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Carry out motor vehicle body resistance spot welding operations

URN: IMIVBR20
Business Sectors (Suites): Vehicle Body Repair
Developed by: IMI
Approved on: 30 Mar 2023

Overview

This standard is about joining materials correctly and effectively using resistance spot welding techniques.

Performance criteria

You must be able to:

P1 use the appropriate personal protective equipment (PPE) and check it is fit for purpose before carrying out resistance spot welding operations 
P2 protect the vehicle, its systems and its contents effectively when carrying out resistance spot welding operations 
P3 prepare material and align to enable suitable join to be achieved, ensuring mating flanges are treated following manufacturers’ procedures before joining 
P4 select, set up and use the correct tools and equipment in order to correctly carry out resistance spot welding operations 
P5 ensure that the tools, equipment and PPE you require are in a safe working condition and are correct for the joining operation that you are to be completing 
P6 set up your equipment to carry out spot welding operations checking: 

P6.1 suitability of the air supply and pressure
P6.2 the current supply
P6.3 the consumables are correct
P6.4 the suitability/serviceability of electrodes and tips 
P7 carry out spot welding operations following: 

P7.1 recognised researched repair methods
P7.2 test procedures in accordance with British Standards (peel/sheer/nugget size)
P7.3 manufacturer's processes, methods and procedures
P7.4 your workplace processes, methods and procedures
P7.5 health, safety and legal requirements 
P8 avoid damaging other components, standards, panels and surfaces on the vehicle and the surrounding work area 
P9 recognise when your weld is not forming correctly and what action needs to be taken 
P10 inspect and assess resistance spot weld quality in accordance to British Standards, including weld pitch, indention/weld profile, heat zone, nugget size and peel and shear test 
P11 check integrity of weld and record the type of weld achieved on the appropriate paper work. Test pieces must be recorded and stored 
P12 dress and protect the repaired area to inhibit corrosion where applicable 
P13 clean and store PPE and equipment in appropriate manner 
P14 promptly report any additional faults you notice during the course of your work to the relevant person(s)  
P15 promptly report any delays in completing your work to the relevant person(s)  
P16 carry out resistance spot welding operations within the agreed timescale 
P17 complete work records accurately, in the format required and promptly pass them to the relevant person(s)

Knowledge and Understanding

You need to know and understand:

K1 the health, safety and legal requirements relating to the joining of materials using resistance spot welding techniques 
K2 your workplace procedures for carrying out appropriate risk assessment(s), the referral of problems, reporting of delays to the completion of work and completion of work records 
K3 the constraints of the type of materials used in vehicle construction places on the choice of repair equipment *
K4 how to prepare, test and adjust all *equipment required for resistance spot welding techniques 
K5 the work that needs to be done and the standard required 
K6 the requirements for protecting the vehicle and contents from damage before, during and after the joining of materials using resistance spot welding techniques 
K7 the importance of selecting, using, maintaining and storing the appropriate PPE when the joining of materials using resistance spot welding techniques 
K8 how to find, interpret and use sources of information (including repair methods) applicable to the joining of materials using resistance spot welding techniques  and the implications of not fully understanding the repair methods presented
K9 how to select, check, maintain, set up and store all of the tools and equipment required to correctly join materials using resistance spot welding techniques 
K10 the different types of welding processes, techniques and joints used for the joining of materials when using resistance spot welding techniques
K11 the correct surface preparation methods to ensure the correct resistance spot weld is achieved and the reasons why surface preparation is important 
K12 the faults and defects that can occur when carrying out resistance spot welding and the common causes of these faults 
K13 the need for correct alignment of materials and the methods used to achieve this 
K14 the types of quality control checks that can be used to ensure correct joining of materials e.g. test coupons 
K15 how to inspect and assess resistance weld quality in accordance to British Standards including weld pitch, indention/weld profile, heat zone, nugget size, peel and shear test 

K16 the correct use of adhesives with resistance spot welding techniques
K17 the implications of electro-magnetic fields and the effects on medical devices 

Scope/range

All of the items listed below form part of this National Occupational Standard.

1. **Personal protective equipment (PPE)** for resistance spot welding operations includes: 

1.1. face mask with appropriate eye protection 
1.2. protective/Flame retardant coveralls 
1.3. protective/Flame retardant gauntlets 
1.4. steel toe cap boots 
1.5. appropriate vehicle protection 
1.6. appropriate protection for others in the workshop 
1.7. appropriate fume mask 

2. Tools and Equipment are: 

2.1. workshop equipment 
2.2. generic hand tools 
2.3. manufacturer's specified and specialist tools
2.4. fume extraction equipment

Scope Performance

Scope Knowledge

Values

Behaviours

Skills

Glossary

Links To Other NOS

External Links

Version Number

1

Indicative Review Date

30 Mar 2026

Validity

Current

Status

Original

Originating Organisation

IMI

Original URN

IMIARBBP20

Relevant Occupations

Accident Repair Technicians, Body Repair and Alignment Technician (Automotive), Body Repair Technician (Automotive)

SOC Code

5232

Keywords

Motor; vehicle; body; resistance; spot; welding; operations;