© commonwealth of australia 2015 -...

CPCPCM2050A – MARK OUT MATERIALS

© Australian National Training Authority 2004 – Version 1

ii

CONSTRUCTION, PLUMBING AND SERVICE

INTEGRATED FRAMEWORK

TRAINING PACKAGE

CPC08

CPCPCM2050A

MARK OUT MATERIALS

LEARNING GUIDE

CPCPCM2050A - MARK OUT MATERIALS


ACKNOWLEDGEMENTS

National Plumbing Services Training Advisory Group

Plumbing Industry Commission Victoria


Construction and Property Services Industry Skills Council PO Box 151 Belconnen ACT 2616 Tel: 02 6253 0002 www.cpsisc.com.au This work is copyright, but permission is given to trainers and teachers to make copies and contextualise the resources for use within their own training organisation or in a workplace where training is being conducted. This permission does not extend to making copies for use outside the immediate training environment for which they are made, or the making of copies for hire or resale to third parties.

This work was first published in 2004 with the assistance of funding provided by the Commonwealth Government through the Australian National Training Authority (ANTA). The 2015 publication has been updated to reflect changes to the national units of competency.

The views expressed in this work do not necessarily represent the views of the Commonwealth of Australia or CPSISC. In addition, the Commonwealth of Australia and CPSISC do not give warranty or accept any legal liability in relation to the content of this work.

The website addresses and other contact information provided in this publication were compiled in good faith and were correct at the time of printing. The updating of these resources was completed by:

National Plumbing and Services Training Advisory Group, with funding and support provided by the Construction and Property Services Industry Skills Council (CPSISC):

This guide was developed in consultation with representatives of the Plumbing Industry by NPSTAG and CPSISC to support the implementation of the CPC08 Construction, Plumbing and Services Training Package.


ii © Commonwealth of Australia 2015

Contents

What is this resource about? ................................................................................................ 1

How do I use this resource? ................................................................................................. 1

Flexible Delivery ................................................................................................................. 1

What do I have to do? .......................................................................................................... 1

Mark out materials ............................................................................................................... 2

Unit Descriptor .................................................................................................................... 2

Element ................................................................................................................................ 2

Performance Criteria ........................................................................................................... 2

Required knowledge ............................................................................................................ 4

How will I be assessed? ....................................................................................................... 4

Are there any prerequisites? ................................................................................................ 4

What other resources will I need? ....................................................................................... 5

Web sites ............................................................................................................................. 5

Video or audio cassettes ...................................................................................................... 5

Introduction ......................................................................................................................... 6

Standards, codes and symbols ............................................................................................. 6

Codes ................................................................................................................................... 6

Prepare for work .................................................................................................................. 6

WHS Requirements ............................................................................................................. 7

Quality assurance ................................................................................................................. 7

Prepared work area .............................................................................................................. 8

Determine equipment requirements ..................................................................................... 8

Mark out the job .................................................................................................................. 9

Checking for accuracy ......................................................................................................... 9

Relevant standards, codes and symbols are interpreted ....................................................... 9

Standards ............................................................................................................................. 9

Parallel line development .................................................................................................. 10

Triangulation ..................................................................................................................... 12



Triangulation development ................................................................................................ 34


© Commonwealth of Australia 2015 iii

Calculations are performed to determine job requirements .............................................. 40

Material is marked out in conformance with determined measurements .......................... 40

Dimensions are checked for accuracy and compliance to plans/specifications ................ 40

Clean up ............................................................................................................................ 41

Tools and equipment ......................................................................................................... 41

Documentation is completed in accordance with workplace requirements ...................... 42

Worksheet ......................................................................................................................... 43

Practical application .......................................................................................................... 50

Assessment checklist ......................................................................................................... 52



What is this resource about?

Welcome to CPCPCM2050A – Mark out materials. This resource will help you gain the skills and

knowledge necessary to demonstrate competence in this unit.

How do I use this resource?

This resource is divided into four main sections:

• A learning unit, which contains background information on marking out materials

• Worksheets, which prepare you for the practical application

• Practical application, which allows you to experience marking out materials

• Assessment materials, which help you demonstrate competency.

To complete this unit of competence you will need to:

• read the information contained in the learning unit

• complete the worksheets as instructed

• have your answers checked by your trainer or supervisor

• work with your trainer or supervisor to practise marking out materials

• read the assessment checklist together with the assessment sheets

• complete the assessment.

Learning Resources are not intended to be the only source of information nor are they intended to be

an exhaustive form of instruction.

Flexible Delivery

The Trainer or Supervisor may adapt and deliver this Learning Resource to suit people from diverse

backgrounds to meet equity principles and conform to Legislative policies.

What do I have to do?

To demonstrate competence in this unit you will be required to show the level of skills and knowledge

for each of the elements involved in CPCPCM2050A – Mark out materials:

• Prepare for work

• Determine equipment requirements

• Mark out job

• Clean up.

If you are unsure of the meaning of these elements you should read the performance criteria on the

following page.


2 © Commonwealth of Australia 2015

CPCPCM2050A Mark out materials

Unit Descriptor This unit of competency specifies the outcomes required to

mark out plumbing materials prior to fabricating piping,

steel sections, ducting and sheet materials, roofing and

cladding.

Element Performance Criteria Elements describe the

essential outcomes of a

unit of competency.

Performance criteria describe the performance needed to

demonstrate achievement of the element. Where bold

italicised text is used, further information is detailed in the

required skills and knowledge section and the range

statement. Assessment of performance is to be consistent

with the evidence guide.

1 Prepare for work 1.1 Plans and specifications are obtained from job

supervisor and job requirements are determined

1.2 Work health and safety (WHS) and environmental

requirements associated with marking out of materials

are adhered to throughout the work

1.3 Quality assurance requirements are identified and

adhered to according to workplace requirements

1.4 Tasks are planned and sequenced in conjunction with

others involved in or affected by the work

1.5 Tools and equipment, including personal protective

equipment (PPE), are selected and checked for

serviceability

1.6 Work area is prepared to support efficient marking out

of materials

2 Determine job

requirements 2.1 Selected materials are checked for compliance with

plans and specifications

2.2 Quantity and type of material required are calculated

from plans and specifications

2.3 Job requirements and development methods are

determined from plans and specifications


© Commonwealth of Australia 2015 3

3 Mark out job 3.1 Dimensions for fabrication and assembly are determined

and transferred

3.2 Relevant standards, codes and symbols are interpreted

3.3 Selected development method is applied as appropriate and

according to workplace procedures and sustainability

principles and concepts

3.4 Calculations are performed to specified job requirements

3.5 Material is marked out in compliance with specified

measurements

3.6 Dimensions are checked for accuracy and compliance with

plans and specifications

4 Clean up 4.1 Work area is cleared and materials disposed of, reused or

recycled according to legislation, regulation, codes of

practice and job specification

4.2 Tools and equipment are cleaned, checked, maintained and

stored according to manufacturer recommendations and

workplace procedures

4.3 Information is accessed and documentation completed

according to workplace requirements

Required knowledge Required knowledge for this unit is:

• identification and correct use of measuring and marking out

equipment

• impact of accurate marking out on fabrication process, work

time and finished work quality

• job safety analysis (JSA) and safe work method statements

(SWMS)

• operation requirements of equipment used for measuring and

calculating

• processes of marking out plumbing materials

• relevant WHS regulations and PPE requirements

• SI system of measurement

• sources of information on characteristics and applications of

materials being marked out

• workplace operating procedures, including required standards

for marking out.

An up to date version of the ‘Unit Descriptor’ may be located on the Australian Government web site

training.gov.au

http://training.gov.au/Search/Training?searchTitleOrCode=&nrtSearchSubmit=Search&includeSupers

ededData=true&includeSupersededData=false&homePage=true&javaScriptEnabled=true&typeAllTra

iningComponents=true



How will I be assessed?

Your trainer will decide with you how you will be assessed. Your assessment activity may include

completion of the student worksheet and practical task selected by your trainer. Your assessment

should allow you to demonstrate all the skills and knowledge required to mark out materials.

This unit may be assessed in conjunction with other units of competence. Your trainer will tell you if

you are to be assessed this way.

Are there any pre-requisites?

Prior to commencing CPCPCM2050A – Mark out materials you must have successfully completed the

following pre-requisite:

• CPCPCM2043A – Carry out WHS requirements

It is also recommended that prior to commencing CPCPCM2050A – Mark out materials you should

have successfully completed the following competencies:

• Nil.

Project work may also group pre-requisite and or co-requisite competencies together to carry out such

projects. It is recommended that the following competencies are grouped with this unit of competency:

• Nil.



What other resources will I need?

To assist you the following resources have been suggested and should be available to you to do this

competency.

Texts

• Standards Australia. 1985, AS1100.301 – 1985 Technical Drawing – Architectural Drawing.

• Standards Australia. 1984, AS1101 – Part 5 – 1984 Graphical Symbols for General

Engineering – Piping, Ducting and Mechanical Services for Buildings.

• Standards Australia AS/NZS3500.3 Stormwater Drainage.

Web sites

Video or audio cassettes



Introduction

In this unit you will look at marking out materials prior to fabrication of piping, steel sections, ducting

(sheet materials), roofing and cladding. Marking out means the preparation of materials for cutting,

drilling, folding and forming as the initial part of a fabrication process. Measuring and marking out is

one of the important processes involved in all fields of plumbing. Not paying attention to detail at this

stage is the major reason for the need to purchase replacement materials. It is therefore important to

‘measure twice and cut once’. Marking out has applications in plumbing for the following.

Standards, codes and symbols

Before you can begin planning you need to be aware of the relevant standards, codes and symbols on

the job plan or specification and how to correctly interpret them.

Codes

The Australian Standards outlined below are National Codes for Plumbing and Gasfitting.

There is an Australian Standard for graphical symbols in general engineering (AS1101). Part 5

provides information on piping, ducting and mechanical services for buildings.

Australian Standards have been drafter for steel pipe (AS1579) and copper tube (AS1432).

Prepare for work

Plan and specification are obtained

To mark out materials safely and effectively you will need to plan your work activities. This could

include information from plans or specifications, quality assurance requirements and workplace health

and safety requirements (WHS).

Part of planning requires you to plan the task considering how the task you are about to do affects

others. You should plan the task with the others involved or affected by the work. Your company may

have procedures regarding this that you will need to take into account.

A second consideration is the personnel who work in factories or at your depot to make components

for your project. You need to inform these personnel of dates when drawings will be forwarded to

them, and expected dates when these components are due for delivery on site. You should also provide

information to the manager for the major contractor outlining these delivery dates, so that this can be

included the Gantt chart to help monitor the progress of the building construction.



O H & S Requirements

Revision of BCM2003A carry out WHS requirements before commencing this unit is advisable.

Workplace health and safety (WHS) requirements need to be observed in accordance with legislation.

You need to be aware of the WHS laws governing your job. Your trainer or supervisor can provide

you with this documentation

Workplace health and safety requirements are to be in accordance with state or territory legislation and

in some cases may require work notices to be submitted. These may include:

• Wearing of personal protective equipment (PPE) and clothing

• Use of tools and equipment

• Workplace environment and safety

• Handling of materials

• Handling of hazardous materials

• Hazard control.

Personal protective equipment

In any work situation you can reduce the risk of injury to yourself and others by using appropriate

personal protective equipment (PPE). The types of PPE that you will need when carrying out the

clearing of blockages includes the following:

• Overall

• Safety boots

• Gloves

• Safety glasses or goggles

• Ear plugs or muffs

• Dust masks or respirators

• Hard hats

Quality assurance

Most companies have a policy for assuring quality to the customer. You must be aware of the

following issues and how they relate to your task.

• Workplace operations and procedures.

• Quality of material.

• Control of handling procedures.

• Use and maintenance of equipment.

• Attention to specifications.



Plan and sequence task

When marking out materials it is important to plan and sequence tasks so as to save time, resources

and materials. You need to consider how best to achieve this for each job. It may be best, for one job

to use triangulation whilst for another parallel line is suited.

Your trainer or supervisor will discuss this with you.

Selected tools and equipment

The tools and equipment you are likely to use include the following:

• Tape measure

• Engineer’s (ball peen) hammers

• Large tri-squares

• Adjustable bevels

• Dividers

• Protractors

• Scribers

• Plumb bobs

Prepared work area

In preparing the work area the required tools and aides need to be placed or kept within an easily

assessable position so as to allow the design to take place without unnecessary delays.

Determine equipment requirements

Materials selected and checked for compliance

To Mark out materials for fabrication you will need to understand the dimensions and other

specifications of the job from the plans and specifications. The job plans or specifications will give

you information about the required measurements for the pipework, ducting and plant required to

complete the job. If the plans or specifications are not clear on these matters, you will need to consult

with others about the requirements.

Calculations quantity and type of materials

In order that you can successfully complete the marking out exercises you will be required to have a

knowledge and understanding of the following calculations:

• Radius or diameters

• Circumferences

• Simple Multiplication and addition

• Basic Geometry



Mark out the job

Now that the planning stage has been completed you can start the marking out. Before you start the

actual task it is worth checking your measurements. This is done so that you can be sure there are no

errors and so the job goes as planned.

Dimensions for fabrication and assembly are determined and transferred

It is important that the plumber can accurately read plans, drawings and specifications, calculate

dimensions and accurately transfer these dimensions from plans to practical worksite or workshop

situations. As an example from a house plan the plumber can calculate the materials required for a

specific job, and accurately install all fixtures and services.

In the case of a Roofing project the plumber can calculate from a dimensioned drawing all materials

required ie gutters, downpipes and roof sheeting, which can then be accurately transferred to the

practical project.

In basic marking out the same principles apply, from a plan or drawing dimensions can be calculated

and transferred for practical applications.

CHECKING FOR ACCURACY

Always check your working out for accuracy before drilling, cutting etc.

Relevant standards, codes and symbols are interpreted

In all plumbing applications an understanding and awareness of standards, codes and symbols is an

important factor. Before commencing a marking out exercise these factors may need to be given some

consideration.

Listed below are the Relevant Standards, Codes and Symbols.

Codes

The Australian Standards outlined below are National Codes for Plumbing and Gasfitting.

Standards

There is a National Plumbing Code covering the installation of both cold and hot water reticulation

systems.

The Australian Standard AS/NZS3500 outlines installation practices for the installation of sanitary

plumbing, drainage, rainwater goods and roof plumbing practices.

An Australian Standard (AS/NZS5601 Gas Installations) outlines the installation practices for

gasfitting.

The Australian Standard AS/NZS1596 outlines the requirements for the storage and handling of

liquefied petroleum gas.

There is an Australian Standard for graphical symbols in general engineering (AS1101). Part 5

provides information on piping, ducting and mechanical services for buildings.

Australian Standards have been drafted for steel pipe (AS/NZS1579) and copper tube (AS1432)



Symbols

The Australian Standard (AS1100.301 – 1985 Technical Drawing – Architectural Drawing), describes

what symbols are used to indicate relevant features (bath, basin etc) on drawings prepared for general

or communication purposes when drawing to scale is impracticable.

Symbols are used on architectural plans to inform the plumber of the fixture or appliance to be

installed at that point. Symbols are small diagrammatic drawings that provide information to the

plumber. They are used to simplify a drawing by reducing the amount of writing.

Selected development method is determined as appropriate and is applied in accordance with workplace procedures.

There are three specific development methods. Each method is used to develop an accurate pattern so

that when it is formed it represents the true shape of the article.

They are:

Parallel line development

Parallel line development is used to construct articles such as cylinders which have been cut off at

various angles such as downpipes branch pipes of various diameters entering main pipes at different

angles.




Radial line development

Radial line development is used to develop right angle shapes such as flue caps, funnels and

round pipe reducers and enlargers.

Radial line development



Triangulation

Similar to both radial line and parallel line, however it is the only method which can develop irregular

shapes. It can be used to develop square to round articles and would be used to develop patterns for

articles such as rain heads and sumps.

There are cases in which more than one method can be used to develop patterns for specific articles,

your choice of method can depend upon factors such as ease of manufacture, line restraints and

appearance of the finished article, for further information on these development methods read the

following pages.

Triangulation development method

There are cases in which more than one method can be used to develop patterns for specific articles.

Your choice of method can depend upon factors such as ease of manufacture, line restraints and

appearance of the finished article, for further information on application of these development

methods follow.




Cylinder cut at 45 degrees

Step 1: Place a sheet of A3 drawing paper in the clamp on the drawing board. Check that the paper is

placed in the board squarely by lining up the top of the title block with the T Square or slide. Adjust

until paper is square.

Step 2: On the bottom left hand side of the paper place two centre lines lightly (using 2H pencil).

Allow enough space to draw a circle at the specified radius plus 15mm on the left and bottom sides.

Step 3: Now draw the bottom view of the article at the specified radius. NOTE: the radius is half the

diameter of the circle which is measured by a straight line passing through the centre point.

Front and base view of cylinder cut at 45º angle

Step 4: Draw the front view of the cylinder approx 20mm above the bottom view.

NOTE: If the lines are projected up off the bottom view the front view will be the same size as the

bottom view.

Step 5: It is now necessary to layout the pattern for the rectangular stretch-out of the cylinder, by

calculating the circumference of the cylinder.



Unrolling of a cylindrical article

To develop a pattern out of the sheetmetal it will depending on the nature of the work and the

tolerances, be necessary to calculate the circumference using centre lines or neutral axis diameters. It

is not the aim of the text to enter into these exacting calculations. We will however, calculate

circumferences using the following formula:

Formula: Circumference (c) = ππππ D

Where (c) = circumference

And ππππ = 3.142

And D = the diameter of the cylinder

So the circumference of the cylinder becomes the length or stretch out and the height of the cylinder

becomes the height of pattern or stretch out.

Further developments are now required to give the shape of the cylinder where it is cut off at 45

degrees.

Step 6. Divide the bottom view of the cylinder into 12 equal parts by using either the 30º – 60º angles

on the protractor head or by using the distance of the radius which is equal to an angle of 60º when

stepped around the bottom view.



Division of base view into 12 equal parts

Step 7. In this stage we will number the points around the bottom view. The starting point is at the

seam which is placed on the shortest side of the cylinder. It is numbered by S at the seam, the next

point is 1, and working around the view until 6 is reached. At this point the number goes in reverse

back to S, as both sides of the base view are identical.

Front and base view showing all divisions

Step 8: Once all of the points have been numbered, project the points off the bottom view onto the top

view. This then indicates on the top view the length of the side when the article is divided, into 12

equal parts. Before progressing any further number the points on the bottom of the top view from S –

6 and on the top of the truncated or cut off cylinder it should be numbered S’, 1’ through to 6’, this

will enable identification of points on the top and on the bottom.



Step 9: The cylinder pattern now has to be divided up into 12 equal parts, just like the bottom view of

the cylinder. The method to do this varies from one tradesperson to the next.

The method described below is one of many. It is a method which can be used within the classroom

or the workshop. This method uses the compass to find the centre line and then it is repeated to find

the centre line of the half section.

The circumference has then been divided into 4 equal parts, it is then necessary to divide each of these

quarter spaces into three equal parts, this giving twelve equal parts. To divide this space into three

equal parts it is necessary to step off a distance (usually the distance from S to 1) this distance is

adjusted (by trial and error) until the distance steps off three times equally.

Step 10. Number all the points from S to 6 and then back to S. Project the points up to the top of the

rectangular pattern. Note that figure S occurs twice as it is the seam.

Division of pattern into 12 equal parts

Step 11. Develop the pattern out by stepping off the distance from S to S’ (from the front view) with a

compass. Then place the compass point on S (on the pattern) and transfer the distance to the line. The

same measurement can be used on the other end at S. This then gives point S’.

Then measure the distance from 1 to 1’ on the front view and transfer this distance onto the pattern.

Continue this process until all the points have been transferred. Number all of these points with the

corresponding number.

Step 12. Complete the pattern by joining the points with a smooth freehand curve or by a flexi curves

French curves. Darken in all outlines.



Completed pattern development

This step by step procedure will be referred to as various patterns are developed. Most parallel line

development uses these basic procedures; it is just the shape of truncated section which changes.

90 DEGREE ELBOW (including allowances).

The pattern for this although it is developed the same as the previous development the placement of

allowances makes this development an important exercise. In this development two types of

allowances have to be allowed for, one being the grooved seam for joining the circumference together

and the other being the joint line allowance on each section so that the two cylinders can be joined

together.

Degree elbow

There are two patterns which have to be developed for this elbow a part “A” and a part “B”, in the

development stage both patterns are identical and can be developed from the one part front view. It is

not necessary for this development to draw a full bottom view as semi-circle (half circle) is sufficient

as both parts of the circle are identical. It is also not necessary to draw a full front view of the elbow

as the joint line of the article is the same angle and shape for part A and B.




Step 1: Proceed to draw the front view and a half base view. Divide the half base view (semi-circle) in

6 equal parts and project these points up and onto the front view and number these points.

Front and base view

Step 2. Calculate the circumference, (formula: circumference = ππππ x d) and draw a line equal to this

length.

Step 3. Divide this line into twelve equal parts and project the 12 equally spaced lines high enough so

that 2 patterns can be drawn, number the points S to 6 to S.

Step 4. Measure the distance from S to S’ on the front view with a pair of dividers and transfer this

distance to the pattern. This length can be used four times if the length is taken from top and bottom

lines to form a pattern starting from the top and another from the bottom. Continue this until all the

points have been transferred from the front view. Join all of these points so that the two basic patterns

are formed.



Basic elbow patterns no allowances added

Step 5. Allowances for joining the two cylindrical pipes together must be placed on the patterns so

that the water or fluid flowing through the pipe does not become obstructed. A 3mm allowance is

placed on pattern A in two places at S′, this allowance then gradually tapers off completely at points

4′. This allows the edge to be dressed on the inside when joining parts A and B together. The grooved

seam allowance can then be calculated using the groove seam formula (3 times the size of the fold + 6

times the metal thickness) and half this allowance is added to each side of the pattern. Note the 30º

angle and the notch on the pattern, this allows the 3mm lap to clear the grooved seam when it is

dressed over.

Basic patterns showing grooved seam and notching allowance

Step 6. On pattern “B” place the same size allowance for the grooved seam as that on pattern “A”.

The allowance for the joining of part A to B is the same, however, it is placed on point 6′ (3mm high)

and gradually tapers off to nothing at point 2′ as shown. By allowing pattern A to go to 4′ and pattern

B to go to 2′ it allows a lap at 3′.



Part B pattern with allowances

Completed 90º elbow patterns

90º Branch pipe equal diameter

In this development no allowances will be added to the completed pattern. In this development the

pattern for the branch pipe and the opening in the main pipe will be developed.

Step 1: Draw the left side view of the development in the top left hand corner of the page, it will be

noted that a half a left side view is sufficient, however a full left side view will be drawn with a semi

circle on the top to represent the half top shape of the branch pipe.

Step 2: Draw the front view from the left side view projecting lines across with the T square or slide,

draw the half top view of the branch pipe on the top of the branch pipe.

90 degree branch pipe front and left side views



Step 3: Divide the half top view into 6 equal parts and number these points. Note: the seam is on the

shortest side. On the left side view project the points down until they touch the main branch pipe,

number these points with a dash. Now divide the half top view (on front view) into 6 equal parts and

project these lines down, it is now necessary to project the points S′ to 6′ across until they intersect the

lines as projected down. These points now form the joint line to the two pipes. It should be a straight

line to point 3”. Number these points with a double dash.

Detailed front and left side view

Step 4: Calculate the circumference for the branch pipe, draw a base line and divide it into 12 equal

parts. Project these points the height of the branch pipe.

Step 5: Transfer the distances from the front view onto the pattern as in the previous examples, the

pattern is completed by joining the points with a curved line and by numbering all points.

Branch pipe pattern

Step 6. The pattern for the opening in the main pipe is the next development. In order to do this it is

necessary to calculate the blank size for the main pipe (Circumference by Height).

As the seam is on the opposite side to the opening it is necessary to draw a centre line on the

rectangular pattern. From this line we can now step out the measured distances off the left side view,

either side of this line.



The first distance is taken from S′, 6′ to 1′, 5′ off the left side view, and transferred either side of the

centre line on the pattern.

The next distance is that of 1′, 5′ to 2′, 4′ and this distance is stepped off from the previous marks.

The last distance is from 2′, 4′ to 3′ this distance is then stepped off from the previous marks. Draw

these lines across the pattern and number these lines.

Note: in this development the distance from S′ to 1′ is the same for all points, to avoid confusion in

future developments the above procedure should always be used.

Step 7. Off the front view transfer the distance from the left hand edge to point S′, place this distance

on line S’, (on the main pipe pattern). This has now given the distance from the left hand edge of the

pipe to the opening at point S′. Do the same for 1′ and place this distance on line 1′, continue this

process until all the points are transferred onto the pattern, and draw in the shape of the opening.

Number all the points.

Completed 90º branch and main pipe patterns

45 Degree branch pipe unequal diameter

In this development the branch pipe is smaller in diameter than the main branch pipe and it enters the

main pipe at a 45 degree angle.

Step 1. Draw the left side view with the half top view above it. The branch pipe can be any height on

the left side view because the actual opening should be drawn as an oblique shape.

Step 2. Draw the front view with the branch pipe at an angle of 45 degrees with a half end shape above

it, now divide all the half top view sections into six equal parts as in the previous developments and

number these points.



Step 3. Project points S through 6 on the half end shape on left side view down until they intersect the

main branch pipe. Project these points across to the front view. Now project the points from the half

end shape on the front view down until the lines intersect the corresponding lines from the left side

view, now draw in the curved joint line.

Step 4. Develop the pattern for the branch pipe by calculating the circumference and drawing a base

line equal to this length. Then divide the base line into 12 equal parts and project these points to the

height of the branch pipe. Number these points S to 6.

Step 5. Transfer the distances off the front view branch pipe onto the pattern and draw in the shape of

the pattern. Number all points on the pattern.

45º branch pipe pattern developed from front and left side views

Step 6. Calculate the circumference for the main pipe and lay out the rectangular pattern. It is now

necessary to find the centre of the pattern and draw a line across the pattern. This is the centre line of

the opening. The next stage is to take the distance from the left side view from S′, 6′ to 1′, 5′ and step

this distance off either side of the centre line.

Then do the same for points 1′, 5′ to 2′, 4′ and from 2′, 4′ to point 3′. These distances are all different

as this is where the small pipe intersects the main pipe.

The next stage is to measure the distance from the left hand edge of the main pipe on the front view to

point S′ and place this distance on the centre line on the pattern. Now proceed to do the same for

points 1′ to 6′, then join all the joints with a line to form the shape of the opening. This shows the

completed shape of the opening.

The distance around the opening should be the same as the distance around the curved part of the

branch pipe pattern. The pattern is now complete except for the allowances for the Grooved Seam and

for joining the two pipes together.



Completed 45º branch and main pipe patterns



Lobster back bend

This development allows cylindrical pipes to change direction gradually, by placing segments or leafs

in the bend. The greater number of segments the smoother the curve, the least number of segments the

sharper the bend. For this development we will use 3 full segments and two half segments which are

on each end of the bend.

Step 1. Draw a 90 degree angle large enough to accommodate the outside radius of the bend.

Step 2. Draw the inside (throat) and outside (heel) radius of the bend from point X.

Step 3. Draw a half base view below the bend radius and to divide the half base view into 6 equal

parts. Number these points S, 1 to 6.

Step 4. Determine the number of segments required. For this bend there are 3 full segments and 2 half

segments. Using a compass bisect the heel into an angle of 45º and draw a line to point X. From this

line bisect the 45 º angle; this gives an angle of 22.5 º which is the centre line of pattern B. Draw a

line to point X.

Step 5. Bisect the two angles just found, this has now formed the joint lines of the segments. See Fig.

31.

Step 6. Project the points S to 6 on the half base view up until they reach the first joint line. This has

formed the first half segment A, there are two half segments to each full segment. Number these

points before moving on the next step.

Formation of lobster back bends half segment



Step 7. Place the compass point on point X and place the lead on point S′, then swing an arc so that it

bisects the next joint line, this point now becomes point S”. Join these two points with a straight line;

it should pass through the throat radius and the centre line of the section where they intersect.

Step 8. Continue the above procedure for points 1′ through to 6′. Number all the new points with a

double dash. This now completes the full segment of B.

Formation of lobster back bends half and full segments

Step 9. Calculate the circumference for the pipe and draw a base line at the calculated length. It is now

necessary to divide this line into 12 equal parts and project these points up the height of the first

section.

Step 10. Transfer the distances from S to S′ onto the pattern, then transfer the points 1, 1′ to 6, 6′ on to

the pattern and join all the points together to form the outline of the half segment A pattern.



Pattern for half segment

Step 11. Although it is not always necessary to develop a full segment, a half segment can be reversed

and traced around to give a full segment, this text will develop, the full segment to show the

procedure. To develop the pattern it is necessary to have a line the length of the circumference

divided into twelve equal parts which has been numbered S to 6 to S. This line becomes the centre

line of segment B.

After dividing the line into the twelve equal parts it is necessary to project the lined either side of the

centre line.

The next step is to take the distance from the centre line of the full segment B to point S′ then check it

by measuring to point S”. Place this distance on the pattern centre line (sometimes called a datum line)

and swing an arc either side from point S.

Proceed to do this for all the other points, and draw a freehand curve connecting all the points.

You will notice that the pattern is a mirror image on both sides of the centre line.

Completed pattern development for 90º lobster back bend



RADIAL LINE DEVELOPMENT

Introduction

Radial line development is used to develop patterns for right cone frustums. It is extensively used

throughout the sheetmetal industry for flue caps, funnels and round pipe reducers or enlargers.

In radial line development, the same general procedures are followed as those used in parallel line

development, except that since the slanting lines of a right cone do not always appear in their true

length in orthogonal views, certain procedures must be followed in order to develop these lengths.

To find the true length of the side, the right cone needs to be rotated around the axis point to give the

article its true length (sometimes called its slant height), on the side of the right cone. The true length

of the side is then the distance from the apex to the given point on the side of the right cone or cone

frustum.

RIGHT CONE DEVELOPMENT

This development is used to produce patterns for various conical articles, the most common being the

flue cap.

Step 1 Draw the full shape of the base view which is circular in shape. Draw this shape in the bottom

left hand side of the paper.

Step 2: From a centre line draw a base line for the front view and measure off the height and width of

the front view. Now draw in the sides to form the apex point.

Step 3: Divide the base view into 12 equal parts each at 30º and number these points S to 6 and back to

S. Refer to Fig. 35. At this point you should notice that, half a base view would have been sufficient as

one side is a mirror image of the other side.

Step 4: Project points S to 6 up at right angles to the base line of the front view, this is where the

points on the base view are on the front view. Number theses points S through 6 and draw lines from

these points up to the apex point.

Step 5: The pattern for the right cone is developed by placing the point of the compass on the apex and

lead on S. This forms the true length (slant height) of the right cone, notice that it is longer than the

original height. Place the compass point on an apex point (on the pattern) and swing an arc, then draw

a line from the apex point to arc, this line is the distance from the apex point to S.



Starting a right cone pattern

Step 6: The pattern is completed by measuring the distance from S to 1 off the base view (this setting

must be checked by stepping off around the base view 12 times and re-adjusting this setting until it

steps off exactly 12 times) this distance is then stepped off around the arc 12 times. As we divided the

arc on the pattern into 12 equal parts, we must divide the arc on the pattern into 12 equal spaces. This

distance or circumference can also be calculated mathematically using the formula pi times diameter.

Once completed it is necessary to draw in lines from these points to the apex point. Number all points

to ensure that 12 equal spaces exist.

Completed right cone pattern



Cone Frustum

The cone frustum is a right cone that has been cut off, on either the bottom or the top of the cone.

There are many different types of cone frustums which can be developed out using this method, in this

text we will concentrate on two, firstly a straight cut on the top of a right cone and secondly an oblique

cut on the base of a right cone.

Step 1: Draw a half bottom view, and divide the semi-circle up into six equal parts, these points should

be numbered from S at the seam and then to 6 as in Fig. 37.

Step 2: Draw the centre line for the front view. The overall diameter can be projected up off the half

base view. At the height specified, draw a line parallel to the base line, and measure the top diameter

(or radius from the centre out each side). Now draw in a line from the base line through the top

diameter until it reaches the centre line, do the same for the other side. At this stage the two lines

should have met on the centre line to form the apex point. See Fig. 37.

Note: It is not essential on this front view to draw in the radial lines as sufficient detail to develop the

pattern already exists.



Cone frustum front and half base views

Step 3: The pattern is developed by adjusting the compass so that the distance is measured from the

apex to the base of the cone. This height is the slant height or true length of the side of the cone. Once

measured place the compass point on a point where the pattern is to be drawn from, and then swing an

arc.

Step 4: Draw a line from the apex point to the arc; this is the starting point for the pattern. The next

stage is to either calculate the circumference mathematically and measure out the pattern or to take the

distance from S to 1 and check that this distance can be stepped off six times exactly, if it doesn’t re-

adjust the compass until it does.

Step 5: With this distance, step off around the arc 12 times. Join the last point up to the apex with a

straight line, number these points S to 6 and then back to S. There is no need to draw all points back to

the apex on this pattern as there is sufficient detail here to enable the article to be made.

Initial pattern formation



Step 6: Complete the pattern by drawing in the shape of the cut off piece; this is achieved by placing

the compass point on the apex and placing the lead on the cut off point on the slant height or true

length line. This distance is then placed on the apex point on the pattern and an arc is swung. Refer to

Fig. 39. The shape is now that of the completed pattern and requires allowances to be added, before

the article is cut out and manufactured.

Completed cone frustum pattern

30º OBLIQUE CONE FRUSTUM

Step 1: Draw a half base view which is divided into six equal parts, and draw the front view which is

cut off at an angle of 30º .

Step 2: To develop this pattern it will be necessary to draw in all radial lines, these are projected off

the half base view, until they reach the base line of the cone. Radial lines are now drawn from the base

line up to the apex point.

Step 3: Where the radial lines intersect the 30º cut it is necessary to project these points across to the

edge or true length line. These lines must be parallel to the base line of the cone. On the edge of the

cone number these points S′, 1′ through to 6′. The distance from the apex to these points is now the

true length of the radial lines on the side.



Detailed 30º oblique cone frustum pattern

Step 4: To develop the pattern take the distance from the apex to point 6′, and place this distance on

the apex point for the pattern and swing the arc. Now draw in the line from the apex point to the arc.

From this point it is necessary to step off the distance from S to 1 off the half base view (check the

distance), this distance has to be stepped off 12 times around the arc. Join the last point to the arc or

circumference back to the apex point, these points should be numbered S to 6 and back to S.

Step 5: Take the distance from the apex point on the front view to point S′ and place this distance on

the apex point on the pattern. On line S (each side) place an arc, this has now formed point S′ on the

pattern, do the same to find point 1′. Continue this procedure until all points have been transferred

across. Join all the points with a free hand curve; this now forms the base line of the pattern.

Step 6: Measure the distance from the apex to the cut off line along its true length and transfer this

across to the pattern. Once this is achieved the pattern is now ready for the placement of allowances

and cutting out.

Completed pattern for 30º oblique cone frustum pattern



TRIANGULATION DEVELOPMENT

INTRODUCTION

Triangulation is a slower and more complex method of development than parallel line or radial line

development, but it more practical for many types of objects. Also it is the only method by which

irregular shapes may be developed. The general use for this development is round to square or

rectangular articles; it may also be used for conical articles where there is a minimal taper.

In the development by triangulation, the article is divided into a series as in radial development.

However there is no single apex for the triangles. The technique is one of finding the true length of

varying oblique lines; this is affected by drawing a true length diagram.

Square to round

The first article to be developed is the square to round with the round opening located centrally.

Step 1: Start by drawing the base view which comprises of a square, with a circle centrally located

within it on the left hand side of the drawing sheet.

Step 2: Draw the front view directly above the base view by projecting the points up from the top

view.

Front and top views of the square to round transition

Step 3: Divide the circle up into twelve equal parts, each of 30º, number these points starting with S in

the centre of one side and continue numbering all points until 6 is reached. On the other side number it

back to S. The points around the square also require identification; this is achieved by placing letters

around the square base, starting with A which is opposite to S. By working back around the square,

place the letters B, and C, on the two corners and letter D should be in the centre opposite 6.



Step 4: Join points D and 6 with a straight line, also join point C with points 6, 5, 4 and 3. This has

formed triangles; now join points 3, 2, 1 and S with point B to form another series of triangles. Join

point S to point A, this has completed half of the base view, complete the rest by drawing in the

appropriate lines. It can be noticed from the base view a half or quarter view would have sufficient.

Detailed front and top views of the square to round transition

Step 5: Draw a true length diagram which is the height of the article. This true length diagram enables

various lines on the base view to be compared with their vertical height to obtain the true length, for

example a ladder that has to reach up a wall 2 meters has to be longer as the ladder has to be on a

slant, if the ladder has to be 1.5 meters off the wall at the base, then the minimum length of the ladder

would have to be 2.5m. This can be calculated mathematically or by drawing down the vertical and

horizontal distances and measuring the distance between the two points, this is the purpose of the true

length diagram.

Step 6: To start the pattern, draw a line in the centre of the right hand side of the paper horizontally

and draw another line at 90º to the first line. The point at which the two lines intersect is point D.

Step 7: Measure the distance from D to C and to transfer this distance to the pattern on either side of

point D at this point is the half way point of the article. This length when taken off the base view is

true length. The distance around the outside of the square is its actual length, and doesn’t require

triangulating.

Step 8: Find the distance from point C to point 6. This can be achieved by measuring the distance from

C to 6 on the base view, this length is not true length so it needs to be triangulated, that is achieved by

placing the measured length on the base line of the true length diagram to the point on the base line,

number this point C-6. This process has found the true length or clant height between these two points.

Now place the compass point on C on the pattern and swing an arc so that it will intersect with the arc

that is drawn from the other point C, this new point is point 6. It should bisect the first line drawn on

the page, join points C and 6 with straight line.



Starting the square to round pattern

Step 9: Locate point 5 on the pattern, this is achieved by measuring the distance C to 5 off the base

view and transferring this distance onto the true length diagram, number this point C-5. By measuring

the true length or slant height off the true length diagram and placing the compass point on C. Along

this arc will be point 5, the distance from 6 to 5 will be the same distance as that on the base view. The

distance around the circular part of the base view, is true length it doesn’t require triangulating. Place a

line from point C to 5.

Locating point 5 on the pattern

If two compasses are used the distance from 6 to 5 can be set on one and left. This will ensure that this

distance remains constant as it will be used 12 times.

Step 10: Measure the distance from C to 4, place it on the true length diagram and step off the true

length of C-4, then swing an arc on the pattern from point C. On this article, this distance is the same

as C to 5. To find where point 4 is on the arc use the pre set compass (distance 6-5) and swing the arc,

the point where the two arcs intersect is point 4. Repeat the above procedure to find point 3. Join these

points back to C.



Locating points 3 and 4

Step 11: Point B is the next point of the triangle C-3-B to be located. Measure the distance off the base

view from C to B (this is true length) and swing an arc from point C, then find the true length of the

line 3 to B, by measuring the distance off the front view and triangulating this length. Then place the

compass point on 3 and swing an arc, the point of intersection is point B. The length of line 3-B

should be the same as 3-C for this article. Join points 3 to B with a line.

Locating point B on the pattern

Step 12: Repeat the procedure used in step 11 to find the following points B to 2, B to 1 and B to S.

This now leaves one point left to locate which is point A. To find this point triangulate the length from

point A to S off the base view, then swing an arc from point S. To find point A measure the length

*which is true length) from B to A, and place the compass on point B, then swing the arc until it

intersects the previous arc which will give point A. Join points as previously done with a straight line.

Step 13: Complete this pattern by drawing a free hand curve between points S to 6 to S, then joining

all other points with a straight line, also draw in the required fold lines. A way of checking the patterns

accuracy is to check that the last corner of the pattern (A-S-B) has a 90º corner, if not it will be

necessary to work back over the pattern to find any mistakes.



Completed Square to round pattern

Round to square transition

This development is similar to the first transition, except that the circular end is larger than the square

end; the same principles apply when drawing the front and base views, a true length diagram is

required. The pattern will differ in the respect that the curved section will form around the outside of

the pattern with the straight line squared section on the inside.

Step 1: Draw half base view, (a full view is not required as the half view gives sufficient detail to

develop the pattern) and then divide the semi circular base into six equal parts. Number these points S

to 6 and those on the square A, B, C, and D. Once numbered join points S, 1, 2, and 3 with B, and

points 3, 4, 5, and 6 to point C.

Round to square front and top views



Step 2: Draw the front view with a true length diagram beside it.

Step 3: Start the pattern by drawing a centre line on the paper and drawing a vertical line at 90º to the

centre line. The intersection is point D, see Fig. 50. From the front view take the length of line D to C

which is true length and step off this distance on the pattern either side of point D to give point C.

Step 4: Measure the distance of C to 6 and place this length on the true length diagram. By measuring

the distance from the top of the true length diagram to the point on the base line, the true length of the

line C to 6 is found. From points C on the pattern swing an arc so that the two arcs intersect, this point

becomes point 6, join and number these points.

Step 5: Take the distance C-5 off the front view triangulate this distance. Then place the compass

point on point C (on the pattern) and seeing an arc. The distance from 6 to 5 is taken off and half base

view from 6 to 5, (check that this distance steps off around the view 6 times exactly if not adjust the

compass until it does.) Place the compass point on point 6 and swing the arc. Repeat this procedure for

points C-4 and C-3, join and number these points.

Part round to square pattern

Step 6: Locate point B by taking the distance from 3 to B off the base view and triangulating this line.

Then swing an arc on the pattern at point 3. Then take the length of line C to B (this is true length) and

swing an arc from point C, the point of intersection is point B. Join and number these points.

Step 7: Repeat the procedures used in step 5 for points 2, 1 and S, and then to use the procedures in

step 6 to give point A.

Step 8: Draw the free hand curve around the points numbered S to 6 to S.



Completed round to square pattern.

Calculations are performed to determine job requirements

You may be required to perform various calculations prior to and during the marking out process. For

example during the pattern development process the plumber will be required to calculate

circumferences, and to demonstrate an understanding of Radius and diameters. During marking out of

copper tube the Plumber will be required to calculate total lengths, which will require some

knowledge and understanding of Bend Radius and the calculating of angles necessary to successfully

Mark out.

Material is marked out in conformance with determined measurements

Plans drawings specifications, codes etc are designed to set the highest possible standards for the

Plumbing Industry, and to provide the best possible result for customers. Set standards are to be

adhered to by the plumber whether installing or maintaining plumbing appliances, or ancillary fittings

and fixtures. It is the Plumbers task to also ensure that whilst marking out to work to the issued plans

and specifications thus ensuring conformance with the determined measurements. It is not the role of

the Plumber to change specifications or dimensions without the appropriate consent.

Dimensions are checked for accuracy and compliance to plans/specifications

After you have finished marking out it is important that you check your work against the job

plans/specifications to ensure that no errors have occurred. You should always measure twice and cut

once. Experience will guide you and raise doubts in your mind if you have measured incorrectly.

Always be guided by these doubts and re-check your calculations and measurements.



Clean up

Work area is cleared and materials disposed of:

On completion of the job you should allow time to clean up. Cleaning up includes clearing the work

site of debris and unused materials and stacking materials to aid good site management.

Tools and equipment

Cleaning, maintenance and storage of your tools and equipment is important. All tools should be

checked for correct operation. If problems are found with any tools or equipment they should be

tagged as faulty and repaired.



Documentation is completed in accordance with workplace requirements

Keeping and maintaining documentation to workplace requirements is an ever increasing task for the

plumber. However, it is important to recognize that documentation often provides the customer with

written details of the completed task outlining the specifications, which can often serve as the

customers’ copy of quality assured installation.

For the Plumber documentation may provide accurate records of the following:

1. Site clean up

2. Have waste or surplus materials been disposed of in accordance with regulations

3. Have all tools been returned to their correct location

4. Has the worksite been left in accordance with E.P.A. requirements

5. Certificate of completion and compliance

6. Manufacturers warranties and specifications

7. Quality assurance documentation



Name:…………………………………………………………

Worksheet

CPCPCM2050A – Mark out materials

The student should complete the following worksheets by answering all questions.

All worksheets should be completed before attempting any of the practical marking out.

1. A Plumbing tradesperson should be able to develop detailed surface patterns of geometric

shapes using the principles of geometry and mathematics?

List the three most common Geometric development methods.

1………………………………………………………………………………………………

2………………………………………………………………………………………………

3………………………………………………………………………………………………

2. Shown below are ten (10) objects that can be developed by geometric development principles.

Select the objects that would be developed using the Parallel Line Development method.

Answer 1…………………………………………

Answer 2…………………………………………

Answer 3………………………………………..

Answer 4………………………………………..



3. What group or class of objects are suitable for development using Parallel Line Drawing

Principles?

Answer:

…………………………………………………………………………………………………………

…………………………………………………………………………………………………………

…………………………………………………………………………………………………………

4 List (4) four commonly fabricated objects (prisms) that can be developed using Parallel Line

Development method.

Answer 1………………………………………………………………………………………………

Answer 2………………………………………………………………………………………………

Answer 3………………………………………………………………………………………………

Answer 4………………………………………………………………………………………………

5. When the ends of an object are not at 90º to the parallel sides or surface lines, then an

imaginary line called a Girth Line should be drawn.

True……………… False ………..



6. At what angle to the parallel sides or surface lines is a girth line drawn?

Answer:

…………………………………………………………………………………………………………


Select the object that would be developed using the Radial Line Development method?

Answer 1…………………………………………

Answer 2…………………………………………

Answer 3………………………………………..

Answer 4………………………………………..

8. Define a right cone?

Answer

A right cone can be defined as

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9. Name three (3) articles that can be manufactured using patterns developed by Radial Line

Drawings principles.

Answer 1………………………………………………………………………………………………

Answer 2………………………………………………………………………………………………

Answer 3………………………………………………………………………………………………



10. Describe the method of Triangulation?

Answer

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Select the objects that are most commonly developed using Triangulation principles.

Answer 1…………………………………………

Answer 2…………………………………………

Answer 3………………………………………..

Answer 4………………………………………..



12. Explain how the true length of a line may be found?

Answer

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13. What are transition pieces used for?

Answer

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Name:……………………………………………………………

Practical application


Your trainer or supervisor will work with you to demonstrate and explain how to mark out materials.

The following points will be covered:

Plans and specifications are obtained from job supervisor and job requirements are determined

WHS requirements associated with the marking out of materials, and the workplace

environment, are adhered to throughout the work

Quality assurance requirements are identified and adhered to in accordance with workplace

requirements

Tasks are planned and sequenced in conjunction with others involved in or affected by the

work

Tools and equipment, including personal safety equipment, are selected and checked for

serviceability

Work area is prepared to support the efficient marking out of materials

Selected materials are checked for compliance with plans or specifications

Quantity and type of material required is calculated from plans or specifications

Job requirements are determined from plans or specifications

Dimensions for fabrication and assembly are determined and transferred

Relevant standards, codes and symbols are interpreted

Selected development method is determined as appropriate and is applied in accordance with

workplace procedures

Calculations are performed to determine job requirements

Material is marked out in conformance with determined measurements

Dimensions are checked for accuracy and compliance to plans or specifications



Work area is cleared and materials disposed of or recycled in accordance with State or

Territory legislation and workplace procedures

Tools and equipment are cleaned, checked, maintained and stored in accordance with

manufacturers’ recommendations and workplace procedures

Documentation is completed in accordance with workplace requirements

On successful completion of this practical application you are then able to attempt your final

assessment.

Trainer or Supervisor’s Signature:………………………………………………….

Date of Completion:…………………………………….



Assessment checklist


Worksheet

Criteria Yes No

Have the worksheets been successfully completed?

Has the practical task been completed?

Are the job specifications available?

Trainer or Supervisor’s Signature: .......................................................................................

Date of Completion: .............................................................................................................

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