Using mechanical fasteners to join marine sheet metal components
Overview
This standard identifies the competences you need to undertake the preparation and making of joints between fabricated marine sheet metal components, using mechanical means, in accordance with approved procedures. You will be required to produce suitable joints, using appropriate methods for the materials to be joined, that meet the specified conditions demanded of the joint. Particular attention will be needed in the preparation and finishing of the materials, so that the finished component is fit for purpose and meets the level of accuracy required. The mechanical fastenings used will include rivets, self-tapping screws, bolts and screwed fittings, anchor nuts and proprietary fasteners, as appropriate to the application and/or specification. The joint will be of two or more materials and may include non-metallic materials and joints of dissimilar metals.
Your responsibilities will require you to comply with organisational policy and procedures for the sheet metal joining activities undertaken and to report any problems with these activities, or with the equipment used, that you cannot personal resolve, or are outside your permitted authority, to the relevant person. 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 the joining activities carried out. You will understand the basic characteristics of the materials to be joined, the various processes used and the appropriate procedures that go with them, in adequate depth to provide a sound basis for carrying out the joining activities.
You will understand the safety precautions required when working with the joining tools and equipment and the safeguards necessary for undertaking the joining processes. You will be required to demonstrate safe working practices throughout and will understand the responsibilities 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 instructions, assembly drawings and any other specifications
- ensure that the specified components are available and that they are in a usable condition
assemble the components in their correct positions using appropriate methods and techniques
secure the components using the specified connectors and securing devices
- check the completed assembly to ensure that all operations have been completed and the finished assembly meets the required specification
- deal promptly and effectively with problems within your control and report those that cannot be solved
Knowledge and Understanding
You need to know and understand:
- the specific safety precautions to be followed when working in a marine fabrication environment and when carrying out joining activities using marine fabricated components (including general workshop and site safety, appropriate personal protective equipment (PPE), accident procedure; statutory regulations, risk assessment procedures and COSHH regulations)
- the personal protective clothing and equipment to be worn when carrying out the joining activities (such as leather gloves, eye/ear protection, safety helmets)
- the hazards associated with carrying out the joining operations (such as handling sheet/fabricated components, handling and using sealants and cleaning agents, using dangerous or badly maintained tools and equipment) and how they can be minimised
- how to recognise and deal with emergencies and the procedures to be followed (such as methods of safely evacuating and closing down compartments in the case of fire or other major incident)
- how to obtain the necessary job instructions, drawings and joining procedure specifications
- how to interpret information from engineering drawings and related specifications, in relation to work undertaken
- the use of manufacturers' specifications for the types of fasteners used
- the various joining processes that are used and the tools and equipment that is required
- the preparations to be carried out on the materials/components prior to joining them (such as materials to be degreased, dry and clean, with holes and flanges de-burred)
- how to set up and align the joints prior to fixing and the tools and methods that can be used (such as clamps, rivet gripping tools, temporary fixings, jacking and supporting devices)
- how to produce a secure joint using blind rivets and the type of riveting tools that are available
- how to produce good riveted joints and the use of the various riveting tools
- how to determine the length of the rivets required to give a properly formed rivet head and a secure joint
- the range of threaded fasteners that are to be used; why it is important to use the correct type of washer; the sequence of tightening bolts on flanged joints and the tools and equipment used to ensure that they are tightened to the required torque
- the various types of proprietary fasteners that are used on fabricated assemblies (such as anchor nuts, clinch nuts, welded studs)
- the checks to be carried out on the tools and equipment prior to use, to ensure that they are in a safe, tested and usable condition (such as condition of plugs and leads on power tools, condition of striking faces on hammers, condition of riveting tools and rivet snaps)
- the importance of using the tools only for the purpose intended and the care that is required when using the equipment and tools
- 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 problems that can occur with the joining operations and how these can be avoided
- the extent of your own responsibility and whom you should report to if you have problems that you cannot resolve
Scope/range
Scope Performance
Carry out all of the following during the joining of the sheet metal components:
- prepare the faces of the materials to be joined
- select the appropriate/specified fixings
- correctly align the materials and faces to be joined
- assemble the components in the correct order or manner
- produce a joint that meets the requirements of the specification
Produce assemblies which include four of the following:
- flanged joints on flat or curved surfaces
- joints with gasket or sealant
- pre-fabricated square/rectangular components
- pipes
- pre-fabricated cylindrical/conical components
- structural components
- access flanges and cover plates
- light rolled section (angle, channel or tee section)
- tanks and tank covers
- stiffeners and frame components
- brackets
- permanent and temporary assemblies
Use three of the following assembly methods and techniques:
- riveting using solid rivets
- riveting using pop/blind rivets
- self-tapping screws
- use of proprietary fasteners
- crimping
- assembling using bolt fittings
- using screw fittings to tapped components
- nuts and (spot welded) screw studs
- locking methods and devices
- clinching
- other specific method
Join the components in three of the following joining positions, access and environmental conditions:
- horizontal
- vertical
- overhead
- in workshop conditions
- internal and confined spaces
Produce joints which meet all of the following requirements, as appropriate to the application:
- joints are accurately assembled and aligned, in accordance with the specifications
- joints are secure and firm
- threaded joints are tightened to the correct torque
- riveted joints are free from excessive material deformation and hammer marks
- pitches of holes meet the specification
- completed joints are clean and free from burrs
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