Welder

This document explains the requirements for end-point assessment (EPA) for the welder apprenticeship. End-point assessment organisations (EPAOs) must follow this when designing and delivering the EPA.

Welder apprentices, their employers and training providers should read this document.

A full-time welder apprentice typically spends 18 months on-programme. The apprentice must spend at least 12 months on-programme and complete the required amount of off-the-job training in line with the apprenticeship funding rules.

The EPA should be completed within an EPA period lasting typically 3 months.

The apprentice must complete their training and meet the gateway requirements before starting their EPA. The EPA will assess occupational competence.

An approved EPAO must conduct the EPA for this apprenticeship. Employers must select an approved EPAO from the apprenticeship provider and assessment register (APAR).

This EPA has 3 assessment methods.

The grades available for each assessment method are below.

Assessment method 1 - multiple-choice test:

• fail

• pass

Assessment method 2 - practical test with questions:

• fail

• pass

• distinction

Assessment method 3 - interview underpinned by a portfolio of evidence:

• fail

• pass

The result from each assessment method is combined to decide the overall apprenticeship grade. The following grades are available for the apprenticeship:

• fail

• pass

• distinction

The EPA is taken in the EPA period. The EPA period starts when the EPAO confirms the gateway requirements have been met and is typically 3 months.

The EPAO should confirm the gateway requirements have been met and start the EPA as quickly as possible.

Gateway should only start once the employer is confident that the apprentice is occupationally competent. That is, they are deemed to be working at or above the level set out in the occupational standard and ready to undertake an EPA. The employer may take advice from the apprentice's training provider, but the employer must make the decision. The apprentice will then enter the gateway.

The apprentice must meet the gateway requirements before starting their EPA.

They must:

• confirm they are ready to take the EPA
• have achieved English and mathematics qualifications in line with the apprenticeship funding rules
• have achieved two welding approval certificates to any of the following standards:

• AWS D1.1 Structural Welding - Steel: Certification: American Welding Society, OR

• AWS D1.2 Structural Welding Code - Aluminium: Certification: American Welding Society, OR

• ASME Section IX, OR

• ISO 9606 Qualification testing of welder, OR

• ISO 14732 Welding personnel - Approval of welding operator, OR

• BS4872 Specification for approval testing of welders when welding procedure approval is not required

The welder approval certificates must be current (completed in the 6 months prior to EPA or revalidated in the 6 months prior to EPA) and match with the two welding processes that are going to be selected for the EPA

• submit a portfolio of evidence for the interview underpinned by a portfolio of evidence

Portfolio of evidence requirements:

The apprentice must compile a portfolio of evidence during the on-programme period of the apprenticeship. It should only contain evidence related to the KSBs that will be assessed during the interview. It will typically contain 8 discrete pieces of evidence. Evidence must be mapped against the KSBs. Evidence may be used to demonstrate more than one KSB; a qualitative as opposed to quantitative approach is suggested.

Evidence sources may include:

• workplace documentation and records, for example:
  • welder approval certificates
  • welding procedure sheets
  • production control cards
  • inspection reports
• workplace policies and procedures
• witness statements
• annotated photographs
• video clips with a maximum total duration of 10 minutes; the apprentice must be in view and identifiable

This is not a definitive list; other evidence sources can be included.

The portfolio of evidence should not include reflective accounts or any methods of self-assessment. Any employer contributions should focus on direct observation of performance, for example, witness statements, rather than opinions. The evidence provided should be valid and attributable to the apprentice; the portfolio of evidence should contain a statement from the employer and apprentice confirming this.

The EPAO should not assess the portfolio of evidence directly as it underpins the interview. The independent assessor should review the portfolio of evidence to prepare questions for the interview. They are not required to provide feedback after this review.

Gateway evidence must be submitted to the EPAO, along with any organisation specific policies and procedures requested by the EPAO.

The assessment methods can be delivered in any order.

The result of one assessment method does not need to be known before starting the next.

Overview

In the multiple-choice test, the apprentice answers questions in a controlled and invigilated environment. It gives the apprentice the opportunity to demonstrate the knowledge mapped to this assessment method.

Rationale

This assessment method is being used because:

• it can assess knowledge
• it is easy to administer
• it can be conducted remotely and administered to multiple apprentices at the same time, potentially reducing cost

Delivery

The multiple-choice test must be structured to give the apprentice the opportunity to demonstrate the knowledge mapped to this assessment method to the highest available grade.

The test can be computer or paper based.

The test will consist of 30 multiple-choice questions.

Multiple-choice questions must have four options, including one correct answer.

The apprentice must be given at least 2 weeks’ notice of the date and time of the test.

Test administration

The apprentice must have 60 minutes to complete the test.

The test is closed book which means that the apprentice cannot refer to reference books or materials whilst taking the test.

The test must be taken in the presence of an invigilator who is the responsibility of the EPAO. The EPAO must have an invigilation policy setting out how the test must be conducted. It must state the ratio of apprentices to invigilators for the setting and allow the test to take place in a secure way.

The EPAO must verify the apprentice’s identity and ensure invigilation of the apprentice for example, with 360-degree cameras and screen sharing facilities.

The EPAO is responsible for the security of the test including the arrangements for on-line testing. The EPAO must ensure that their security arrangements maintain the validity and reliability of the test.

Marking

The test must be marked by an independent assessor or marker employed by the EPAO. They must follow a marking scheme produced by the EPAO. Marking by computer is allowed where question types support this.

A correct answer gets 1 mark.

Any incorrect or missing answers get zero marks.

The EPAO is responsible for overseeing the marking of the test.

Assessment location

The apprentice must take the test in a suitably controlled and invigilated environment that is a quiet room, free from distractions and influence. The EPAO must check the venue is suitable.

The test can take place remotely if the appropriate technology and systems are in place to prevent malpractice.

Question and resource development

The EPAO must develop a purpose-built assessment specification and question bank. It is recommended this is done in consultation with employers of this occupation. The EPAO should maintain the security and confidentiality of EPA materials when consulting with employers. The assessment specification and question bank must be reviewed at least once a year to ensure they remain fit-for-purpose.    

The assessment specification must be relevant to the occupation and demonstrate how to assess the KSBs mapped to this assessment method. The EPAO must ensure that questions are refined and developed to a high standard. The questions must be unpredictable. A question bank of sufficient size will support this.  

The EPAO must ensure that the apprentice has a different set of questions in the case of re-sits or re-takes.

The EPAO must produce the following materials to support the test:

• assessment materials for independent assessors and markers which includes:
  
  • training materials
  • administration materials
  • moderation and standardisation materials
  • guidance materials
  • grading guidance
  • test specification
  • sample test and mark schemes
  • live tests and mark schemes
  • question bank
• EPA guidance for the apprentice and the employer

The EPAO must ensure that the EPA materials are subject to quality assurance procedures including standardisation and moderation.

Overview

In a practical assessment with questions, an independent assessor observes the apprentice completing a task or series of tasks set by the EPAO. The EPAO decides where it takes place. The assessment environment must closely relate to the apprentice’s natural working environment. It gives the apprentice the opportunity to demonstrate the KSBs mapped to this assessment method.

Rationale

This assessment method is being used because:

• this is a practical role, which can be demonstrated through completing tasks
• it allows for consistency of opportunity for apprentices to demonstrate their competence against the mapped KSBs
• it assesses KSBs holistically and objectively
• it is a valid assessment because it involves direct testing under controlled conditions

Delivery

The practical test with questions must be structured to give the apprentice the opportunity to demonstrate the KSBs mapped to this assessment method to the highest available grade.

An independent assessor must conduct and assess the practical test with questions.

The independent assessor must only observe a maximum of four apprentices at a time to ensure quality and rigour. They must be as unobtrusive as possible.

The EPAO must give an apprentice 2 weeks' notice of the . practical test with questions

The practical test with questions must take 6 hours.

The independent assessor can increase the time of the practical test with questions by up to 10%. This time is to allow the apprentice to complete a task or respond to a question if necessary.

The practical test with questions may take place in parts but must be completed over 1 working day. A working day is typically considered to be 7.5 hours long. The reason for this split is to allow the apprentice to move between locations to set up different equipment and provide flexibility in delivery of the assessment process.

The EPAO must manage invigilation of the apprentice during the assessment, to maintain security of the EPA, in line with their malpractice policy. This includes breaks and moving between locations.

The independent assessor must explain to the apprentice the format and timescales of the practical test with questions before it starts. This does not count towards the assessment time.

The independent assessor must observe the following during the practical assessment:

General:

• follow health and safety regulations, including the use of personal protective equipment (PPE)
• using information from welding documentation
• obtaining and checking materials
• checking tools and equipment
• preparation of welding machines including the fitting of all cables and gases if required
• use of hand or power tools to carry out material preparation
• production of manual or mechanised welds
• the use of two different welding processes, for example: tungsten inert gas (TIG), plasma arc welding (PAW), manual metal arc (MMA), metal inert or metal active gas (MIG or MAG), flux cored arc welding (FCAW), submerged arc welding (SAW), tractor-mounted metal inert or metal active gas (MIG or MAG), tractor- mounted flux cored arc welding (FCAW), tractor-mounted or orbital tungsten inert gas (TIG), tractor-mounted or orbital plasma arc welding (PAW)
• the use of two different materials, for example: carbon steel, low alloy steel (3-7% alloy content), high alloy ferritic or martensitic steel (>7% alloy content), austenitic stainless steel, duplex stainless steel, nickel and nickel alloys, aluminium and aluminium alloys, titanium and titanium alloys, copper and copper alloys
• the welded joints
  • a minimum test piece length when manually welding plate is 200mm; the examination length is 150mm
  • for orbital pipe welding a minimum of one test piece is required for pipe with an outside diameter (OD) of 50mm or above, a minimum of two test pieces are required for pipe OD's between 20 and 50mm, three test pieces will be required for pipe OD's below 20mm
  • a minimum test piece length when using a tractor-mounted welding process is 400mm; the examination length is 350mm
• the material used must be a minimum of 5mm and a maximum of 15mm in thickness for manual processes, a minimum of 1mm and a maximum of 20mm for orbital TIG or PAW and a minimum of 5mm and maximum of 25mm for MIG, MAG, FCAW and SAW mechanised processes
• Restore the work area on completion of the activity

Apprentices must complete two of the following three activities

Activity 1: Manual welding

Prepare, set up and weld a butt joint in the horizontal (PC,2G) position

Activity 2: Manual welding

Prepare, set up and weld a T fillet in the vertical (PG, PF, PH, PJ or 3F,5FF) position

Activity 3: Mechanised welding

Prepare, set up and weld plate or pipe using an orbital or mechanised tractor welding unit

Specification tolerance

Activity 1 and 2: Manual welding

The distinction criteria only need to be met once if both manual welding activities are chosen but a pass must be achieved in the second to secure a distinction.

• weld meets the minimum specified length
• welds must be free from cracks, lack of fusion, end crater shrinkage pipe, stray arc marks, continuous undercut, cold lap, burn through or melt through
• plate alignment: Pass: alignment is within + or - 10 degrees, Distinction: alignment is within + or - 5 degrees
• intermittent undercut maximum depth less than 1.5mm: Pass less than 25% of the total weld length, Distinction less than 20% of the total weld length
• cap height or excess fillet leg length: Pass shall be between 0 and7mm, Distinction 0 and 6mm
• weld seam variation: Pass no more than 6mm along the length of the weld, Distinction no more than 4mm along the length of the weld

Activity 3: Mechanised welding

• due to the tolerance of the finished welding being determined by the welding program rather than the operator the mechanised option shall only achieve a pass or fail. The criteria for determining a pass or distinction shall be determined by the manual practical test.
• weld meets the minimum specified length
• welds must be free from cracks, lack of fusion, end crater shrinkage pipe, stray arc marks, continuous undercut, cold lap, burn through or melt through
• plate alignment: Pass: alignment is within + or - 10 degrees
• intermittent undercut maximum depth less than 1.5mm: Pass less than 25% of the total weld length
• cap height or excess fillet leg length shall be between 0 and 5mm
• weld seam variation no more than 5mm along the length of the weld

These activities provide the apprentice with the opportunity to demonstrate the KSBs mapped to this assessment method.

The independent assessor must ask questions.

The purpose of the questions is:

• to seek clarification where required
• to assess the level of competence against the grading descriptors

Questioning can occur both during and after the practical assessment. The time for questioning is included in the overall assessment time. The independent assessor must ask at least 4 questions. To remain as unobtrusive as possible, the independent assessor should ask questions during natural stops between tasks and after completion of work rather than disrupting the apprentice’s flow. The independent assessor must use the questions from the EPAO’s question bank or create their own questions in line with the EPAO’s training.

The independent assessor can ask follow-up questions to clarify answers given by the apprentice. These questions are in addition to the above set number of questions for the practical test with questions.

The independent assessor must make the grading decision. The independent assessor must assess the practical assessment and responses to questions holistically when deciding the grade. 

The independent assessor must keep accurate records of the assessment. They must record:

• the KSBs observed
• the apprentice’s answers to questions
• KSBs demonstrated in answers to questions
• the grade achieved

Assessment location

The practical test with questions must take place in a simulated environment selected by the EPAO for example, the EPAO’s or employer’s premises. The simulated environment must relate to the apprentice’s natural work environment. Equipment and resources needed for the practical test with questions must be provided by the EPAO, who can liaise with the employer to provide these.

Additional venue requirements that must be in place include:

• adequate power supply
• segregation and separation of material types, for example, carbon steel and stainless steel
• appropriate risk assessments, fire risk assessments
• local extraction and ventilation (LEV)
• enclosed or partially enclosed welding booths or workstations

Question and resource development

The EPAO must develop a purpose-built assessment specification and question bank. It is recommended this is done in consultation with employers of this occupation. The EPAO must maintain the security and confidentiality of EPA materials when consulting with employers. The assessment specification and question bank must be reviewed at least once a year to ensure they remain fit-for-purpose.

The assessment specification must be relevant to the occupation and demonstrate how to assess the KSBs mapped to this assessment method. The EPAO must ensure that questions are refined and developed to a high standard. The questions must be unpredictable. A question bank of sufficient size will support this. 

The EPAO must ensure that the apprentice has a different set of tasks and questions in the case of re-sits and retakes, to minimise predictability.

The EPAO must produce the following materials to support the practical test with questions:

• independent assessor assessment materials which include:
  • training materials
  • administration materials
  • moderation and standardisation materials
  • guidance materials
  • grading guidance
  • question bank
• EPA guidance for the apprentice and the employer

The EPAO must ensure that the EPA materials are subject to quality assurance procedures including standardisation and moderation.

Overview

In the interview, an independent assessor asks the apprentice questions. It gives the apprentice the opportunity to demonstrate the KSBs mapped to this assessment method.

The apprentice can refer to and illustrate their answers with evidence from their portfolio of evidence.

Rationale

This assessment method is being used because:

• it assesses KSBs holistically and objectively
• it allows for the assessment of KSBs that do not occur on a predictable or regular basis
• it allows for assessment of responses where there are a range of potential answers
• it can be conducted remotely, potentially reducing cost

Delivery

The interview must be structured to give the apprentice the opportunity to demonstrate the KSBs mapped to this assessment method to the highest available grade.

An independent assessor must conduct and assess the interview.

• teamwork and communication
• equity, diversity and inclusion
• environment and sustainability
• faults, issues and escalation procedures
• welding defects

The EPAO must give an apprentice 2 weeks' notice of the interview.

The independent assessor must have at least 2 weeks to review the supporting documentation.

The apprentice must have access to their portfolio of evidence during the interview.

The apprentice can refer to and illustrate their answers with evidence from their portfolio of evidence however, the portfolio of evidence is not directly assessed.

The interview must last for 45 minutes. The independent assessor can increase the time of the interview by up to 10%. This time is to allow the apprentice to respond to a question if necessary.

The independent assessor must ask at least 6 questions. The independent assessor must use the questions from the EPAO’s question bank or create their own questions in line with the EPAO’s training. Follow-up questions are allowed where clarification is required.

The independent assessor must make the grading decision.

The independent assessor must keep accurate records of the assessment. They must record:

• the apprentice’s answers to questions
• the KSBs demonstrated in answers to questions
• the grade achieved 

Assessment location

The interview must take place in a suitable venue selected by the EPAO for example, the EPAO’s or employer’s premises.

The interview can be conducted by video conferencing. The EPAO must have processes in place to verify the identity of the apprentice and ensure the apprentice is not being aided.

The interview should take place in a quiet room, free from distractions and influence.

Question and resource development

The EPAO must develop a purpose-built assessment specification and question bank. It is recommended this is done in consultation with employers of this occupation. The EPAO must maintain the security and confidentiality of EPA materials when consulting with employers. The assessment specification and question bank must be reviewed at least once a year to ensure they remain fit-for-purpose.

The assessment specification must be relevant to the occupation and demonstrate how to assess the KSBs mapped to this assessment method. The EPAO must ensure that questions are refined and developed to a high standard. The questions must be unpredictable. A question bank of sufficient size will support this.

The EPAO must ensure that the apprentice has a different set of questions in the case of re-sits or re-takes.

The EPAO must produce the following materials to support the interview underpinned by a portfolio of evidence:

• independent assessor assessment materials which include:
  • training materials
  • administration materials
  • moderation and standardisation materials
  • guidance materials
  • grading guidance
  • question bank
• EPA guidance for the apprentice and the employer

The EPAO must ensure that the EPA materials are subject to quality assurance procedures including standardisation and moderation.

Performance in the EPA determines the overall grade of:

• fail

• pass

• distinction

An independent assessor must individually grade the practical test with questions and interview underpinned by a portfolio of evidence in line with this EPA plan.

The EPAO must combine the individual assessment method grades to determine the overall EPA grade.

If the apprentice fails one assessment method or more, they will be awarded an overall fail.

To achieve an overall pass, the apprentice must achieve at least a pass in all the assessment methods. To achieve a distinction the apprentice must achieve a distinction in the practical assessment and a pass in the other two assessment methods.

Grades from individual assessment methods must be combined in the following way to determine the grade of the EPA overall.

If the apprentice fails one assessment method or more, they can take a re-sit or a re-take at their employer’s discretion. The apprentice’s employer needs to agree that a re-sit or re-take is appropriate. A re-sit does not need further learning, whereas a re-take does. The apprentice should have a supportive action plan to prepare for a re-sit or a re-take.

The employer and the EPAO should agree the timescale for a re-sit or re-take. A re-sit is typically taken within 2 months of the EPA outcome notification. The timescale for a re-take is dependent on how much re-training is required and is typically taken within 3 months of the EPA outcome notification.

Failed assessment methods must be re-sat or re-taken within a 6-month period from the EPA outcome notification, otherwise the entire EPA will need to be re-sat or re-taken in full.

Re-sits and re-takes are not offered to an apprentice wishing to move from pass to a higher grade.

The apprentice will get a maximum EPA grade of pass for a re-sit or re-take, unless the EPAO determines there are exceptional circumstances.

The EPAO must have reasonable adjustments arrangements for the EPA.

This should include:

• how an apprentice qualifies for reasonable adjustment
• what reasonable adjustments may be made

Adjustments must maintain the validity, reliability and integrity of the EPA as outlined in this EPA plan.

Internal quality assurance refers to the strategies, policies and procedures that an EPAO must have in place to ensure valid, consistent and reliable EPA decisions.

EPAOs for this EPA must adhere to the requirements within the roles and responsibilities table.

They must also appoint independent assessors who:

• have recent relevant experience of the occupation or sector to at least occupational level 3 gained in the last 3 years or significant experience of the occupation or sector

Affordability of the EPA will be aided by using at least some of the following:

• completing applicable assessment methods online, for example computer-based assessment

• utilising digital remote platforms to conduct applicable assessment methods

• assessing multiple apprentices simultaneously where the assessment method permits this

• using the employer’s premises

This apprenticeship is not aligned to professional recognition.