This standard identifies the competencies you need to bend and form plate for fabrications, in accordance with approved procedures, using power-operated pinch or pyramid rolls which may be hand adjusted or console controlled. You will be required to operate the power rolling machine as instructed, based on the operations to be performed and the thickness and size of the material to be rolled. Setting the rolls will involve setting and adjusting the gap between feed and forming rolls to suit plate thickness, positioning side roller(s) and adjusting to suit the required radius, checking and setting parallelism of rollers, and applying suitable pressure to rollers throughout the forming operation.

You will be expected to carry out the rolling operation in a manner that ensures material is formed to the required profile without flats or deformities. You will also need to ensure that all the required safety devices are operating correctly, and that the machine guards are in place and correctly adjusted. Items to be rolled may include ferrous and non-ferrous materials, and will include operations such as rolling cylinders and cones, producing curved sections, counter-curved sections, pipe sections and plate straightening. This will call for care in using the right machine for the job, and using it in the correct way, so as to avoid damage to the tools and danger to oneself.

Your responsibilities will require you to comply with organisational policy and procedures for the activities undertaken, and to report any problems with the equipment, materials, or rolling activities that you cannot personally resolve, or are outside your personal authority, to the relevant people. You will be expected to work to instructions, with a minimum of supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.

Your underpinning knowledge will be sufficient to provide a good understanding of your work, and will provide an informed approach to applying the power-rolling procedures required. You will have an understanding of the rolling process and its application, and will know about the equipment and materials, in adequate depth to provide a sound basis for carrying out the activities to the required specification.

You will understand the safety precautions required when working with power rolls, and the safeguards necessary for undertaking the activities safely and correctly. You will be required to demonstrate safe working practices and procedures throughout, and will understand the responsibilities you owe to yourself and others in the workplace.

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1. work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
2. confirm that the equipment is set up correctly and is ready for use
3. manipulate the machine controls safely and correctly in line with operational procedures
4. produce formed components to the required specification
5. carry out quality sampling checks at suitable intervals
6. deal promptly and effectively with problems within your control and report those that cannot be solved
7. shut down the equipment to a safe condition on conclusion of the machining activities

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1. the specific safety precautions to be taken when working with rolling machines in a fabrication environment (general workshop and site safety, appropriate personal protective equipment (PPE), accident procedure; statutory requirements, risk assessment procedures and relevant requirements of HASAWA, COSHH and Work Equipment Regulations; safe disposal of waste materials)
2. checks to be carried out to ensure that the power rolls are safe and are in a fit condition to use
3. the personal protective clothing and equipment to be worn when working with heavy platework (such as gloves, eye/ear protection, safety helmets)
4. the handling precautions and correct methods of moving or lifting sheet or plate materials
5. the hazards associated with fabrication work (such as handling sheet/fabricated components, using hot metal techniques, using dangerous or badly maintained tools and equipment, moving parts of power rolling machines), and how they can be minimised
6. how to obtain the necessary drawings, specifications and job instructions
7. how to use and extract information from engineering drawings and related specifications (to include symbols and conventions to appropriate British, European or relevant International standards in relation to work undertaken)
8. marking out conventions used in platework, and how to recognise the bending, forming and cutting lines
9. the basic principle of operation of the power rolling machine used, and the type of work it can perform
10. how to set up the machine to produce the required form (cylinders, cones, curved sections, straightening plates)
11. techniques of rolling (including pre-setting plate edges, adjusting pressure throughout the rolling operations, checking component for parallelism or form throughout the operations)
12. how to release the rolls and remove the workpiece when rolling cylindrical and conical sections
13. the ways of limiting distortion, marking, creases and flats in curved sections
14. how the materials need to be prepared prior to rolling, and the effects of raw material scale or burrs on the finished article
15. material characteristics with regard to forming using rolling machines
16. the care and maintenance procedures to be observed to ensure the machines are in a serviceable condition
17. the problems that can occur with the forming activities, and how they can be avoided
18. the organisational quality control procedures, and how to recognise rolling defects
19. the inspection checks to be carried out, and the tools and equipment that are used
20. the accuracy that can be achieved by rolling, and limitations of the rolling processes
21. the extent of your own authority and whom you should report to if you have problems that you cannot resolve
22. reporting lines and procedures, line supervision and technical experts

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1. Confirm that the equipment is safe to use and fit for purpose, by carrying out all of the following checks:

   1. the rolls are appropriate for the material used and the operations being performed
   2. the machine guards and safety devices are in position and operating correctly
   3. rolls are appropriate for the operation and are in a serviceable condition (suitable diameter; free from damage)
   4. roll settings are suitable for the material thickness and operations to be performed
   5. equipment for supporting the plate at the start of the rolling operations is in place

2. Use one of the following types of power rolling machine:

   1. powered rolls (hand adjusted)
   2. powered rolls (console adjusted)
   3. different roll sizes (diameter and power)

3. Perform rolling operations that produce three of the following:

   1. cylinders
   2. cones
   3. segments of a cylindrical tank
   4. curved section or sector of an otherwise flat plate
   5. counter-curved sections
   6. pipe sections
   7. flattening or straightening plate

4. Carry out rolling operations on one type of material from the following:

   1. carbon steel
   2. stainless steel
   3. aluminium
   4. special metals
   5. other specific material

5. Produce rolled components that conform to all of the following quality and accuracy standards:

   1. dimensional accuracy is within the specification tolerances
   2. the rolled section conforms to best practice and/or specification, without deformation or cracking
   3. the component conforms to the required shape/geometry (to the template profile)

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​​Additional Information

You will be able to apply the appropriate behaviours required in the workplace to meet the job profile and overall company objectives, such as:

• strong work ethic
• positive attitude
• team player
• dependability
• responsibility
• honesty
• integrity
• motivation
• commitment

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3

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2020

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Current

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Original

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Semta

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SEMFWE237

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Engineering, Engineering and Manufacturing Technologies, Metal Forming, Welding and Related Trades

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5213

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engineering; welding; fabrication; machining; forming; platework; power rollers; roll size; conical forms

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