National Occupational Certificate: Boilermaker

The purpose of this qualification is to prepare a learner to operate as a Boilermaker.

Boilermakers' marks-off and fabricates structural steel and other steel profiles to make or repair metal products and structures which may include pressure vessels and pipes.

(Note: Metal Products and Structures include but are not limited to: Manufacture or repair metal structures, vessels, pipe systems, pressure vessels, heavy duty equipment, sheet metals, road tankers, oilrig stations, mechanical chassis, bins, water tanks, yachts, work boats, high speed vessels, square to rounds, cones, boilers, ducting, water tubes, shell boiler, railway trucks, chutes etc.).

A qualified learner will be able to

• Interpret drawings, develop patterns and templates and use tools and equipment.
• Cut and weld materials and components for fabrication.
• Fabricate components and/or structures.
• Erect and assemble plate and pipe.

A qualified learner will demonstrate the following key attributes: principles and procedurally oriented, problem solving, accuracy, analytic, professionalism.

Rationale

The qualification is a vital response to the increasing demand for highly skilled professionals in the manufacturing and engineering sectors. As industrial operations become more complex, Boilermakers are tasked with a range of critical responsibilities. Modern boilermakers are expected to possess an understanding of plating and structural steel workers' drawings and the ability to develop intricate patterns and templates. Additionally, they must be proficient in using a wide array of specialised tools and equipment which are essential for accurate fabrication and construction. Boilermakers play a central role in the cutting and welding of materials and components, often requiring advanced techniques to ensure structural integrity and safety. This is a core responsibility that this qualification addresses comprehensively. The fabrication of complex components and structures demands a high level of skills and precision. Boilermakers are at the forefront of this task, responsible for crafting everything from pressure vessels to structural components with the utmost attention to quality and safety. The assembly and erection of plate and pipe structures, such as those found in manufacturing and construction, require specific expertise. Boilermakers must have the proficiency to accurately erect and assemble these structures according to specifications.

As the demands on Boilermakers have evolved, there is a pressing need for a qualification that equips learners with comprehensive knowledge and practical skills to excel in these core responsibilities. This NQF Level 4 qualification is designed to prepare Boilermakers with the required skills essential for the tasks as well as equip them with a deeper understanding of engineering principles, advanced fabrication techniques, and structural design.

Currently there are no similar qualifications for this occupation registered on the NQF.

The manufacturing and engineering sectors will gain a highly skilled workforce capable of performing tasks with precision. This will result in improved efficiency, advanced innovation, and a raised quality of workmanship, ensuring the structural integrity of industrial components and safety in complex fabrication processes.

The increased quality and safety standards in manufacturing directly benefit society by reducing workplace accidents and ensuring the integrity of industrial structures and equipment, from power generation to construction.

A thriving manufacturing sector driven amongst others by skilled Boilermakers who can competently perform these four key tasks contributes to economic growth, job creation, and international competitiveness. Moreover, the qualification offers promising career prospects, invigorating economic activity.

Typical learners for the NQF Level 4 Boilermaker qualification encompass individuals seeking to advance their careers within the manufacturing and engineering sectors, specifically those aspiring to excel in interpreting drawings, developing patterns, cutting and welding materials, fabricating components and structures, and erecting and assembling plate and pipe structures. This qualification is ideal for those already employed in related roles, as well as recent graduates with a strong interest in becoming highly skilled Boilermakers capable of executing these core tasks with precision.

Recognition of Prior Learning (RPL)

RPL for Access to Training

Learners may use the RPL process to gain access to training opportunities for a programme of learning, qualification, part-qualification or skills programme if they do not meet the formal, minimum entry requirements for admission. RPL assessment provides an alternative access route into a programme of learning, qualification, part-qualification, or skills programme.

Such an RPL assessment may be developed, moderated and conducted by the accredited Skills Development Provider which offers that specific qualification/part qualification/skills programme. Such an assessment must ensure that the learner is able to display the equivalent level of competencies required for access, based on the NQF level descriptors.

RPL for Exemption of Modules

For exemption from modules through RPL, learners who have gained the stipulated competencies of the modules of a programme of learning, qualification, part-qualification or skills programme through any means of formal, informal or non-formal learning and/or work experience, may be awarded credits towards relevant modules, and gaps identified for training, which is then concluded.

RPL for Access to the External Integrated Summative Assessment (EISA) or Final Integrated Supervised Assessment (FISA)

Learners who have gained the stipulated competencies of the modules of a programme of learning, qualification, part-qualification or skills programme through any means of formal, informal or non-formal learning and/or work experience, may be awarded credits towards relevant modules, and gaps identified for training, which is then concluded.

A valid Statement of Results is required for admission to the EISA in which confirmation of achievement is provided that all internal assessment criteria for all modules in the related curriculum document have been achieved.

Upon successful completion of the EISA, RPL learners will be issued with the QCTO certificate for the qualification, part-qualification or skills programme. Quality Partners are responsible for ensuring the RPL mechanism and process for qualifications and part-qualification is approved by the QCTO.

Entry Requirements

An NQF Level 1 qualification with mathematics.

This qualification is made up of compulsory Knowledge, Practical Skill and Work Experience Modules

Knowledge Modules

• 651302-000-01-KM-01, Introduction to Boilermaker Trade, NQF level 3, 9 Credits.
• 651302-000-01-KM-02, Environmental Protection, Health, and Safety, NQF Level 3, 6 Credits.
• 651302-000-01-KM-03, Boilermaker Tools, Equipment, Machines and Materials , NQF Level 3, 10 Credits.
• 651302-000-01-KM-04, Fabrication and Pipework, NQF Level 4, 28 Credits.
• 651302-000-01-KM-05, Assembling and Joining, NQF Level 4, 28 Credits.
• 651302-000-01-KM-06, Cutting and Welding, NQF Level 4, 28 Credits.
• 651302-000-01-KM-07, Boilermaker's Drawings, NQF Level 4, 12 Credits.
• 651302-000-01-KM-08, Basics Principles of Environmental Awareness and Ethic, NQF Level 2, 2 Credits.
• 651302-000-01-KM-09, Emotional Intelligence and Active Learning, NQF Level 2, 3 Credits.
• 651302-000-01-KM-10, Basics of Computers and Computing Systems, NQF Level 2, 3 Credits.
• 651302-000-01-KM-11, Workplace Fundamentals and Workplace Safety, NQF Level 4, 6 Credits.
• 651302-000-01-KM-12, Workplace Relationships and Performance, NQF Level 4, 6 Credits.
• 651302-000-01-KM-13, Decision Making, level 4, 6 Credits.
• 651302-000-01-KM-14, Basic Slinging and Lifting, and Load Securing Operations, NQF Level 2, 15 Credits.

Total number of credits for Knowledge Modules: 162

Practical Skill Modules

• 651302-000-01-PM-01, Visualise Structures and Components and Develop Templates, NQF Level 4, 32 Credits.
• 651302-000-01-PM-02, Maintain and Use Tools, Equipment and Machinery, NQF Level 3, 20 Credits.
• 651302-000-01-PM-03, Cut and Weld Components Required for Fabrication of a Specific Task, NQF Level 4, 32 Credits.
• 651302-000-01-PM-04, Manipulate and Fabricate Profiles and Metal Sections Using Heating and Cold Bending Processes, NQF Level 4, 44 Credits.
• 651302-000-01-PM-05, Erect, Assemble and Repair Metal Structures, NQF Level 4, 32 Credits.
• 651302-000-01-PM-06, Work Safely and Respond to Emergencies, NQF Level 2, 4 Credits.
• 651302-000-01-PM-07, Apply Safety Standards and Housekeeping Practices, NQF Level 2, 4 Credits.
• 651302-000-01-PM-08, Liaise and Communicate with Others, NQF Level 2, 2 Credits.
• 651302-000-01-PM-09, Sling, Lift and Secure Loads for Transportation, NQF Level 2, 13 Credits.

Total number of credits for Practical Skill Modules: 183

Work Experience Modules

• 651302-000-01-WM-01, Pattern and Template Development Processes, NQF Level 4, 35 Credits.
• 651302-000-01-WM-02, Tools, Equipment and Machinery Maintenance and Operation Processes, NQF Level 4, 30 Credits.
• 651302-000-01-WM-03, Workshop or On-Site Cutting and Welding Processes, NQF Level 4, 45 Credits.
• 651302-000-01-WM-04, Fabrication, Assembling and Repairing of Metal Components and Structures, NQF Level 4, 45 Credits.
• 651302-000-01-WM-05, Assembling and Erecting Processes for Structures and Components, NQF Level 4, 40 Credits.

Total number of credits for Work Experience Modules: 195

1. Read and interpret plating and structural steel workers' drawings and technical documents and develop templates using appropriate tools and equipment to mark off materials.
2. Fabricate components and conduct visual and mechanical inspections, applying knowledge of legal and industry standards compliance.
3. Fabricate simple components and craft workpieces with precision when manipulating and fabricating profiles and metal sections using the understanding of both heating and cold bending processes.
4. Assemble plates and pipe components into structures, and operate, position and align equipment using various methods by applying knowledge of design specifications and industry standards.

Associated Assessment Criteria for Exit Level Outcome 1

ELO 1: Read and interpret plating and structural steel workers' drawings and technical documents and develop templates using appropriate tools and equipment to mark off materials.

• Read plating and structural steel workers' drawings by identifying all lines and elevations and defining and using all terms and abbreviations, symbols and abbreviations.
• Compile materials list with all the quantity and specifications according to the drawing.
• Draw and interpret simple plate, pipe and structural steel plate, pipe and structural steel drawing using drawing techniques and methods, presenting projections, and different views.
• Mark-off materials and parts and develop templates adhering to set tolerances and standards.
• Use tools, equipment and machinery in accordance with safety requirements to deliver components that adhere to the specified standards and tolerances.

Associated Assessment Criteria for Exit Level Outcome 2

ELO 2: Fabricate components and conduct visual and mechanical inspections, applying knowledge of legal and industry standards compliance

• Cut materials using different methods and equipment including plasma, shears, saws, and ironworker machines.
• Weld components for fabrication in accordance with standard operating procedures.
• Conduct visual and mechanical inspections for compliance with task requirements.

Associated Assessment Criteria for Exit Level Outcome 3

ELO 3: Fabricate simple components and craft workpieces with precision when manipulating and fabricating profiles and metal sections using the understanding of both heating and cold bending processes.

• Form material using rollers and benders in sequence, using the required equipment and tools and in accordance with work safety standards and without damage to workpiece or equipment.
• Fabricate components, sub-components and structures by applying various methods, with accurately marked-off workpiece in a clean work environment.
• Fabricate pipe sections in accordance with the drawing specifications.
• Select and apply heat manipulation processes on plate, pipe and structural materials for forming in accordance with sequence, procedures and techniques, and quenching medium requirements.

Associated Assessment Criteria for Exit Level Outcome 4

ELO 4: Assemble plates and pipe components into structures, and operate, position and align equipment using various methods by applying knowledge of design specifications and industry standards.

• Position and join sub-components and components in accordance with assembly drawings.
• Assemble and mechanically join sheet, plate, tube, pipe, and steel sections applying a variety of basic lifting techniques and rigging hand signals according to OHS Act.
• Fasten components as required by the applied drawing specifications (bolting, riveting and / welding).
• Erect assemble, check pipes and steel structures for compliance as per final assembly drawing.

Integrated Assessment

Integrated Formative Assessment

The Skills Development Providers will use the curriculum to guide them on the stipulated internal assessment criteria and weighting. They will also apply the scope of practical skills and applied knowledge as stipulated by the internal assessment criteria. This formative assessment leads to entrance into the integrated External Summative Assessment.

Integrated Summative Assessment

An External Integrated Summative Assessment, conducted through the relevant QCTO Assessment Quality Partner is required to issue this qualification. The External Integrated Summative Assessment will focus on the Exit Level Outcomes and Associated Assessment Criteria. Additional to the written assessment the learner must also submit a portfolio of evidence compiled of outcomes achieved in the workplace.