Carrying out repairs to marine composite mouldings
Overview
This standard identifies the competences you need to carry out repairs to composite mouldings, in accordance with approved procedures. You will be required to use appropriate specifications, documentation and materials to carry out the repairs to the composite components, using the correct techniques. The marine components and assemblies to be repaired will include items such as the hull, bulkheads, superstructure, wheel houses, cabins, masts, spars, fairings, air intakes, steering equipment, rudders, skegs, tanks, casings and coverings, davits and internal fitments such as berths, vanity standards, consoles, seating and shower standards.
You will be required to obtain all relevant and current documentation relating to the repair, to obtain the tools and equipment for the repair operations, and to check that they are in a safe and usable condition. In carrying out the repair, you will be required to follow company procedures and specified repair 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 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, with a minimum of supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.
Your underpinning knowledge will be sufficient to provide a sound basis for your work, and will provide an informed approach to applying composite moulding repair procedures to marine components. You will have an understanding of 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:
- work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
- follow the relevant specifications for the component to be repaired
- prepare the component for repair
- carry out the repairs within agreed timescale using approved materials and components and methods and procedures
- ensure that the repaired component meets the specified operating conditions
- produce accurate and complete records of all repair work carried out
- deal promptly and effectively with problems within your control and report those that cannot be solved
- dispose of waste and excess materials in line with agreed organisational procedures
- leave the work area in a safe and appropriate condition on completion of the activities
Knowledge and Understanding
You need to know and understand:
- health and safety precautions to be taken and procedures used when working with composite materials, consumables, tools and equipment in the specific work area
- the hazards associated with carrying out repairs to composite materials, consumables, tools and equipment, and how to minimise these in the work area
- protective equipment that is needed for personal protection (PPE) and where required, the protection of others
- the application of COSHH regulations in relation to the storage, use and disposal of composite materials and consumables
- the specific workshop environmental conditions that must be observed when producing marine mouldings (such as temperature, humidity, styrene levels to threshold limits, fume/dust extraction systems and equipment)
- the requirements for working in confined spaces - including an understanding of the importance of emergency procedures and safe systems of work (including permits to work, required air quantities (RAQs) and local exhaust ventilation (LEV) to maintain safe conditions, the provision of adequate and safe lighting and avoidance of sources of ignition)
- how to use and extract information from repair drawings and related specifications
- the quality procedures used in the workplace to ensure that repairs are carried out satisfactorily
- how to identify and use information from engineering drawings and related documentation in relation to work undertaken
- conventions and terminology used when repairing composite mouldings (such as disbonds, de-lamination, resin injection, resin voids, core potting, repair patches)
- the different types of composite resin systems, fibres and reinforcements, and the repair techniques that can be used
- methods of cleaning and preparing the components in readiness for the repair
- the various bonding agents and methods used
- the importance of carrying out dimensional/tolerance checks on completion of the repair activity
- the procedure used to determine if additional testing (such as joint integrity, strength testing) is required following a repair
- correct methods for storage and handling of composite materials
- tools and equipment used for the various activities associated with repairing composite mouldings
- why tool/equipment control is critical and what to do if a tool or piece of equipment is unaccounted for on completion of the activities
- the extent of your own authority, and whom you should report to if you have problems that you cannot resolve
- the documentation to be completed during and/or on completion of the repair activity
Scope/range
Scope Performance
Carry out all of the following during the repair activities:
- use the appropriate documentation (such as job instructions, drawings, specifications, correct issue number)
- use relevant health and safety documentation (such as material data sheets, COSHH sheets, risk assessments)
- obtain the correct tools and equipment for the activity, and check that they are in a safe, tested and usable condition
- check what needs to be repaired and the method of repair to be used
- apply appropriate and safe repair techniques and procedures at all times
- keep the work area in a safe and tidy condition
- return all tools and equipment to the correct location on completion of the composite repair activities
Carry out repairs to three of the following types of marine composite mouldings:
- bulkhead
- rudders
- steering equipment (wheel, tiller)
- hull
- air intakes/vents
- superstructure
- fairings
- skegs
- masts
- hatches
- tanks
- spars
- casings and covers
- radar/navigational domes
- cabins
- consoles
- vanity standards
- wheel houses
- closing panels
- housings
- berths
- shower standards
- seats
- trim
- composite mould tools
- other specific marine components
Repair composite mouldings using three of the following methods:
- localised curing
- relieving distortion
- resin injection
- core patching
- fettling
- separation of bonds
- wet-lay patching
- insert/core potting
- surface filling
- bonding
- pre-preg patching
- repair patches/kits
- colour matching
- polishing
- osmosis
- laminating
Repair composite mouldings using techniques and materials applicable to both of the following:
- resins (such as polyester, vinyl ester, epoxy, phenolic, bismaleimide, cyanate ester, acrylic)
- fibres (such as polyethylene, glass, aramid, carbon, hybrid materials)
Repair five of the following types of defect/damage in marine composite mouldings:
- incomplete curing
- blisters
- voids
- damaged cores
- dimensional
- bridging
- disbonds
- wrong inserts
- surface finish
- de-lamination
- dents or `dings'
- incorrect insert positions
- distortion
- broken fibres
- excessive adhesive
- impact damage
- cosmetic (can be filled)
- fractures
- gouges
- abrasion/erosion
- hole damage (access from both sides)
- hole damage (external access only)
Carry out repairs to composite mouldings, in accordance with one of the following standards:
- BS, ISO or BSEN standards and procedures
- customer standards and requirements
- company standards and procedures
- recognised compliance agency/body's standards
Complete the relevant paperwork, to include one from the following and pass it to the appropriate people:
- repair records
- quality/acceptance documentation
- system log
- job cards
- work authorisation documents
- other specific reporting method
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