Block B – Fabrication

Trends

Computerized systems such as Computer-Aided Design (CAD) and Computer Numerical Controlled (CNC) software and equipment are becoming common place for determining specifications, material ordering, design and cutting. These systems are taking emphasis away from traditional fabrication and layout methods.

Related Components (including, but not limited to)

Metal and specialty materials; screws, nuts, bolts, washers, pop rivets, solid rivets and other hardware such as hinges, quadrants and locks; consumable welding products; insulation; lagging; pins; strapping gaskets; caulking; adhesives; sealants and paint.

Tools and Equipment

See Appendix A.

Task 4 Performs pattern development.

Context

Pattern development is the starting point of fabrication and one of the most important steps. Sheet metal workers develop a pattern by hand or computer using one or more of the four methods of layout to build a finished product. They need to be able to identify which method to use.

Required Knowledge

• K 1 mathematical formulas
• K 2 orthographic and isometric diagrams
• K 3 types of layout tools such as trammel points, dividers, squares, circumference rules, markers and scratch awls
• K 4 triangulation method and its applications such as square-to-round, transitions and sweep offsets
• K 5 radial line method and its applications such as cones and round reducers
• K 6 parallel line method and its applications such as round elbows, tees and take-offs
• K 7 simple layout and its applications such as square and round duct, countertops and pans
• K 8 joints such as flanges, standing seams, slip and drive, and pre-engineered duct connectors
• K 9 seams such as button lock, Pittsburgh lock and groove seams
• K 10 seam and material thickness allowances
• K 11 information to write on piece such as break lines, kink lines, bend up/down and pattern in/out
• K 12 labelling practices for CAD and CNC including plasma tables
• K 13 software used to assist in the design and development of patterns

Sub-task - B-4.01 Develops patterns using triangulation method.

Key Competencies

• B-4.01.01 visualize finished product in three dimensions
• B-4.01.02 develop views required for fitting such as plan view and elevation view
• B-4.01.03 find true lengths by using the two known points
• B-4.01.04 lay out flat pattern and allow for transverse joint and longitudinal seam allowances according to specifications
• B-4.01.05 connect points to finish pattern using layout tools
• B-4.01.06 mark braking lines and braking diagrams on pattern for future forming

Sub-task - B-4.02 Develops patterns using radial line method.

Key Competencies

• B-4.02.01 visualize finished product in three dimensions
• B-4.02.02 develop views required for fitting such as plan view and elevation view
• B-4.02.03 find common apex using layout tools and mathematical formulas
• B-4.02.04 calculate circumference stretch-out
• B-4.02.05 divide stretch-out lengths into equal parts, spaced according to required accuracy, and corresponding to developed plan and elevation views
• B-4.02.06 transfer points from plan and elevation views to pattern, and add allowances for seams and edges
• B-4.02.07 connect points to finish pattern using layout tools
• B-4.02.08 mark braking lines and braking diagrams on pattern for future forming

Sub-task - B-4.03 Develops patterns using parallel line method.

Key Competencies

• B-4.03.01 visualize finished product in three dimensions
• B-4.03.02 develop views required for fitting such as plan view and elevation view
• B-4.03.03 divide plan and elevation into equal parts to achieve required accuracy
• B-4.03.04 calculate stretch-out
• B-4.03.05 divide stretch-out lengths into equal parts, spaced according to required accuracy, and corresponding to developed plan and elevation views
• B-4.03.06 connect points to finish pattern and add allowances for seams and edges
• B-4.03.07 mark braking lines and braking diagrams on pattern for future forming

Sub-task - B-4.04 Develops patterns using simple and straight line layout.

Key Competencies

• B-4.04.01 visualize finished product in three dimensions
• B-4.04.02 determine cut size of blank piece while allowing for seams and edges and to minimize waste
• B-4.04.03 mark and notch material to identify seams and bend marks
• B-4.04.04 mark braking lines and braking diagrams on pattern for future forming

Sub-task - B-4.05 Uses computer technology for pattern development.

Key Competencies

• B-4.05.01 visualize finished product in three dimensions
• B-4.05.02 select required product to be developed from computer database
• B-4.05.03 input dimensions into computer based on type and size of finished product
• B-4.05.04 select all joint and seam information from computer database based on finished product requirements
• B-4.05.05 label blank pieces with forming information such as layout of pieces, braking lines and seam allowances

Task 5 Fabricates sheet metal components for air and material handling systems.

Context

Fabrication of air and material handling systems is the process of producing finished ductwork or fittings from a flat pattern or sheet using various tools.

Required Knowledge

• K 1 components such as ductwork, fittings, flexible connectors, hanger systems, supports and bases
• K 2 properties of materials such as stainless steel, galvanized steel and aluminium
• K 3 building standards such as LEED
• K 4 thickness of materials such as insulation, gaskets and metal sheets
• K 5 bend allowances and notching
• K 6 joint and seam allowances
• K 7 forming techniques such as bending and rolling
• K 8 reinforcing techniques such as cross-braking, beading and stiffeners
• K 9 types of insulation such as rigid or flexible
• K 10 properties of insulation such as fibrous or non-fibrous, and acoustic or thermal
• K 11 pin placement
• K 12 fittings to assemble such as square-to-round, elbow and offset
• K 13 assembly techniques such as welding, spot welding and the use of Pittsburgh locks
• K 14 joints such as standing seams, slip and drives, and pre-engineered duct connectors
• K 15 hardware and fasteners such as solid rivets, pop rivets, screws, rods, nuts and bolts
• K 16 types of dampers such as opposed blade, parallel blade and butterfly
• K 17 types and properties of flexible connectors
• K 18 materials used for hanger systems such as brackets, saddles, channels, threaded rods, angle iron, flat bar and beam clamps
• K 19 load bearing capacity and specifications
• K 20 equipment supports and bases such as curbs and stands
• K 21 types, size and weight of air and material handling units
• K 22 epoxies and sealants

Sub-task - B-5.01 Cuts ductwork, fittings and flexible connectors.

Key Competencies

• B-5.01.01 select and use tools such as snips, shears, grinders, hack saws, cut -off saws and marking tools
• B-5.01.02 verify measurements for seam allowances and duct length
• B-5.01.03 create cut list based on drawing to minimize waste
• B-5.01.04 cut blanks according to cut list
• B-5.01.05 scribe allowances for horizontal and longitudinal seams
• B-5.01.06 notch pieces based on seam allowances and pattern
• B-5.01.07 mark braking lines and braking diagrams on pieces for future forming

Sub-task - B-5.02 Forms ductwork, fittings and flexible connectors.

Key Competencies

• B-5.02.01 examine braking diagrams to establish order of operations
• B-5.02.02 cross brake pieces as required to strengthen piece and eliminate vibration and noise
• B-5.02.03 select and use forming tools such as brakes, roll formers, rolls and stakes
• B-5.02.04 form longitudinal seams according to braking diagram or scribes
• B-5.02.05 form transverse seams according to braking diagram or scribes

Sub-task - B-5.03 Insulates ductwork and fittings.

Key Competencies

• B-5.03.01 select insulation thicknesses, properties and types according to specifications
• B-5.03.02 select fastening method such as adhesives and pins
• B-5.03.03 select and use tools and equipment such as knives, tape measure, straight edge and pin spotter
• B-5.03.04 measure and cut insulation according to type and thickness
• B-5.03.05 seal cut edges of insulation according to specifications
• B-5.03.06 apply insulation using selected fastening method
• B-5.03.07 apply perforated metal according to specifications using methods such as spot welding and using mechanical fasteners

Sub-task - B-5.04 Assembles ductwork, fittings and flexible connectors.

Key Competencies

• B-5.04.01 select and use tools and equipment such as hammers, setting tools and screwdrivers
• B-5.04.02 use welding equipment for assembly if required
• B-5.04.03 select and use fasteners such as pop rivets and spot welds
• B-5.04.04 select and use epoxies and sealants
• B-5.04.05 refer to labels and diagrams for order of assembly and orientation of pieces
• B-5.04.06 align pieces and fasten according to locks and seams
• B-5.04.07 install or form transverse joints as required
• B-5.04.08 fasten overlapping sections of flexible connectors using methods such as stapling and gluing

Sub-task - B-5.05 Fabricates dampers.

Key Competencies

• B-5.05.01 determine damper type required according to specifications
• B-5.05.02 measure and size damper according to application
• B-5.05.03 select and use tools and equipment such as drills, snips and screwdrivers
• B-5.05.04 select hardware required for damper such as quadrant arms, linkages and ball joints according to specifications
• B-5.05.05 cut and form damper blades and body
• B-5.05.06 assemble blades, hardware and body according to damper type
• B-5.05.07 verify damper operation to ensure correct orientation and blade movement

Sub-task - B-5.06 Fabricates hanger systems, supports and bases.

Key Competencies

• B-5.06.01 determine size and weight of equipment and materials to be supported according to specifications
• B-5.06.02 select materials and components based on isolation and seismic restraint requirements according to specifications
• B-5.06.03 select hangers for height, size and run of air or material handling systems according to insulation requirements, specifications and industry standards
• B-5.06.04 determine required number of hangers for specified length of air or material handling systems and spacing of hangers according to codes and specifications
• B-5.06.05 select and use tools and equipment such as tape measures, welding equipment, drills, snips, abrasive cut-off saws and hack saws
• B-5.06.06 determine location according to plans and specifications for required installation
• B-5.06.07 perform layout for hanger systems, supports and bases
• B-5.06.08 pre-drill holes for mounting hanger systems, supports and bases as required
• B-5.06.09 assemble components of hanger systems, supports and bases according to specifications and plans

Task 6 Fabricates flashing, roofing, sheeting and cladding.

Context

Flashing, roofing, sheeting and cladding are fabricated to provide protection and aesthetics to structures. Fabrication of flashing, roofing (and roofing drainage systems), sheeting and cladding is the process of producing finished products from a flat pattern or sheet using a variety of tools.

Required Knowledge

• K 1 types of seams such as standing, batten and lap
• K 2 joints such as S-joints, lap joints and standing joints
• K 3 types of materials such as copper, galvanized steel , pre-finished material, composite materials and aluminium
• K 4 expansion and contraction properties of materials
• K 5 types of flashing, roofing, sheeting and cladding
• K 6 bend allowances
• K 7 sealing and joining methods such as caulking and soldering
• K 8 drainage requirements
• K 9 environmental impact from weather conditions such as rain, snow and ice
• K 10 LEED standards and green roofing technologies

Sub-task - B-6.01 Cuts metal for flashing, roofing, sheeting and cladding.

Key Competencies

• B-6.01.01 select and use tools and equipment such as tape measures, snips and shears
• B-6.01.02 select seam type according to strength, aesthetics, type of material being used and specifications
• B-6.01.03 calculate and measure material, taking into account factors such as expansion, contraction, seams and bend allowances B-6.01.04 calculate size of area to be covered to determine material required and to minimize waste
• B-6.01.05 shear material to gross blank size (stretch-out)
• B-6.01.06 notch material according to selected seams
• B-6.01.07 mark brake lines and diagrams

Sub-task - B-6.02 Forms flashing, roofing, sheeting and cladding.

Key Competencies

• B-6.02.01 select and use tools and equipment such as brakes, rolls and stakes
• B-6.02.02 plan and follow order of operations for forming material
• B-6.02.03 mark braking lines and diagrams on pieces
• B-6.02.04 bend or roll material according to brake lines and diagrams
• B-6.02.05 select sealing and joining methods such as caulking and soldering

Task 7 Fabricates specialty products.

Context

This is the process of producing finished specialty products from designs. Specialty products may include kitchen equipment, medical facility products, food processing equipment, pharmaceutical laboratory products, decorative accessories and plastic products.

Required Knowledge

• K 1 types and thickness of materials such as stainless steel, copper, plastic, composite materials and aluminium
• K 2 bend and seam allowances
• K 3 types of finishes such as brushed, mirrored and dull
• K 4 specialty products such as canopies, sinks and polyvinyl chloride (PVC) fittings
• K 5 specialty product applications such as food preparation, corrosive environments and medical environments
• K 6 pattern development and basic specialty product design
• K 7 forming techniques such as bending, rolling and heat forming
• K 8 assembly techniques such as welding, spot welding and gluing
• K 9 fasteners such as solid rivets, pop rivets, bolts and screws
• K 10 handling procedures of materials such as stainless steel, copper, plastic, composite materials and aluminum

Sub-task - B-7.01 Cuts material for specialty products.

Key Competencies

• B-7.01.01 select materials and fabrication methods according to specifications
• B-7.01.02 select and use tools and equipment for cutting specific material such as plastic, PVC-coated and stainless steel
• B-7.01.03 calculate and measure material, taking into account factors such as expansion, contraction, seams and bend allowances
• B-7.01.04 shear or saw material according to manufacturers’ specifications
• B-7.01.05 notch material according to selected seams
• B-7.01.06 mark brake lines and diagrams

Sub-task - B-7.02 Forms specialty products.

Key Competencies

• B-7.02.01 select and use tools and equipment for forming specific material such as plastic, PVC-coated and stainless steel
• B-7.02.02 use specialized procedures for forming specialty products such as pre-heating material for bending and annealing to relieve stress
• B-7.02.03 plan and follow order of operations for forming materials
• B-7.02.04 bend or roll material according to brake lines and diagrams

Sub-task - B-7.03 Assembles specialty products.

Key Competencies

• B-7.03.01 select and use tools and equipment such as welding equipment, soldering irons and drills
• B-7.03.02 select and use fasteners according to material and specifications
• B-7.03.03 assemble product components according to plans and specifications

Sub-task - B-7.04 Finishes specialty products.

Key Competencies

• B-7.04.01 select and use tools and equipment such as buffers, grinders, files and chemical compounds
• B-7.04.02 finish product using methods such as grinding, filing and buffing to achieve surface finish according to specifications
• B-7.04.03 perform quality control for conditions such as sharp edges and overall appearance
• B-7.04.04 select and use sealants according to specifications