This standard covers a range of basic competences that you need to form and assemble electrical wiring support systems such as conduit, trunking and traywork systems. It will prepare you for entry into the engineering or manufacturing sectors, creating a progression between education and employment, or it will provide a basis for the development of additional skills and occupational competences in the working environment.

You will be expected to prepare for the assembly of the electrical wiring support systems by obtaining all the necessary job instructions, components, tools, equipment and any documentation that may be required.

The assembly activities will include the forming and assembly of metallic and/or non-metallic systems, and will cover the selection of the appropriate materials, cutting and bending/forming the appropriate pieces that make up the support system. You will also need to assemble the prepared pieces, using a range of connection devices, and to position, align and secure them in the correct locations, using the specified/appropriate techniques. On completion of the assembly activities, you will be expected to return all tools and equipment to the correct location, and to leave the work area in a safe and tidy condition.

Your responsibilities will require you to comply with health and safety requirements and organisational policy and procedures for the assembly of the electrical wiring support systems. You will need to report any difficulties or problems that may arise with the assembly activities, and to carry out any agreed actions. You will work under a high level of supervision, whilst taking responsibility for your own actions and for the quality and accuracy of the work that you carry out.

Your underpinning knowledge will provide an understanding of your work, and will enable you to apply appropriate assembly techniques and procedures safely for electrical wiring support systems. You will understand the forming and assembly methods and procedures used, and their application, and will know about the various wiring support systems and components used to produce the assemblies, to the required depth to provide a sound basis for carrying out the activities to the required specification.

You will understand the safety precautions required when carrying out the assembly activities, especially those for handling long lengths of conduit or trunking. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.

Specific Standard Requirements

At least one of the electrical wiring support systems produced must include a combination of components and assembly techniques and procedures, for example: by producing a support system that requires you to cut and bend conduit, produce screw threads, and assemble the conduit using running couplings and Tee pieces.

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1. work safely at all times, complying with health and safety legislation, regulations and other relevant guidelines
2. obtain the correct tools and equipment for the cutting, forming and assembly operations, and check that they are in a safe and usable condition
3. cut and form the electrical wiring support system components to the required size and shape, using appropriate tools and techniques
4. assemble the electrical wiring support system, using the appropriate connectors
5. mount and secure the electrical wiring support system components safely and correctly to meet the specification
6. check the completed assembly to ensure that all operations have been completed, and that the finished assembly is secure and meets the required specification
7. report any difficulties or problems that may arise with the electrical wiring support system assembly activities, and carry out any agreed actions
8. leave the work area in a safe and tidy condition on completion of the assembly of the electrical wiring support systems

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1. the specific safety practices and procedures that you need to observe when forming and assembling electrical wiring and support systems (including any specific legislation, regulations or codes of practice for the activities, equipment or materials)
2. the hazards associated with forming and assembling electrical wiring and support system components, and with the tools and equipment used (such as using bending and forming equipment, handling long lengths of pipe and trunking, using solvents and adhesives), and how they can be minimised
3. the importance of wearing appropriate protective clothing and equipment (PPE), and keeping the work area safe and tidy
4. the interpretation of circuit diagrams, wiring diagrams, and other relevant specifications (including BS and ISO schematics, wiring regulations, symbols and terminology)
5. the various types of electrical wiring support system used, and their typical applications
6. marking out lengths to be cut, taking into account any allowances (such as for bending, screwing, cementing)
7. methods of holding workpieces without damaging them (such as use of pipe vice)
8. the tools and equipment used in the cutting, bending and forming operations (such as the use of conduit bending machines, threading equipment, hot air torches and bending springs)
9. methods of producing bends and sets in conduit materials (such as 90 degree bends, offsets, bridge sets)
10. methods of bending plastic conduit (such as using hot air guns and springs)
11. how to produce fabricated bends in trunking and traywork section material (such as bends, tee junctions, double and saddle sets)
12. the methods of forming screw threads on ends of conduit, and using appropriate tools to remove all sharp edges and burrs
13. the various fittings used to assemble conduit, trunking and traywork systems (including screwed fittings, cemented fittings, straight connectors, bends, tees, inspection fittings, light, power and control outlet boxes)
14. the importance and use of inspection fittings (such as elbows and junction boxes)
15. the problems to look for when checking finished components/assemblies (such as dimensional checks, position and angle of bends/sets, out of alignment, loose connections, insufficient supports, damaged threads, deformed pipe around area of bend, burrs and sharp edges that could damage cables)
16. how to check alignment of components (including use of plumb bobs, levels and by visual means)
17. the methods of supporting and securing the components (such as position and spacing of supporting brackets and devices, using pipe clips, saddles and supports)
18. problems that can occur with the assembly operations, and how these can be overcome
19. when to act on your own initiative and when to seek help and advice from others
20. the importance of leaving the work area in a safe and clean condition on completion of the assembly activities (such as returning tools and equipment to the designated location, cleaning the work area, and removing and disposing of waste)

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1. Carry out all of the following during the electrical wiring support system forming and assembly activities:

   1. adhere to procedures or systems in place for risk assessment, COSHH, personal protective equipment (PPE) and other relevant safety regulations
   2. follow job instructions and assembly/installation drawings at all times
   3. ensure that the electrical cable support system is kept free from foreign objects, dirt or other contamination
   4. apply safe and appropriate forming and assembly techniques and procedures at all times
   5. return all tools and equipment to the correct location on completion of the assembly/installation activities

2. Form and assemble one of the following types of electrical wiring support systems:

   1. metal conduit systems  
   2. non-metallic trunking systems
   3. traywork systems
   4. non-metallic conduit systems
   5. metal trunking system

3. Construct electrical wiring support system components, to include carrying out four of the following:

   1. cutting the materials to the correct lengths (taking into account allowances for bends or joints required)
   2. removing all burrs and sharp edges         
   3. producing or fabricating offsets
   4. producing external threads on conduit     
   5. producing or fabricating bridge/saddle sets
   6. producing or fabricating bends

4. Assemble electrical cable support systems that include the use of three of the following:

   1. straight connectors/couplings               
   2. reducers
   3. bends/elbows (solid or inspection type)          
   4. conversion units and adaptors
   5. tee pieces (such as solid or inspection type)     
   6. crossover units (such as saddle sets)
   7. boxes (such as circular or square, terminal or multi branch) 
   8. inside and outside risers

5. Assemble electrical wiring support systems that include four of the following:

   1. horizontal runs                      
   2. tee junctions             
   3. offsets
   4. bends                       
   5. vertical drops     
   6. bridge/saddle sets

6. Check the completed assembly, to include carrying out all of the following:

   1. checking for level and alignment
   2. checking that all connections are secure
   3. ensuring that sufficient supports are used and that they are correctly spaced
   4. correct outlets are used (such as for sockets, switches, light fittings, wire junction and inspection fittings)

7. Produce electrical wiring support systems, in compliance with one of the following standards:

   1. BS 7671/IET wiring regulations
   2. other BS and/or ISO standards
   3. company standards and procedures
   4. component manufacturers standards

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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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SEMPEO1-21

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Engineering, Engineering and Manufacturing Technologies

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5221

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performing engineering operations; electrical wiring support systems; conduit systems; trunking systems; traywork systems; manufacturing; materials; cutting; bending; forming

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