7485 Candidate Pack v1

7485 Level 2 Certificate
in Forgework
Candidate Guide
August 2008
www.nptc.org.uk
Supported by Farriery Training Agency

Level 2 Certificate in Forgework (7485-01) Candidate Guide August 2008
Publications and enquiries
Publications for this qualification are available as a pdf file from www.nptc.org.uk under the
‘Qualifications’ tab and then click on ‘Blacksmithing’.
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2
NPTC Level 2 Certificate in Forgework (7485 -01)
Contents Page
Introduction 5
Aims 5
Objectives 5
General Information 5
Qualification Structure 5
Assessment and Quality Assurance 6
Test Specification 6
Candidate Guidelines for the Forgework Certificate and Practical Exam 8
Unit 001 - The operation, basic maintenance and control of forge hearths 9
Unit 002 - Practical forge work 13
Unit 003 - Using and maintaining blacksmith’s tools 19
Appendix 1 – Forging exercises for farriery apprentices 21
3
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4
Introduction
This qualification is aimed at candidates who:
• wish to develop a career as a farrier or within blacksmithing

• wish for progression within or career change to the sector
• are looking for progression into the Advanced Apprenticeship in Farriery, for which this
qualification is a pre-requisite, or apprenticeship in Blacksmithing
• wish to add to their continuous professional development
Aims
To provide an accredited qualification that will be available to all prospective blacksmiths, farrier
apprentices, and others seeking a certificate of forgework competence. This qualification is
appropriate for all potential apprentice farriers.
Objectives
The qualification is designed to ensure that candidates are competent in the practical skill of forging
techniques with relevant understanding and underpinning knowledge. Forging techniques will include:
• Forging
• Forming
• Cutting
• Joining
General Information
The qualification is suitable for people 16 years and above looking for a career in blacksmithing or
farriery. It provides a valuable route for candidates as an N/SVQ is not available.
In view of the hazardous environment of the forge workshop, a full risk assessment must be in place,
taking into account the age, experience and group size of learners. The requirements of all relevant
legislation must be adhered to.
This vocationally related qualification has been designed by NPTC to support government initiatives
towards the National Qualifications Framework and DEFRA’s Learning, Skills and Knowledge Review of
the Land-based Industry. It has been devised in consultation with the Warwickshire College, Hereford
College of Technology, Myerscough College Oatridge College, and the Farriers Registration Council.
Qualification Structure
For the Level 2 Certificate in Forgework there are three mandatory units
Unit 001: The operation, basic maintenance and control of forge hearths
Unit 002: Practical forgework
Unit 003: Using and maintaining blacksmith’s tools
240 guided learning hours have been allocated for all the units 001 002 and 003.
This may be on a full-time or part-time basis.
5
Assessment and Quality assurance
To gain the Level 2 Certificate in Forgework candidates must complete the following:
1. Produce a portfolio of forging evidence. This portfolio is to include ALL mandatory test pieces
from the current Forging Exercise Booklet. (Appendix 1) Candidates must bring these test pieces
with them on the day of the practical examination. (Please refer to the examination guidelines on
the next page.) These test pieces will be marked by the external examiner on the day of the
practical examination.
2. A practical forging exam at the end of the course. The exam will consist of two mandatory test
pieces taken from the Forging Exercise Booklet. Test pieces will not include the Tie Bar or Tongs.
Time given to each test piece is laid down in the Forging Exercise Booklet (Appendix 1) and this will
be stated to the candidate before the exam commences. The practical examination is marked by
an NPTC External Examiner.
3. A single multiple choice test available via the City and Guilds Global Online Assessments System
assessing the knowledge and understanding of all three units. The test includes 30 questions
and candidates must achieve a minimum 70% correct answers in order to pass the test, i.e. at least
21 questions answered correctly. The test specification below indicates the subjects that are
assessed in the multiple choice test.
The entire test will be conducted via the candidate’s VDU. All data relating to the assessment will be
held by City & Guilds with results and performance feedback being delivered back to the approved
centre.
The table below shows a breakdown of the content that will be assessed in the multiple choice test.
Paper title: Level 2 Certificate in Forgework
Test duration: 1 hour Total number of questions: 30

Unit Outcome Number of
questions per
test
001 1. Identify and operate solid fuel forge hearths or gas furnaces 12
2. Recognise and apply safe working practices when operating solid
fuel forge hearths or mobile gas furnaces
002 Know how to: 10

1. Use basic forging techniques appropriately and safely
2. Use basic forming techniques appropriately and safely
3. Use basic cutting techniques appropriately and safely
4. Use a basic joining technique appropriately and safely to produce a
simple artefact
003 1. Identify and report on a range of basic blacksmith tools 8
Total 30
6
All three elements must be successfully achieved before the candidate achieves the
Forgework Certificate.
Please note: Candidates must produce a portfolio of forgework pieces before taking the practical
examination. These pieces must be brought to the practical examination with the candidate and they will
be assessed during the practical examination by an NPTC Approved Examiner. If candidates fail either
the portfolio or the practical examination they must re-sit the practical exam and put together a new
portfolio of forging pieces. The portfolio of a failed student will be retained by the college and marked so
that the pieces cannot be reoffered at a future date.
However, candidates who fail either the Multiple choice test or the practical/ portfolio can re-sit these
components individually. E.g. a candidate passing the practical/ portfolio but failing the Multiple choice
test will only need to re-sit the multiple choice test and vice versa.
No candidate is permitted to retake either the multiple choice test or the practical examination within a
month of failing an exam.
Exam guidelines and procedures are detailed on the next page.
7
Candidate Guidelines for the Forgework Certificate and Practical Exam
• All prospective candidates must apply directly to the college of choice for a place on the
forgework exam.
• External candidates that are not enrolled on a forgework Certificate course with a college must
contact an assessment centre for advice on costs and registering.
• The assessment centres can reserve the right to refuse a candidate entry for the examination.
• All those taking the forging exam must be registered with NPTC. The college will do this prior
to the assessment taking place.
• The college will provide candidates with detailed guidelines prior to the exam.
• Candidates are to provide all the tools and Personal Protective Equipment that are needed to
complete the exam
• Candidates must arrive with a full set of mandatory test pieces before they are permitted to
start the exam.
• No candidate is permitted to retake any part of the exam within one month of failing.
• The portfolio of a failed student will be retained by the college and marked so the pieces are
not reoffered at a future date.
• There will be an additional charge for anybody needing to re-sit the multiple choice test or the
practical exam.
• The total time allowed will be given to the candidate on the day of the practical exam.
Depending on the exercises given, this will vary, but will not exceed 2 hours.
• If during the assessment the candidate makes an error they will be allowed to use extra
materials to restart that piece if they wish as long as it is within the stipulated overall time.
• Forge hearths will be marked with your candidate name. Please check anvil for height (If
there is a problem consult with the examiner)
• Pre cut materials will be provided
• The college will provide steel forges and a selection of hollow and flat bit tongs but NO
hammers, cutting tools, punching tools, wire brush, safety glasses, centre dots or rules.
• Only the specified tools are to be used no special tools, if in doubt ask the examiners. No
toolboxes in the working area.
• The practical examination will take place on solid fuel forges.
• Candidates will be allowed 15 minutes to read instructions and prepare tools prior to the
start. Marking out will be permitted but no hot work allowed.
• Candidates will be informed when they have 30 minutes remaining.
• After time is called candidates must down tools immediately. No extra time allowed.
• Candidates are reminded that during the examination Health and Safety is their responsibility
and the examination will be terminated for non compliance.
• No mobile telephones during the examination
• No jewellery is allowed
• On successful completion of all three elements of the qualification, candidates will receive a
certificate.
Candidates wishing to take up the farriery apprenticeship must do so within three years of achieving
the forgework certificate.
8
Unit 001 The Operation, Basic Maintenance and Control of

Forge Hearths
Rationale
This unit is compulsory. It covers the different types of forge hearth used in blacksmith or farriery
businesses, and requires candidates to be competent in the operation, maintenance and control of
either a gas furnace or solid fuel forge hearth.
Learning Outcomes
There are two outcomes for this unit. The candidate will be able to:
1. Identify and operate solid fuel forge hearth or gas furnaces

2. Recognise and apply safe working practices when operating solid fuel forge hearths or
mobile gas furnaces
Assessment
The outcomes for this unit will be assessed on evidence resulting from practical performance, and
completion of the multiple choice question paper, assessing underpinning knowledge.
9

Forge Hearths
Outcome 1 Identify and operate solid fuel forge hearths or
gas furnaces
Practical Activities
The candidate will be able to:
1. Carry out basic maintenance for solid fuel forge hearths or mobile furnaces, to include cleaning,
safety checks and report faults
2. Select the resources needed to operate a forge, including fuel and other supplies
3. Safely light and adjust solid fuel forge hearths or mobile furnaces and maintain fuel supply
4. Safely control the fire to the correct heat and size for the specific tasks
5. Shut down the solid fuel forge hearth or mobile furnace safely
Underpinning Knowledge
The candidate will be able to demonstrate knowledge of:
1. Identify different types of forge hearth / furnace used in blacksmithing or farriery businesses, to
include:
a) Fixed solid fuel forges, e.g. coke side blast

b) Mobile gas furnace, e.g. venturi gas
2. The advantages and disadvantages of various fixed forge hearths and gas furnaces, to include:
a) Different areas of the fire – e.g. oxidising, neutralising, reducing

b) Maintenance requirements
c) Ease of use for a range of tasks
3. Different fuel types and supply for the operation of forge hearths and furnaces.
4. Appropriate visual metal heats for working with mild steel – i.e. black, red, orange, yellow
5. Control methods to produce the working heats on mild steel
6. The effects of scaling and burning
10

Forge Hearths
Outcome 2 Recognise and apply safe working practices when
operating solid fuel forge hearths or mobile gas furnaces
1. Apply safe working practices to include use of personal protective equipment, consideration for
others
2. Show awareness of hazards when working with a solid fuel forge hearth or mobile furnace, and
assess the level of risk, e.g. heat, fumes, obstacles in the work area
3. Implement the requirements of a risk assessment and comply with establishment safety rules and
manufacturers’ instructions
1. Health and safety responsibilities of an employee
2. Hazards associated with forgework and specific risks of operating solid fuel forge hearths and
mobile gas furnaces
3. The risks associated with specific hazards to include:
a) heat
b) fumes
c) obstacles in the work area
d) dust
e) noise
f) impact injuries
4. Relevant legislation
5. Personal protective equipment (PPE)
11
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12
Unit 002 Practical Forgework
Rationale
This unit is compulsory. It covers the basic techniques on mild steel that form the foundation for all
forgework tasks. Tasks to be completed are specified in the Forging Exercise Booklet. (Appendix 1)
Marking criteria for the pieces are available from the NPTC website www.nptc.org.uk. Click on
‘Qualifications’ and then click on ‘Blacksmithing’.
Learning Outcomes
There are five outcomes for this unit. The candidate will be able to :
1. Use basic forging techniques appropriately and safely

2. Use basic forming techniques appropriately and safely
3. Use basic cutting techniques appropriately and safely
4. Use a basic joining technique appropriately and safely to produce a simple artefact
5. Produce a portfolio of forging exercises as stated in the forging exercise booklet.
Assessment
The outcomes for this unit will be assessed on a practical portfolio of specified forged pieces and an
independently assessed practical examination in which specified pieces will be made in a time limit.
These demonstrate that candidates have acquired the appropriate practical competence and
underpinning knowledge for their production.
The underpinning knowledge is assessed via the multiple choice exam.
13

Outcome 1 Use basic forging techniques appropriately and safely
1. Over the range of required exercises, use appropriate forging techniques on mild steel for given
tasks, including:
• upsetting
• drawing down
• spreading
• setting down
2. Select appropriate blacksmiths tools for all forging tasks
3. Control forge heat to produce the desired effect
4. Work safely at all times
1. The differing effects of forging on mild steel – e.g. grain deformation, introduction of galls /
forging faults
2. The different forging techniques / tooling for given tasks, as in the forging exercise booklet.
3. Safe working practices for forging operations
4. Management, maintenance and control of the forge fire/furnace in forging operations
14

Outcome 2 Use basic forming techniques appropriately and safely
1. Use appropriate forming techniques for given tasks, e.g.
• Bending evenly and to specification

• Twisting
2. Select appropriate blacksmiths tools for all forming tasks
3. Manage, maintain and control the forge fire
4. Use appropriate working heats, including appropriate use of spot heat techniques
5. Control section dimensions and surface quality during the forming process
1. The effects of bending and twisting on steel – e.g. grain structure, mean line
2. The different forming techniques / tooling required for given tasks
3. Safe working practices for forming operations
4. Management, maintenance and control of the forge fire/furnace in forming operations
5. The use of cooling media in spot heating/cooling
15

Outcome 3 Use basic cutting techniques appropriately and safely
1. Cut or split mild steel using blacksmith tools
2. Punch holes accurately using punches and drifts
3. Select appropriate blacksmiths tools for all cutting tasks
4. Manage, maintain and control the forge fire whilst cutting and punching
5. Control distortion whilst cutting and punching
1. Various processes for hot cutting and punching of mild steel by hand – e.g. slot / taper punches,
drift / slitter punches, hot chisel / hot sett
2. Appropriate tools for different cutting and punching tasks
3. Safe working practices in cutting and punching tasks
4. Management, maintenance and control of the forge whilst cutting and punching mild steel
16

Outcome 4 Use a basic joining technique appropriately and safely to
produce a simple artefact
1. Work within tolerance to given specification
2. Produce separate elements using blacksmithing techniques
3. Assemble finished artefact from elements using a basic joining technique – e.g. rivet, hinge plate
and justify the technique used
4. Inspect and test artefact to ensure fitness for purpose
5. Use appropriate tools throughout
1. Reasons for working to specifications
2. The appropriate production techniques/ tools required for given tasks
3. Assembly techniques
4. Safe working practices in joining tasks
17

Outcome 5: Produce a portfolio of forging evidence
1. Produce a portfolio of forging evidence. This must include ALL test pieces from the current
Forging Exercise Booklet. The candidate will be required to bring test pieces along to their
practical exam.
2. Under examination conditions, produce two test pieces from the Forging exercise booklet. These
pieces will be randomly selected by NPTC prior to the exam taking place.
Tasks to be completed are specified in the Forging Exercise Booklet. (Appendix 1)

Marking criteria for the pieces are available from the NPTC website www.nptc.org.uk. Click on
‘Qualifications’ and then click on ‘Blacksmithing’.
Please note: Mandatory exercise 10 (Tongs) can be made right or left handed.
18
Unit 003 Using and Maintaining Blacksmith’s Tools
Rationale
This unit is compulsory. It covers the recognition, use and maintenance of some of the basic tools
used in blacksmithing and forgework.
Learning Outcomes
There is one outcome for this unit. The candidate will be able to:
1. Use, identify and report on a range of basic blacksmith tools
Assessment
The outcome for this unit will be assessed by production of a practical log and the multiple choice
exam on the use of a range of tools.
19
Unit 003 Using and Maintaining Blacksmith’s Tools
Outcome 1 Identify and report on a range of basic blacksmith tools
1. Use and inspect a range of blacksmith hand tools to include:
a) hand hammer
b) tongs
c) rule
d) punches
e) hot chisel
f) wire brush
g) top and bottom tools
h) rasp
2. Identify common faults and related hazards in basic tools, e.g. mushroomed heads, deformed
shanks, loose handles/shafts, lubrication
3. Suggest appropriate maintenance activity to correct faults
1. Hazards associated with using basic blacksmiths tools
2. Identification of a range of blacksmith hand tools to include:
a) hand hammer
b) tongs
c ) rule
d) punches
e) hot chisel
f) wire brush
g) top and bottom tools
h) rasp
3. Identification of parts of the anvil
4. Identification of parts of the leg vice
5. Materials used in basic tool production:
a) associated hazards
b) basic metallurgy of plain carbon steel
c) heat treatments
5. Faults likely to occur in basic tools and appropriate maintenance procedures
20
Appendix 1
21
ACKNOWLEDGEMENT
The design and content was produced by Mr H B Pomfret at Herefordshire

College of Technology, based on the original booklet by Mr G T Sutton.
Copyright
This booklet may be used and copied without restriction for use in conjunction
with the Advanced Modern Apprenticeship in Farriery or NPTC Level 2 Certificate
in Forgework.
Use of the booklet, or material contained within it for any other purpose is not
permitted without the permission of Herefordshire College of Technology.
© HCT 2001-2006
CONTENTS
INTRODUCTION i
TOOLS & EQUIPMENT ii
CONVERSION TABLES iii
GUIDELINE MAXIMUM TIME LIMITS iv
MANDATORY EXERCISES PAGE
1) FORGING TO SECTION - (A) FLAT, (B) SQUARE (C) ROUND M-1
2) FORGING POINTS - (A) CHISEL, (B) SQUARE, (C) ROUND, (D) DIAMOND M-2, M-3
3) STAPLE - FLAT M-4
4) UNWELDED EYE - ROUND M-5
5) FLAT RING M-6
6) FIGURE 8 - ROUND M-7
7) SET EYE HOOK M-8, M-9
8) BOW SHACKLE - LARGE - SET EYE M-10
9) TIE BAR M-11
10 FLAT BIT TONGS M12, M13
OPTIONAL EXERCISES PAGE
1) FORGING TO SECTION - SET DOWN SECTIONS O-1
2) STAPLE - ROUND O-2
3) UNWELDED EYE - FLAT O-3
4) FIGURE 8 - FLAT O-4
5) BOW SHACKLE - SMALL - TURNED EYE O-5
6) HEART - FORGED RIGHT ANGLE BEND O-6

INTRODUCTION
This book is intended to help potential blacksmiths and farriery apprentices to
demonstrate a level of competence in basic forge techniques and processes.
These techniques cover the forging and forming skills that are used in basic
forging and shoe production.
IMPORTANT INFORMATION
Trainees are not expected to make the exercises in this publication without first
being given instruction, demonstration and guidance.
It is for this reason that any instructions given here are brief and merely represent points
to remember when working through the exercises.
It is also assumed that after suitable instruction, anyone attempting these exercises will be
able to:
1. Practice and have knowledge of current Health & Safety regulations
2. Prepare and control a fire to the correct heat and size. If possible the
student should have experience of using both solid fuel and gas hearths.
3. Hold and correctly use several types of hammer. There are opportunities
to work as smith and striker with some of the exercises although it is
recommended that the student first becomes adept with hand hammers.
4. Select and use tongs correctly to ensure safe and efficient working. Please
note that badly fitting tongs are dangerous and can easily cause injury.
5. Identify the correct temperatures for forging, bending and finishing and be
aware of the effects of heat and forging on the internal structure of the metal
6. Take, and control, heats on metal, of the required lengths and in the required
positions, using both the forge hearth and water bosh as appropriate.
7. Be familiar with the various parts of the anvil and how they should be used
when shaping metal.
8. Keep the fire, the metal and the anvil clean.
9. Acquire co-ordination between hand and eye, particularly when accurately

forging sizes of stock material or bending complicated shapes.
10. Have confidence in working hot metal accurately and cleanly.
POINTS TO NOTE:
The objective is to complete all the exercises, (except where indicated for the Tie Bar),
WITHOUT the use of rasps or files.
All the pieces can be produced as many times as is necessary for the potential apprentice
and ATF or tutor to be satisfied that they can, during the forging test:
a) be reproduced within the given time limits, and,
b) be reproduced to the standard required.

i
TOOLS & EQUIPMENT
TOOLS & EQUIPMENT

In the production of the exercises in this booklet, the student will need,
(as a minimum), the following:
Personal Protective Equipment (PPE). Including:

Safety spectacles, (Not Ski type goggles).
Steel toecapped work boots.
Ear defenders or ear plugs.
Overalls or leather apron.
Leather gloves (optional).
Hand hammer .
Tongs - Flat bits to hold 6mm & 10 mm stock (1/4" & 3/8").
Tongs - Hollow bits for 16mm square (5/8") and 20mm square (3/4").
Steel or brass rule. 300mm (1 Foot) minimum. Avoid aluminium rules or those with
the divisions printed on them
Wire brush. Butchers block brush is best but ordinary type will do.
Centre punch.
Stud punch -10mm (3/8").

Or tapered round punch (and) 10mm (3/8") diameter drift.
Bolster plate (optional) 10-12mm hole.
Hot chisel.
Cutting plate (optional).
ii
CONVERSIONS
CONVERSION TABLE - METRIC TO IMPERIAL

These conversions are approximations for use as a guide.
For example, in certain circumstances, 5mm bar stock may be used in place
of either 3/16" or 1/4" as as 5mm lays somewhere between the two sizes.
As the size increases, so the accuracy decreases. For example, 300mm is

used as the equivalent of one foot whereas the actual metric equivalent is
305mm, nearly 1/4" difference.
The student must familiarise him/herself with all the commonly used stock
sizes and should be able to recognise them without the aid of a ruler.
1.5mm 1/16"
3mm 1/8"
4.5mm 3/16"
6mm 1/4"
8mm 5/16"
10mm 3/8"
12mm 1/2"
16mm 5/8"
20mm 3/4"
22mm 7/8"
25mm 1"
50mm 2"
75mm 3"
100mm 4"
150mm 6"
200mm 8"
250mm 10"
300mm 1' (1Foot)
iii
MAXIMUM TIME LIMITS
MANDATORY EXERCISES TIME LIMIT
1) FORGING TO SECTION
FLAT 30 MINUTES
SQUARE 30 MINUTES
ROUND 30 MINUTES
2) FORGING POINTS
CHISEL 15 MINUTES
SQUARE 15 MINUTES
ROUND 20 MINUTES
DIAMOND 20 MINUTES
3) STAPLE - FLAT 25 MINUTES
4) UNWELDED EYE - ROUND 15 MINUTES
5) FLAT RING 30 MINUTES
6) FIGURE 8 - ROUND 25 MINUTES
7) SET EYE HOOK 60 MINUTES
8) BOW SHACKLE - LARGE - SET EYE 60 MINUTES
9) TIE BAR 60 MINUTES
10) FLAT BIT TONGS 180 MINUTES
OPTIONAL EXERCISES TIME LIMIT
1) FORGING TO SECTION - SET DOWN SECTIONS 60 MINUTES
2) STAPLE - ROUND 20 MINUTES
3) UNWELDED EYE - FLAT 30 MINUTES
4) FIGURE 8 - FLAT 35 MINUTES
5) BOW SHACKLE - SMALL - TURNED EYE 35 MINUTES
6) HEART - UPSET RIGHT ANGLE BEND 60 MINUTES
iv
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MANDATORY EXERCISE 1
FORGING TO SECTION
STOCK: OBJECT:
OLD HORSE SHOES After straightening the shoe, to forge
a minimum of 8 inches (200mm) of
PLEASE NOTE
parallel section.
You may forge to a size of your
own choosing but the forged
This section is to be as free of
section must be at least 8"
hammer marks as possible and to
(200mm) long
have a clean finish
8" (200mm)
1. FLAT minimum
Take a long yellow heat and forge with overlapping blows, working along the bar.
Forge the edges in to achieve the flat section.
As the section develops, reduce the heat to the orange range and finally through the reds to
finish.
Check that the width is constant along the length frequently, that the bar is straight and that
the sides are at right angles to each other
2. SQUARE
As with the flat section but you will need to turn the metal often to maintain an even section.
The forged section must be straight, parallel and square.
3. ROUND
To forge a round section you must first forge a square section which must be even, straight
and true.
Then forge in the corners from end to end until you have an octagonal (8 sided) section. If
some flats are wider than others then you do not have a true octagon.
Only when this step is complete, forge in the corners of the octagon along the length. DO NOT
try to round up before this point.
At a finishing heat and with lighter blows, round up by slowly rotating the piece under the
hammer M-1
FORGING POINTS - CHISEL, SQUARE, ROUND, DIAMOND
STOCK: OBJECT:
5" OF 5/8 SQUARE
Developing the skills of forging to
(125mm x 16 Sq) section from exercises 1 & 2, you will
now forge the basic point forms, .
Chisel, Square, Round and Diamond.
Use a ruler or other straight edge to
check the sides of the points are
straight.
Make sure the points are centred on
the bar when looked at from all four
sides
Centre punch at Each point should have a clear
2" (50mm) transition from the stock size starting
from one end at the 2"(50mm) centre punch mark.
STOCK
CHISEL
SQUARE
OCTAGON
ROUND
DIAMOND
The Round point begins

as a square point.
This is forged to an
octagon (8 sides)
The octagon can then
be rounded up
M-2
MANDATORY EXERCISE 2 - continued
FORGING POINTS - CHISEL, SQUARE, ROUND, DIAMOND
PLEASE NOTE:
Points and tapers of most kinds can be forged starting at the mark and forging to the end but
this requires a very good eye. You may find that forging the point down almost to the finished
size, then forging from the mark to the point may be a more reliable method
CHISEL
There should be a clean even taper top

and bottom, which is centred on the bar.
The sides should be parallel and straight.
The 5/8" (16mm) width must be kept all
the way to the point.
SQUARE
The Square point must be even on all four

sides. When forging, keep turning and work
all sides evenly. A crisp transition at the
punch mark is required.
The OCTAGON is the mid point between Square and round. It is VERY important to make sure
that ALL the sides are the same width. If not, it will not be a true octagon and it will be
difficult to make a good round section. Notice that the transition point at the punch mark is
where the section is a TRUE octagon, not just a square with the corners knocked off
ROUND
After forging the Octagon and
straightening, lightly forge in the remaining
corners.
Then begin to round up with light blows at
a finishing heat while slowly turning the bar
under the hammer. It should be fully round
at the mark
DIAMOND
With the Diamond point the stock is held on
the diagonal.
When forging, make sure that the corner
facing you is DEAD CENTRE and that you
strike it squarely or it will twist. Work all
four sides evenly.
Note that the back point of the diamond
(the transition point), is level with the
punch mark M-3
STAPLE - FLAT
STOCK: OBJECT:
7" OF 5/8" X 1/4" FLAT To produce a level, well balanced
(175mm X 16 X 5mm) staple with square points.
The outside edges of the legs should
be parallel.
The bend should be even about the
centre mark.
There should be no loss of thickness
Mark at centre of section towards the points.
Take an even heat about the centre mark and bend to a right angle.
Take a heat on each end in turn and draw out a square point.
Each taper should be of equal length.
The outside edges should be straight.
Take an even heat on the middle section and bend around

until the legs are parallel.
The points should be in line and the bend should be even

about the centre
M-4
UNWELDED EYE - ROUND
STOCK: OBJECT:
9" OF 1/4" or 5/16" ROUND
(225mm OF 6mm or 8mm) To form a clean circular eye, centred
on the bar.
When finished, the eye must be
circular and level There should be little
Mark at 3" (75mm) evidence of hammer marks or
from one end distortion of the section.
Take a yellow heat at the mark. Quench either side and bend
almost to 90o.
Straighten either side and make sure the piece is flat.
Take a short yellow heat on the end.

Quickly bend the end over the tip of the bick, being careful not
to squash the section.
Flatten, but keep the round section. Don't hit it too hard or too
hot.
Another yellow heat. This time just in front of the mark.

Quench the first bend to stop it opening up as you quickly bend
over the bick.
NOTE:
Steps 2 and 3 could be reversed. The important thing is to
make the difficult bends either end of the eye before closing up.
Be sure not to put flats on the round section.
Take an even orange heat between the last two bends.

Quench bend No. 1 if necessary, then close up the eye.
Make sure the piece is flat and that the eye is circular and
centred on the bar.
The material should still be round in section.
M-5
FLAT RING
STOCK: OBJECT:
11" of 3/4" X 1/4" FLAT
(280mm of 20mm X 6mm) To bend a ring on edge from flat
bar by eye.
The ring must be circular, level and

be free from major hammer marks.
NOTE:
Take care not to reduce the section.
Take a short heat and back up the end to form an angle.

One edge will be around 1/4" (6mm) shorter than the other.
Repeat on other end
Take a heat on about a quarter of the length

and bend over the Bick.
Note which side the angle on the end is.
Flatten and straighten.
Repeat the last step on the other end.
Finally, take an EVEN heat over the centre section and

bring the two ends around until they meet.
Flatten and round up the circle.
The use of a mandrel for rounding is not permitted.
M-6
FIGURE OF EIGHT - ROUND
STOCK: OBJECT:
8" OF 1/4" OR 5/16" ROUND
To forge a shape using the Bick of the
(200mm OF 6mm OR 8mm) anvil to form two connected circles.
This to be done without flattening or
mutilating the round section.
The final piece is to be symmetrical,
level and clean.
Mark at centre
Take a SHORT yellow Take another yellow heat Take an even heat
heat on the end of around the mark. between the two bends
the bar and quickly and almost complete the
Quench just short of the
turn it over the bick. circle.
mark as well as the first
Straighten any bend and turn the second Leave it a little open for
distortion in the rest bend. now.
of the bar.
NOTE: Steps 1 & 2 could Straighten and level.
be reversed
Repeat step 1 on the Repeat step 2. Repeat step 3.

other end of the bar.
You must have a good Note that the ends are
heat and work quickly in not yet closed in. This is
order to form the bend to allow a degree of
cleanly without any access to refine the
straight section near the shape if necessary.
mark.
Level if distorted. Don't
flatten the section.
Finally, take a heat and close in the ends which should meet at
the centre mark.
If you have difficulty in refining the shape on the ends, twist
them to the sides to enable you to get at them with the hammer.
Level up
M-7
SET EYE HOOK
STOCK: OBJECT:
7 3/4" OF 3/4" X 1/4" FLAT
(195mm of 20mm X 6mm) To produce a flat hook with an
unwelded, forged eye.
The hook should be of clean finish

and hang centrally from the eye,
(see final step).
1 1/2" 2 3/4"
Mark
(38mm) (70mm)
From the 2 3/4" (70mm) mark, draw an even, straight taper 4 1/4" (106mm) long
Turn the piece around and set down at the 1 1/2" (38mm) mark.
Draw it out to 3/8" (10mm) square. It should be about 2" (50mm) long.
Make sure the section is parallel and not tapering.
Forge the square section into an octagon.

If the end is becoming smaller in section, upset it
and square up the end.
Round up the section. Straighten and true up.

By now it should be approximately 2 1/2" (63mm) long
Draw a taper behind the round section. The taper should be 4 1/4" (106mm) long.
Straighten and true up.
NOTE:- Make sure that the set remains well defined as a step
M-8
SET EYE HOOK
Take a yellow heat. Quench up to the end of the

taper and quickly turn the round section almost
to 90o.
Take another heat. Quench up to the bend to chill it

and quickly knock the end over.
Take a SHORT yellow heat and set the curve right up

to the tip.
Take an even orange heat to complete the eye.

See that it is centralised.
Take a heat behind the eye. Quench the eye to

prevent distortion and set a curve as shown.
Repeat on the other end.
Flatten
Take an even orange heat in the central section

and bend in the opposite direction over the Bick.
Flatten and align as necessary so that when

hung from the eye, a line can be drawn
vertically through the centre of the bend.
M-9
BOW SHACKLE - LARGE - SET EYE
STOCK: OBJECT:
12" OF 3/8" ROUND To set down a section, round up and
(300mm OF 10mm) form an eye on each end of a bar.
To shape the bar into a well
balanced, circular form with the eyes
parallel and spaced 3/4" (20mm)
apart.
The whole to be clean, level and
Mark at 1 1/2" (38mm) from each end without loss of the round section.
Take a heat on one end and set down on two sides only.
Forge to a 5/16" (8-9mm) square section 2" (50mm) long.
Forge this to an octagonal section and round up, by which time it should be
approximately 21/4" (55mm) long.
Repeat on the other end. Both ends must be the same length and section.
Take a yellow heat at the set, quench up to the set and quickly bend.
Straighten any distortion created.
Form the eye as in previous exercises.

Repeat on the other end.
Straighten up.
Crank one of the eyes over to about 45o and repeat on the other end.
Straighten up again and see that the eyes are in line and not twisted.
It is very important that the bar between the eyes is perfectly straight
or a smooth bend will be very difficult to achieve.
Take a heat on about a quarter of the length, quench

3/4" the eye to prevent distortion and bend over the bick.
(20mm) Repeat on the other end.
Finally, take an EVEN heat over the central section,
chill the ends if necessary and complete the bend.
See that the form is circular and that the eyes are
M-10 properly aligned, not twisted and 3/4" (20mm) apart.
TIE BAR
STOCK: OBJECT:
8" OF 5/8" SQUARE
By upsetting, to form a circular eye.
(200mm OF 16mm) A ring may then be connected.
To split and open the bar to provide a

balanced, ragged end to fix.
The whole must be level. The eye is

Mark at 2" (50mm) from one end to be central and the bar split evenly
down the centre.
Take a short yellow heat up to the

mark. If necessary, quench to just
short of the mark.
Upset the end. Each heat should be
1" to the same point to produce the
shoulder.
The final upset should be 1" (25mm)
1" square and slightly thicker than the
(25mm) bar.
Forge the corners of the square to

produce an octagon
Forge in the corners. Then round

up the shape
Punch a hole in the centre and drift
out to 3/8" (10mm).
3/8" (10mm) Diameter

Mark 3" (75mm)from the other end
and using a hot chisel, split one
side to the centre.
Then cut from the other side to the
centre, parting the two halves.
Open out the split ends.

Hot rasp off ripped edges if present and
LIGHTLY forge in the section.
4"
(100mm) Set a balanced curve on each leg leaving
the ends 4" (100mm) apart.
The whole piece should retain a clean finish
and be level.
M-11
SMALL FLAT BIT TONGS
STOCK: OBJECT:
8" OF 5/8" SQUARE
(200mm of 16mmSq) To produce a pair of small flat bit
(Two pieces) tongs with a clean finish.
NOTE:
Two pieces are necessary.
At each step, make sure both pieces
are matched.
Mark at 1 3/8" (35mm) FROM END
Set down at the mark.

Do not forge the width back to 5/8" (16mm) or when finished, it will be undersize.
Better larger than smaller as you will come back to finish the jaw & hinge area later.
The dimensions of the jaw at this stage should be approximately 2" X 5/16" X 7/8"
(50 X 8 X22mm).
Turn 90o to the left and set down at 45o. Make sure the set lines up with the corner of the
first set.
Again, allow the metal to spread. Forge to approx 5/16" X 7/8" (8mm X 22mm). True up.
Turn 90o to the left again and set down at around 1 1/2" (38-40mm) from the first set.
Set down only about a third of the width. REMEMBER, THIS IS THE POINT WHICH
NEEDS MAXIMUM STRENGTH. It is as thick as the hinge plate and two thirds as high.
Draw out the rein. There should be enough material to draw to 12" (300mm). The size
at the end should be about 5/16" X 1/4" (8mm X 6mm) and the taper between the last
set and the end should be straight and clean.
DO NOT reduce the section behind the hinge plate.
From just behind the hinge plate, knock off the corners. use gentle blows to start, becoming
a little heavier as you work towards the end.
True up the rein.
M-12
SMALL FLAT BIT TONGS
Having knocked the corners off, now round

up the top and bottom of the rein.
Then tip the end down a little. this will help prevent the tongs slipping in the hand and to
locate a ring if needed.
True up.
Take a heat on the hinge area and resting the set at 45o on
the anvil, strike the upper edge to set the angles.
Flatten with the set side down on the anvil. Repeat if
necessary.
Note that this shortens and broadens the hinge.
True up.
45o
At a bright orange/yellow heat, take a short scrap

piece of 1/4" (6mm) round and hold it in the centre
of the jaw. Get an assistant to hammer it in. MAKE
SURE it is central before you go too far.
Do the same thing at right angles to the first one.
This will make the tongs more useful as they will
also be able to hold small rounds and squares
Punch a 3/8" (10mm) hole in the centre of the hinge plate. Flatten out any distortion and
drift the hole to its true size.
If the hinge plates are slightly different sizes, punch the smaller one first and use this to
mark the other from.
Rivet up and set the jaws using a scrap piece of 1/4" (6mm) flat between them.
Set the reins to a comfortable size.
M-13
OPTIONAL EXERCISE 1
FORGING TO SECTION - SET DOWN SECTIONS
STOCK: OBJECT:
7" of 5/8" SQUARE
(180mm of 16mm Sq) To forge to controlled sections by
setting down and drawing out.
The sections are to be as free of
hammer marks as possible, to be
parallel and to have a clean finish.
Mark at 3" (75mm) from end
Set down from the 3" (75mm) mark and draw out the remainder to
5/8" X 5/16" (16mm X 8mm).
Square off the end and make sure the bar is straight & true. Mark at
1 1/2" (38mm) from the set.
Set down from the mark and draw out the remainder to 5/16" X 5/16"
(8mm X 8mm).
Straighten and mark at 2" (50mm) from the last set.
From the mark, knock off the corners to produce a true octagonal (8
sided) section.
Check that all 8 sides are the same width.
Straighten and mark at the mid point of the octagonal section.
From this point knock the corners off the octagon working up and down
the length, then work off any remaining corners.
Round up at a finishing heat with light blows while slowly rotating the bar.
O-1
OPTIONAL EXERCISE 2
STAPLE - ROUND
STOCK: OBJECT:
6" OF 3/8" ROUND
To produce a well balanced staple
(150mm OF 8mm) with chisel points.
The points should be in line and the
outside edges of the legs should be
paralell.
Mark at centre The piece should be clean with no

distortion of the round section.
Take an even heat about the centre mark and bend to a right angle.
Take a heat on each end in turn and draw out a chisel point.
Each taper should be of equal length, about half the length of the leg.
The outside edges should be straight and paralell.
Looked at from the side, the section should not reduce.
Take an even heat on the middle section and bend around

until the legs are parallel.
The points should be in line and the bend should be even

about the centre
O-2
OPTIONAL EXERCISE 3
UNWELDED EYE - FLAT
STOCK: OBJECT:
10" OF 5/8" X 1/4" FLAT
(250mm OF 16 X 5mm) To form a clean circular eye, centred
on the bar.
When finished, the eye must be

circular and level.
Mark at 3" (75mm) There should be little evidence of
from one end hammer marks.
Take a yellow heat at the mark. Quench either side and bend
almost to 90o.
Straighten either side and make sure the piece is level.
Take a short yellow heat on the end.

Quickly bend the end over the tip of the bick, being careful not
to reduce the width.
Another yellow heat. This time just in front of the mark.

Quench the first bend to stop it opening up as you quickly bend
over the bick.
NOTE:
Steps 2 and 3 could be reversed. The important thing is to
make the difficult bends either end of the eye before closing up
Take an even orange heat between the last two bends.

Quench bend No. 1 if necessary, then close up the eye.
Make sure the piece is level and that the eye is circular and
centred on the bar.
O-3
OPTIONAL EXERCISE 4
FIGURE OF EIGHT - FLAT
STOCK: OBJECT:
11" OF 5/8" X 1/4" FLAT
(280mm OF 16 X 5mm) To forge a shape using the Bick of the
Anvil to form two connected circles.
This to be done without reducing the
width or thickness of the flat section.
The final piece is to be symmetrical,
level and clean.
Mark at centre
Take a SHORT yellow Take another yellow heat Take an even heat
heat on the end of around the mark. between the two bends
the bar and quickly and almost complete the
Quench just short of the
turn it over the bick. circle.
mark as well as the first
Straighten any bend and turn the second Leave it a little open for
distortion in the rest bend. now.
of the bar.
NOTE: Steps 1 & 2 could be Straighten and level.
Do not reduce the reversed
width.
Repeat step 1 on the Repeat step 2. Take a heat between the two
other end of the bar.
You must have a good heat bends and close up the
and work quickly in order second half.
to form the bend cleanly
without any straight section Adjust so that the centre of
near the mark. each end lines up with the
punch mark.
O-4
OPTIONAL EXERCISE 5
BOW SHACKLE - SMALL - TURNED EYE
STOCK: OBJECT:
10" OF 1/4" ROUND
(250mm OF 6mm) To form an eye on each end of a bar.
To shape the bar into a well
balanced circular form with the eyes
parallel and spaced 3/4" (20mm)
apart.
The whole to be clean, level and
Mark at 21/4" (55mm) from ends without loss of the round section.
Take a SHORT heat about Take a SHORT yellow Take another short heat
the mark and bend over heat at the tip and ahead of the first bend.
the edge of the anvil. quickly bend it to the
radius of the finished eye. Quench just up to the
the bend should be first bend and knock
Take care not to squash
almost 90o. forwards.
the section at the tip.
Straighten either side of Quenching the first bend
the bend. will prevent distortion
Straighten.
Close up the eye. Repeat on the other end. Crank the eyes over
to approximately 45o.
The eye should be as Keep the bar straight
circular as possible and and the eyes centred. See that they are not
centred on the bar. twisted and are still
centred
Take a long even heat. True up and align the eyes.
Quench the eyes and bend around. The eyes should be 3/4" (20mm) apart.
O-5
OPTIONAL EXERCISE 6
HEART - UPSET RIGHT ANGLE BEND
STOCK:
8" OF 1/2" SQUARE OBJECT:
(200mm OF 12mm)
To forge a right angle bend by
upsetting.
Then, by drawing down and controlled

bending with the hammer, to produce
Mark at centre a clean, level and balanced heart
Take a SHORT heat in the Again, using short heats, Continue working up the bend
centre of the bar. work each arm in turn, by upsetting the arms into it
upsetting into the bend. and also using the hammer
It may help to quench either on the outside faces to
side of the punch mark. Keep the mark in the centre produce a crisp, sharp corner.
of the bend.
Bend the piece but DO NOT As the work progresses, the Notice the punch mark is still
bring it to 900. angle of the bend should in the centre.
become tighter but at this
The punch mark should be in stage, still not quite 900.
the centre of the bend.
Maintain a small radius on the
inside of the bend.
Starting almost in the corner,

draw out each arm to an even
Scroll the two ends using
taper of equal lengths.
hammer only.
Finally, bring the two arms
Chill the bend or it will distort together.
Keep checking to see that
during this process.
they are balanced.
Chill the bend to prevent
The outer edges should be at distortion.
right angles to each other.
Be sure to take EVEN heats
and keep checking for
balance O-6

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7485 Level 2 Certificate

Supported by Farriery Training Agency

Publications and enquiries

General information may be obtained from

© 2008 NPTC All rights reserved.

Registered Charity No: 1096429 Company Registration No: 4542170

NPTC Level 2 Certificate in Forgework (7485 -01)

Assessment and Quality Assurance 6

Candidate Guidelines for the Forgework Certificate and Practical Exam 8

Unit 002 - Practical forge work 13

Unit 003 - Using and maintaining blacksmith’s tools 19

Appendix 1 – Forging exercises for farriery apprentices 21

This page is intentionally blank

• wish to develop a career as a farrier or within blacksmithing

This may be on a full-time or part-time basis.

Assessment and Quality assurance

Paper title: Level 2 Certificate in Forgework

Test duration: 1 hour Total number of questions: 30

002 Know how to: 10

003 1. Identify and report on a range of basic blacksmith tools 8

Exam guidelines and procedures are detailed on the next page.

Candidate Guidelines for the Forgework Certificate and Practical Exam

Unit 001 The Operation, Basic Maintenance and Control of

1. Identify and operate solid fuel forge hearth or gas furnaces

Unit 001 The Operation, Basic Maintenance and Control of

The candidate will be able to:

The candidate will be able to demonstrate knowledge of:

a) Fixed solid fuel forges, e.g. coke side blast

a) Different areas of the fire – e.g. oxidising, neutralising, reducing

Unit 001 The Operation, Basic Maintenance and Control of

The candidate will be able to:

The candidate will be able to demonstrate knowledge of:

1. Health and safety responsibilities of an employee

3. The risks associated with specific hazards to include:

5. Personal protective equipment (PPE)

This page is intentionally blank

Unit 002 Practical Forgework

1. Use basic forging techniques appropriately and safely

The underpinning knowledge is assessed via the multiple choice exam.

Unit 002 Practical Forgework

The candidate will be able to:

2. Select appropriate blacksmiths tools for all forging tasks

3. Control forge heat to produce the desired effect

4. Work safely at all times

The candidate will be able to demonstrate knowledge of:

3. Safe working practices for forging operations

4. Management, maintenance and control of the forge fire/furnace in forging operations

Unit 002 Practical Forgework

The candidate will be able to:

1. Use appropriate forming techniques for given tasks, e.g.

• Bending evenly and to specification

2. Select appropriate blacksmiths tools for all forming tasks

3. Manage, maintain and control the forge fire

The candidate will be able to demonstrate knowledge of:

2. The different forming techniques / tooling required for given tasks

3. Safe working practices for forming operations

4. Management, maintenance and control of the forge fire/furnace in forming operations

5. The use of cooling media in spot heating/cooling

Unit 002 Practical Forgework

The candidate will be able to:

1. Cut or split mild steel using blacksmith tools

2. Punch holes accurately using punches and drifts

3. Select appropriate blacksmiths tools for all cutting tasks

5. Control distortion whilst cutting and punching