Checking marine composite components/mouldings for defects
Overview
This standard identifies the competences you need to check marine composite components/mouldings for defects, and to identify and deal with any defects found, in accordance with approved procedures. You will be required to follow appropriate drawings, specifications and documentation to carry out the checks of the components/mouldings, which will include visual and sensory checks as well as the use of measuring instruments and non-destructive testing methods. The marine composite components/mouldings will include items such as hulls, bulkheads, superstructure, masts, spars, fairings, air intakes, hatches, steering equipment, rudders, skegs, tanks, casings and coverings, radar/navigational domes, davits and internal fitments such as berths, vanity standards, consoles, seating and shower standards. You will be expected to be able to identify a range of defects in a variety of resin and fibre materials, and to take the appropriate action to deal with them.
Your responsibilities will require you to comply with organisational policy and procedures for the checking activities undertaken, and to report any problems with the activities 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 identifying defects in marine composite components/mouldings. You will have an understanding of composite materials, and their application, and will know about the associated defects, in adequate depth to provide a sound basis for identifying the defects in line with organisation practice and procedures.
You will understand the safety precautions required when working with the composite components/mouldings, and when using 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
- identify defects with regard to the marine composite/moulding
- assess the defects and determine action required to return the composites/mouldings to specified condition
- report recommendations for action to the appropriate people promptly and in accordance with organisational procedures
- record details of defects in accordance with quality assurance and control systems and 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:
- the health and safety precautions to be taken, and procedures to be used when working with composite materials, consumables, tools and equipment in the specific work area
- the hazards associated with working with composite materials, consumables, tools and equipment, and how to minimise these in the work area
- the 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
- how to use and extract information from engineering drawings and related specifications (to include symbols and conventions to appropriate BS,EN or ISO standards) in relation to work undertaken
- how to use imperial and metric systems of measurement, workpiece reference points and system of tolerancing
- quality procedures used in the workplace to ensure production control (in relation to currency, issue, meeting specification), and the procedures for completion of appropriate documents
- the basic conventions and terminology used when identifying and rectifying defects (such as disbonds, de-lamination, resin injection, resin voids, core potting, repair patches)
- failure modes for various composite mouldings, and what can contribute to these
- how to recognise the different types of defect that can occur in composite mouldings
- the different methods used to identify defects in composite mouldings including sensory checks, hand measuring tools and machine tools
- the importance of identifying defects in composite mouldings and the implications if defects are not identified
- correct methods of storage and handling of composite materials
- the various methods that can be used to help identify if defects are present in the mouldings (to include visual inspection, touch, sound, measurement, mechanical and NDT tests)
- tools and equipment used for checking the various 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 checking activity
Scope/range
Scope Performance
Carry out all of the following during the checking activities:
- use the appropriate documentation (such as job instructions, drawings, specifications, current issue number)
- use relevant health and safety documentation (such as material data sheets, COSHH sheets, risk assessments)
- use the correct tools and equipment for the activity, and check that they are in a safe and usable condition
- keep the work area in a safe and tidy condition
- return all tools and equipment to the correct location on completion of the activities
Check for defects in composite components/mouldings, using all of the following methods:
- touch
- sound
visual
and one of the following:
- mechanical tests
- non-destructive testing (NDT)
- measurement
- stage inspection
- co-ordinate measuring machines (CMM)
- other (to be specified)
Identify defects in marine composite components/mouldings, to include: Either one of the following:
- hull
- superstructure
- masts
- cabins
- bulkheads
- spars
- wheel houses
- other major marine components
OR three of the following types of components/mouldings:
9. rudders
10. steering equipment (wheel, tiller)
11. berths
12. air intakes/vents
13. skegs
14. showers
15. fairings
16. tanks
17. seats
18. hatches
19. radar/navigational domes
20. trim
21. casings and covers
22. vanity standards
23. composite mould tools
24. consoles
25. housings
26. other specific marine components
Identify defects applicable to two of the following resin types:
- polyester
- vinyl ester
- phenolic
- acrylic
- epoxy
- bismaleimide
- cyanate ester
- other specific resin type
Identify defects applicable to two of the following fibre types:
- polyethylene
- glass
- aramid
- carbon
- hybrid
- other specific fibre type
Identify six of the following types of defect in marine composite components/mouldings:
- incomplete curing
- distortion
- splintering
- thin gel coat
- dimensional
- blisters
- voids
- excessive adhesive
- ply orientation
- bridging
- dents or `dings'
- damaged cores
- wrong join type
- de-lamination
- disbonds
- wrong inserts
- colour leaching
- wrinkles
- resin rich areas
- impact damage
- surface finish
- broken fibres
- incorrect material
- contamination
Check marine components/mouldings against one of the following standards:
- BS, ISO or BSEN standards and procedures
- company standards and procedures
- customer standards and requirements
- recognised compliance agency/body's standards
Complete the relevant paperwork, to include one from the following and pass it to the appropriate people:
- build 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