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Carrying out repairs on composite mouldings

URN: SEMCOMP220
Business Sectors (Suites): Composite Engineering Suite 2
Developed by: Enginuity
Approved on: 28 Feb 2018

Overview

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This standard identifies the competences you need to repair composite mouldings (such as cured panels, moulds, components and jigs), in accordance with approved procedures.  You will be required to use appropriate drawings, specifications and documentation to repair composites materials, using the approved techniques.

You will repair a range of composite mouldings with various defects using a range of methods.  Mouldings repaired will include a range of resin and fibre materials.

Your responsibilities will require you to comply with organisational policy and procedures for the repair activities undertaken and to report any problems with the repair activities, equipment or materials that you cannot personally resolve, or are outside your permitted authority, to the relevant people.  You will be expected to work to instructions under supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you produce.

Your underpinning knowledge will provide a good understanding of your work and will provide an informed approach to applying composite moulding repair procedures.  You will understand the repair techniques used and their application, in adequate depth to provide a sound basis for carrying out the activities to the required specification. 

You will understand the safety precautions required when carrying out the repair activities and when using the associated tools and equipment.  You will be required to demonstrate safe working practices throughout and will understand the responsibility you owe to yourself and others in the workplace.

Performance criteria

You must be able to:

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  1. work safely at all times, complying with health and safety, environmental and other relevant regulations, directives and guidelines
  2. follow the relevant drawings and documentation for the moulding to be repaired
  3. complete any preparation required prior to undertaking the repair
  4. repair defects within agreed timescale using approved materials and components and methods and procedures
  5. carry out any checks to confirm the repaired moulding meets the specified operating conditions
  6. deal promptly and effectively with problems within your control and report those that cannot be solved
  7. dispose of waste and excess materials in line with agreed organisational procedures
  8. produce accurate and complete records of all repair work carried out using organisational procedures and documentation
  9. leave the work area in a safe and appropriate condition on completion of the activities

Knowledge and Understanding

You need to know and understand:

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  1. the health and safety precautions to be taken and procedures used when working with composite materials, consumables, tools and equipment in the specific work area
  2. the hazards associated with carrying out composite repair activities and with the composite materials, consumables, tools and equipment used and how to minimise these and reduce any risks
  3. the protective equipment (PPE) that is needed for personal protection and where required, the protection of others
  4. the application of COSHH regulations in relation to the storage, use and disposal of composite materials and consumables
  5. the specific environmental conditions the must be observed when repairing composite mouldings (such as temperature, humidity, fume/dust extraction systems and equipment)
  6. the safe working practices that are required when working in confined spaces (such as ventilation, use of flammable materials) and emergency procedures that may need to be followed
  7. how to identify and use information from engineering drawings and related documentation, to include symbols and conventions to appropriate BS, ISO or BSEN standards in relation to work undertaken
  8. how to interpret drawings, lay up manuals, systems of measurement, workpiece reference points and system of tolerancing
  9. the quality procedures used in the workplace to ensure production control (in relation to currency, issue, meeting specification) and the completion of such documents
  10. the basic conventions and terminology used when repairing composite mouldings (such as dis-bonds, de-lamination, resin injection, resin voids, core potting, repair patches)
  11. the methods used to repair composite mouldings
  12. the methods used to cure bonded repairs and their applications
  13. the function resin systems, fibres, reinforcements play in the production of mouldings
  14. the function bonding agents play in the production of mouldings
  15. the importance of carrying out dimensional/tolerance checks on completion of the repair activity
  16. why repairs may affect the structural integrity of the composite moulding
  17. describe the procedure used to determine if additional testing (such as joint integrity, strength testing) is required following a repair
  18. the correct methods of storing and handling composite materials
  19. the tools and equipment used for various activities associated with repairing composite mouldings
  20. the extent of your own responsibility and to whom you should report if you have problems that you cannot resolve
  21. the documentation to be completed during and/or on completion of the repair activity

Scope/range

Scope Performance

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  1. Carry out all of the following during the repair activities:

    1. use the appropriate documentation (such as job instructions, drawings, material data sheets, specifications, planning and quality control documentation)
    2. adhere to procedures or systems in place for risk assessment, COSHH, personal protective equipment and other relevant safety regulations and procedures to realise a safe system of work
    3. maintain a safe working environment for the composite repair activities
    4. check that all tools and equipment to be used are correct for the operation to be carried out and are in a safe and usable condition
    5. follow safe practice/approved composite repair techniques and procedures at all times
    6. return all tools and equipment to the correct location on completion of the composite repair activities
    7. segregate and dispose of waste materials using the correct procedure

  2. Carry out all of the following activities when preparing for the repair activity:

    1. confirm what has to be prepared
    2. confirm the method of repair to be used
    3. check availability of ancillary materials required
    4. confirm the tools, materials and equipment selected is suitable for the repair activity
    5. identify and protect the moulding and repair materials in the work area

  3. Carry out two of the following types of repair:

    1. temporary
    2. cosmetic
    3. non structural
    4. structural
    5. temporary mould
    6. graft/pre-cured patch
    7. laminate only
    8. partial thickness laminate
    9. through laminate
    10. type A sandwich panel
    11. type B sandwich panel
    12. type C sandwich panel
    13. single sided access
    14. double sided access

  4. Repair defects in three of the following types of composite moulding:

    1. internal corners
    2. external corners
    3. horizontal surface
    4. vertical surface
    5. double curvature
    6. concave surface
    7. convex surfaces
    8. flat surfaces
    9. return surfaces
    10. joggle details
    11. nett edges
    12. webs/ribs
    13. inserts
    14. fixtures
    15. other (to be specified)

  5. Repair defects in composite mouldings using two of the following methods:

    1. localised curing
    2. fettling
    3. surface filling
    4. laminating
    5. relieving distortion
    6. bonding
    7. osmosis
    8. resin injection
    9. wet-lay patching
    10. pre-preg patching
    11. polishing
    12. core patching
    13. insert/core potting
    14. repair patches/kits
    15. colour matching

  6. Repair defects using techniques/materials applicable to one of the following resin types:

    1. bio resin
    2. thermoplastic
    3. polyester
    4. vinyl ester
    5. epoxy
    6. phenolic
    7. bismaleimide
    8. cyanate ester
    9. other (to be specified)

  7. Repair defects using techniques/materials applicable to one of the following fibre types:

    1. natural fibre
    2. thermo plastic
    3. glass
    4. aramid
    5. carbon
    6. hybrid
    7. other (to be specified)

  8. Repair defects in one of the following core materials (where applicable to the Sector or process):

    1. solid timber
    2. end grain balsa
    3. rigid foam
    4. expanding foam
    5. coremat
    6. honeycomb
    7. fibrous honeycomb
    8. aluminium honeycomb
    9. syntactic core
    10. expanding core
    11. thermoplastic
    12. other (to be specified)

  9. Repair four of the following types of defect in composite mouldings:

    1. dimensional
    2. tolerances
    3. surface finish
    4. colour separation
    5. distortion
    6. blisters
    7. dents or 'dings'
    8. surface cracks
    9. incorrect material
    10. contamination
    11. bridging
    12. broken fibres
    13. stray fibres
    14. ply orientation
    15. wrong join type
    16. gaps at joins
    17. incorrect overlap
    18. wrinkles
    19. splintering
    20. voids
    21. resin rich areas
    22. fibre deviation
    23. damaged cores
    24. dis-bonds
    25. excessive adhesive
    26. wrong inserts
    27. insert positions
    28. porosity
    29. local exotherm
    30. fayed/burned area
    31. incomplete curing
    32. de-lamination
    33. impact damage
    34. puncture
    35. gouges
    36. holes
    37. abrasion/erosion
    38. fluid ingress
    39. fractures
    40. other (to be specified)

  10. Where applicable cure bonded repairs using one of the following methods:

    1. room temperature
    2. oven
    3. autoclave
    4. heated tools/moulds
    5. heat mats
    6. curing lamps
    7. infrared heating
    8. UV curing
    9. electro-magnetic inductance
    10. micro-wave

    11. hot bonder

    12. other (to be specified)

  11. Repair a range of mouldings in compliance with one of the following standards:

    1. BS, ISO or BSEN standards and procedures
    2. customer standards and requirements
    3. company standards and procedures
    4. recognised compliance agency/body standards

  12. Complete the relevant documentation, to include one of the following:

    1. production documentation
    2. quality control documentation
    3. job cards

Scope Knowledge

Values

Behaviours

You will be able to apply the appropriate behaviours required in the workplace to meet the job profile and overall company objectives, such as:

  • strong work ethic
  • positive attitude
  • team player
  • dependability
  • responsibility
  • honesty
  • integrity
  • motivation
  • commitment

Skills

Glossary

Links To Other NOS

External Links

Version Number

2

Indicative Review Date

01 Feb 2021

Validity

Current

Status

Original

Originating Organisation

Semta

Original URN

SEMCOMP220

Relevant Occupations

Composite Fitter, Composite Technician, Laminator, Moulding Technician

SOC Code

8114

Keywords

Engineering; repair; composite; mouldings; components; laminating; resin; fibre; assemblies; mark out; drawings