SAQA All qualifications and part qualifications registered on the National Qualifications Framework are public property. Thus the only payment that can be made for them is for service and reproduction. It is illegal to sell this material for profit. If the material is reproduced or quoted, the South African Qualifications Authority (SAQA) should be acknowledged as the source.
SOUTH AFRICAN QUALIFICATIONS AUTHORITY 
REGISTERED UNIT STANDARD: 

Repair rail-manufactured frogs 
SAQA US ID UNIT STANDARD TITLE
120442  Repair rail-manufactured frogs 
ORIGINATOR
SGB Manufacturing and Assembly Processes 
PRIMARY OR DELEGATED QUALITY ASSURANCE FUNCTIONARY
-  
FIELD SUBFIELD
Field 06 - Manufacturing, Engineering and Technology Engineering and Related Design 
ABET BAND UNIT STANDARD TYPE PRE-2009 NQF LEVEL NQF LEVEL CREDITS
Undefined  Regular  Level 3  NQF Level 03  23 
REGISTRATION STATUS REGISTRATION START DATE REGISTRATION END DATE SAQA DECISION NUMBER
Reregistered  2018-07-01  2023-06-30  SAQA 06120/18 
LAST DATE FOR ENROLMENT LAST DATE FOR ACHIEVEMENT
2024-06-30   2027-06-30  

In all of the tables in this document, both the pre-2009 NQF Level and the NQF Level is shown. In the text (purpose statements, qualification rules, etc), any references to NQF Levels are to the pre-2009 levels unless specifically stated otherwise.  

This unit standard does not replace any other unit standard and is not replaced by any other unit standard. 

PURPOSE OF THE UNIT STANDARD 
This unit standard is for a learner within the fabrication and welding fields. Learners credited with this unit standard will be able to repair rail-manufactured frogs safely by means of welding, grinding and cutting processes to a high degree of accuracy in accordance with required quality specifications and standards.

The qualifying learner is capable of:
  • Obtaining the correct equipment, tools, consumables and human resources.
  • Testing the operation of equipment.
  • Applying safe working procedures and instructions related to the repairing of rail manufactured frogs.
  • Performing pre- and post heating procedures correctly.
  • Executing none destructive test on rails.
  • Performing controlled cooling procedures correctly.
  • Dealing with unforeseen circumstances.
  • Removing equipment from rail in accordance with company and manufacturer's instructions. 

  • LEARNING ASSUMED TO BE IN PLACE AND RECOGNITION OF PRIOR LEARNING 
    It is assumed that learners are already competent in:
  • Communication and Mathematical Literacy at NQF Level 2
  • The following unit standards at NQF Level 2:

    > "Operate rail disc cutting equipment "
    > "Operate rail-grinding equipment "
    > "Grind rails with rail grinding equipment"
    > "Cut rails of various profiles and grades"
    > "Operate hydraulic rail shearing machine"
    > "Shear rails"
    > "Cut rail of various profiles and grades" 

  • UNIT STANDARD RANGE 
    The level assigned to this unit standard is appropriate because, performance may be carried out:
  • In different weather conditions
  • During day and night time
  • In different yard layouts/mainline/siding/shed/workshop (might or might not include overhead traction)
  • Within a specific time-span
  • Under hazardous conditions

    This unit standard is exclusive of chrome-manganese rails, mono block crossings and rail-bound turnouts. 

  • Specific Outcomes and Assessment Criteria: 

    SPECIFIC OUTCOME 1 
    Plan and prepare machines, equipment and resources prior to the repairing of rail-manufactured frog. 
    OUTCOME RANGE 
  • Rail shearing machine
  • Rail grinding machine
  • Rail disc cutting machine
  • Welding machine 

  • ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    Equipment, tools, consumables and fire-fighting equipment are obtained, verified, loaded and off- loaded in accordance in accordance with Permanent way welding specifications. 

    ASSESSMENT CRITERION 2 
    The correct personal protective equipment is identified, obtained and used at all times as required. 

    ASSESSMENT CRITERION 3 
    The necessary precautions are taken to prevent injury to personnel when working with Perway and welding equipment according to Permanent way specifications. 

    ASSESSMENT CRITERION 4 
    Vehicle inspection is done in accordance with company procedures and specifications. 
    ASSESSMENT CRITERION RANGE 
    Road Transport Act.
     

    SPECIFIC OUTCOME 2 
    Plan and prepare for the repairing of rail-manufactured frogs according to company specifications and procedures. 

    ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    Fire hazards are identified, limited or removed according to company specifications. 

    ASSESSMENT CRITERION 2 
    On-track protection is placed correctly and timeously according to Permanent way welding specifications. 

    ASSESSMENT CRITERION 3 
    Roll marks on rails are identified correctly and the applicable work procedure(s) are applied. 

    ASSESSMENT CRITERION 4 
    Rail-manufactured frogs are measured, location is logged and specific repair process is determined correctly. 

    ASSESSMENT CRITERION 5 
    Frogs are cleaned and checked for cracks by means of non-destructive tests according to Permanent way welding specifications. 

    ASSESSMENT CRITERION 6 
    Preparatory grinding/cutting to remove loose metal and cracks on the crown and splice rail is performed safely and correctly according to Permanent way welding specifications. 

    ASSESSMENT CRITERION 7 
    Area to be welded is measured and marked out according to company procedures and specifications. 

    ASSESSMENT CRITERION 8 
    Non-destructive testing is performed correctly in accordance with specified company procedures and specifications. 

    SPECIFIC OUTCOME 3 
    Repair rail-manufactured frog. 

    ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    Extremities of defect in the rail are measured and marked out correctly according to company procedures and specifications. 

    ASSESSMENT CRITERION 2 
    All bolts on the frog and sleeper fastenings are loosened off according to company procedures. 

    ASSESSMENT CRITERION 3 
    Preheating process is performed safely and correctly according to company procedures and specifications. 

    ASSESSMENT CRITERION 4 
    The welding process is performed safely and correctly according to company-specific procedures and specifications. 

    ASSESSMENT CRITERION 5 
    Grinding process is performed safely and correctly according to company-specific procedures and specifications. 

    ASSESSMENT CRITERION 6 
    Cutting process is performed safely and correctly according to company-specific procedures and specifications. 

    ASSESSMENT CRITERION 7 
    Measurements are taken to ensure that rail-manufactured frog conforms to specified tolerances as per company-specific specifications. 

    ASSESSMENT CRITERION 8 
    Equipment, tools and consumables are removed from track safely and correctly and work area is cleaned in accordance with company and legislative safety policies, procedures and specifications. 

    ASSESSMENT CRITERION 9 
    Non-destructive tests are performed correctly in accordance with company-specified procedures and specifications. 

    ASSESSMENT CRITERION 10 
    Information on register block is recorded safely and correctly in accordance with company- specified procedures and specifications. 

    SPECIFIC OUTCOME 4 
    Compile the relevant technical documentation. 

    ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    Work orders and instructions are interpreted and understood in accordance with company's policies and procedures. 

    ASSESSMENT CRITERION 2 
    All documentation is completed accurately and timeously according to company procedures. 

    ASSESSMENT CRITERION 3 
    Information is reported to the relevant parties in line with the set standards. 

    ASSESSMENT CRITERION 4 
    The completed documentation is administered in accordance with company's policies and procedures. 


    UNIT STANDARD ACCREDITATION AND MODERATION OPTIONS 
  • Anyone assessing a learner or moderating the assessment of a learner against this unit standard must be registered as an assessor with the relevant Education, Training, Quality, Assurance (ETQA) Body, or with an ETQA that has a Memorandum of Understanding with the relevant ETQA.
  • Any institution offering learning that will enable the achievement of this unit standard must be accredited as a provider with the relevant Education, Training, Quality, Assurance (ETQA) Body, or with an ETQA that has a Memorandum of Understanding with the relevant ETQA.
  • Assessment and moderation of assessment will be overseen by the relevant Education, Training, Quality, Assurance (ETQA) Body, or by an ETQA that has a Memorandum of Understanding with the relevant ETQA, according to the ETQA's policies and guidelines for assessment and moderation.
  • Moderation must include both internal and external moderation of assessments, unless ETQA policies specify otherwise. Moderation should also encompass achievement of the competence described in the Unit Standard.
  • Anyone wishing to be assessed against this unit standard may apply to be assessed by any assessment agency, assessor or provider institution that is accredited by the relevant ETQA. 

  • UNIT STANDARD ESSENTIAL EMBEDDED KNOWLEDGE 
    Learners can understand and explain:
  • The purpose, function and use of measuring equipment.
  • District asset diagram reading.
  • The purpose, function and operation of tools and equipment.
  • The purpose, function, identification and use of consumables.
  • Act 85 related to applicable equipment and machines used.
  • Lifting equipment (Code of Practice No 29 & 30).
  • The stowage of equipment.
  • Track Maintenance instructions and specifications related to the repairing of rail-manufactured frogs.
  • Track welding specifications related to the repairing of rail-manufactured frogs.
  • The safe work procedures related to rail manufactured frogs.
  • Basic electricity.
  • The purpose, function and use of personal protective equipment.
  • Rails identification (Roll marks).
  • The parameters of limits as stated in specification for the length and depth of defects.
  • Crack detection by non-destructive test.
  • The identification, purpose and use of Track fastenings.
  • The pre-heat process and procedures for different rail types.
  • The rail-manufactured frog welding process, procedures and specifications.
  • Stencilling.
  • Coding. 

  • UNIT STANDARD DEVELOPMENTAL OUTCOME 
    N/A 

    UNIT STANDARD LINKAGES 
    N/A 


    Critical Cross-field Outcomes (CCFO): 

    UNIT STANDARD CCFO IDENTIFYING 
    Problem solving

    Learners have the generic ability to identify and solve problems with regard to:
  • Equipment failures.
  • Weather conditions.
  • Deviances in rail heights that exceeds specified limits.
  • Correctness, quantity and quality of material. 

  • UNIT STANDARD CCFO WORKING 
    Teamwork

    Learners can work effectively in teams when:
  • Preparing for and performing the repair process of rail-manufactured frogs.
  • Working with cross-functional disciplines. 

  • UNIT STANDARD CCFO ORGANISING 
    Self-organisation and -management

    Learners can organise and manage oneself by:
  • Observing and assessing the work area to limit hazards and ensure safe working conditions for fellow employees.
  • Planning and organise the repair of rail-manufactured frogs, taking into account prevailing conditions that might hinder activities. 

  • UNIT STANDARD CCFO COLLECTING 
    Information Evaluation

    Learners can evaluate information:
  • Related to work procedures and specifications.
  • Whilst measuring a defect in the rail to determine specific process to be applied. 

  • UNIT STANDARD CCFO COMMUNICATING 
    Learners can communicate effectively:
  • By means of verbal and written reports.
  • By receiving and giving instructions verbally and in writing.
  • With relevant parties, for example sub-ordinates, technical personnel, etc. 

  • UNIT STANDARD CCFO SCIENCE 
    Learners can use science and technology by:
  • Performing various non-destructive tests.
  • Performing the heat treatment in order to maintain an acceptable metallurgical structure in the weld deposit as well as in the parent rail.
  • Controlling the heat input during welding thus controlling the current and travelling speed to suit the size of the electrode. 

  • UNIT STANDARD CCFO DEMONSTRATING 
    Interrelatedness of systems

    Learners can understand that, by eliminating the dynamic effects in the frog, the life-span of the components and track structure is enhanced, thus contributing to the safe passage of rail traffic. 

    UNIT STANDARD CCFO CONTRIBUTING 
    Learner and societal development

    Learners can understand the importance of:
  • Safety rules and guidelines in the usage of electrical/gas equipment and appliances.
  • Working and living in a multi-cultural environment. 

  • UNIT STANDARD ASSESSOR CRITERIA 
    N/A 

    REREGISTRATION HISTORY 
    As per the SAQA Board decision/s at that time, this unit standard was Reregistered in 2012; 2015. 

    UNIT STANDARD NOTES 
    Supplementary information:

    Rail vehicles include all trains and other on-track inspection and maintenance vehicles capable of travelling on railway track. 

    QUALIFICATIONS UTILISING THIS UNIT STANDARD: 
      ID QUALIFICATION TITLE PRE-2009 NQF LEVEL NQF LEVEL STATUS END DATE PRIMARY OR DELEGATED QA FUNCTIONARY
    Elective  49795   National Certificate: Rail Construction and Maintenance  Level 3  NQF Level 03  Reregistered  2023-06-30  TETA 


    PROVIDERS CURRENTLY ACCREDITED TO OFFER THIS UNIT STANDARD: 
    This information shows the current accreditations (i.e. those not past their accreditation end dates), and is the most complete record available to SAQA as of today. Some Primary or Delegated Quality Assurance Functionaries have a lag in their recording systems for provider accreditation, in turn leading to a lag in notifying SAQA of all the providers that they have accredited to offer qualifications and unit standards, as well as any extensions to accreditation end dates. The relevant Primary or Delegated Quality Assurance Functionary should be notified if a record appears to be missing from here.
     
    NONE 



    All qualifications and part qualifications registered on the National Qualifications Framework are public property. Thus the only payment that can be made for them is for service and reproduction. It is illegal to sell this material for profit. If the material is reproduced or quoted, the South African Qualifications Authority (SAQA) should be acknowledged as the source.