
• Inspection criteria for wear, cracks, and damage.
• Cleaning, oiling, and storage best practices.
• Practical session: tool identification and condition assessment.

Objectives:
• Identify power tools used in perway work (impact wrenches, rail saws, grinders).
• Understand pneumatic tool operation and safety.
• Perform pre-use checks and basic troubleshooting.
• Apply lock-out/tag-out procedures.

Topics:
• Types of power tools: electric vs. pneumatic vs. hydraulic.
• Safe operation of rail drills and cut-off saws.
• Air compressor setup and hose management.
• Common faults: overheating, loss of power, vibration.
• Practical: starting, operating, and shutting down tools.

Objectives:
• Describe the function of tamping machines and ballast regulators.
• Identify key components and controls.
• Understand basic operating principles and safety zones.
• Explain routine pre-operation checks.

Topics:
• Introduction to mechanised perway equipment.
• Tamping machine: tamping units, lifting, lining.
• Ballast regulator: plough, broom, and wings.
• Operator responsibilities and daily inspection checklists.
• Safety around moving machinery and track possession.

Objectives:
• Operate rail saws and drills for cutting and drilling rails.
• Perform rail grinding to restore profile.
• Apply correct cutting fluids and speeds.
• Interpret rail defect marking systems.

Topics:
• Rail saw types: abrasive, friction, and cold saws.
• Rail drill alignment and bit selection.
• Grinding stones and angles for defect removal.
• Measuring rail head wear and profile gauges.
• Practical: cutting and drilling a rail section.

Objectives:
• Use track gauges, levels, and string lines to measure track geometry.
• Interpret measurement data for gauge, cross-level, and alignment.
• Understand tolerance limits per SANS 3000 series.
• Record and report deviations accurately.

Topics:
• Tools: track gauge, spirit level, optical level, theodolite.
• Measuring gauge, superelevation, and twist.
• String lining for alignment and versine measurement.
• Data recording forms and defect classification.
• Practical: field measurement exercise on a test track.

Objectives:
• Identify different fastening systems (clips, bolts, baseplates).
• Use tensioning tools and torque wrenches correctly.
• Perform installation and removal of fastenings.
• Check and adjust fastener tension to specifications.

Topics:
• Types: Pandrol, Fastclip, and traditional fishplate.
• Tools: clip applicators, impact wrenches, torque multipliers.
• Torque specifications and calibration.
• Inspection for broken clips and loose bolts.
• Practical: installing and tensioning clips.

Objectives:
• Sharpen cutting tools (drill bits, saw blades).
• Calibrate measuring instruments (gauges, levels).
• Understand the importance of tool maintenance schedules.
• Maintain tool logs and service records.

Topics:
• Sharpening techniques for drill bits and chisels.
• Saw blade dressing and replacement criteria.
• Calibration procedures for track gauges and levels.
• Lubrication schedules and oil types.
• Record keeping: tool register and maintenance log.

Objectives:
• Apply safe lifting and carrying techniques.
• Secure tools and equipment for transport on rail vehicles.
• Implement tool control and anti-theft measures.
• Respond to spills and tool-related incidents.

Topics:
• Manual handling risk assessment.
• Lashing and securing loads on trolleys and trains.
• Tool crib management and sign-out procedures.
• Emergency procedures for tool failure or accidents.
• Practical: loading and securing tools on a trailer.

Objectives:
• Operate spike pullers and screw spikers safely.
• Perform spike removal and installation with correct torque.
• Troubleshoot common operational issues.
• Understand hydraulic and mechanical systems.

Topics:
• Hydraulic spike puller: setup, operation, maintenance.
• Screw spiker: depth control and torque adjustment.
• Common faults: hydraulic leaks, worn jaws, misalignment.
• Preventive maintenance: filters, fluids, seals.
• Practical: removing and installing spikes.

Objectives:
• Identify specialised tools for switch and crossing maintenance.
• Use switch tampers and point adjustment tools.
• Measure and adjust switch gaps and throw.
• Maintain crossing nose and wing rails.

Topics:
• Tools: switch tampers, point gauges, crossing templates.
• Measuring switch opening, stock rail gauge, and flangeways.
• Adjusting switch rods and stretcher bars.
• Crossing nose profile measurement and grinding.
• Practical: adjusting a set of points.

Objectives:
• Conduct systematic tool inspections using checklists.
• Identify defects: cracks, wear, deformation, corrosion.
• Classify defects as critical, major, or minor.
• Complete inspection reports and recommend actions.

Topics:
• Inspection intervals and criteria per tool type.
• Non-destructive testing basics: visual, magnetic particle.
• Defect classification and tagging system.
• Reporting chain: operator to supervisor to maintenance.
• Practical: inspect a set of tools and complete report.

Objectives:
• Organise tool storage for accessibility and protection.
• Implement inventory control systems (manual/electronic).
• Conduct stock takes and reconcile discrepancies.
• Ensure compliance with company policies.

Topics:
• Storage conditions: cleanliness, climate, security.
• Shelving, shadow boards, and tool chests.
• Inventory methods: barcode, RFID, manual logs.
• Reorder levels and procurement procedures.
• Practical: set up a shadow board and perform stock count.

Objectives:
• Select appropriate tools for common perway tasks.
• Plan tool usage sequences for efficiency.
• Apply risk assessments to tool selection.
• Demonstrate team coordination during tool deployment.

Topics:
• Task analysis: rail replacement, tamping, fastener renewal.
• Tool selection matrix: task vs. tool vs. condition.
• Worksite organisation: tool layout and access.
• Communication and hand signals for tool handling.
• Practical: plan and execute a small perway task with tools.

Objectives:
• Demonstrate competence in tool selection, use, and maintenance.
• Complete a practical assessment on a simulated track.
• Pass a written test on safety and procedures.
• Receive feedback and certification guidance.

Topics:
• Review of key concepts from all days.
• Practical assessment: tool inspection, operation, and maintenance.
• Written assessment: multiple-choice and short-answer.
• Individual feedback and areas for improvement.
• Issuance of certificates and closing.