Producing marine composite components using wet lay-up techniques

This standard identifies the competences you need to produce marine composite mouldings such as hulls, superstructure, masts, spars, bulkheads, fairings, air intakes, hatches, steering equipment, rudders, skegs, tanks, casings and coverings, radar navigational domes, davits and internal fitments such as berths, vanity units, consoles, seating and shower units, using wet lay-up techniques, in accordance with approved procedures. You will be required to use appropriate drawings, specifications and documentation to produce the various mouldings, using the correct wet lay-up production techniques.

You will be expected to prepare the tooling, apply release agents and prepare the composite materials. You will produce the composite mouldings, which will incorporate a range of features, using a range of application methods. Mouldings produced will include laminates and sandwich structures, using suitable resin, fibre and core materials.

Your responsibilities will require you to comply with organisational policy and procedures for the wet lay-up production 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 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 provide a good understanding of your work, and will provide an informed approach to applying composite moulding wet lay-up techniques and procedures to produce marine composite components. You will understand the production techniques used, and their application, in adequate depth to provide a sound basis for carrying out the activities, correcting faults, and ensuring that the work output is produced to the required specification.

You will understand the safety precautions required when carrying out the wet lay-up moulding 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.

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1. work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
2. follow the correct component drawing or any other related specifications for the component to be produced
3. determine what has to be done and how this will be achieved

4. obtain and prepare the appropriate tools, equipment and materials

5. carry out the moulding or laying-up activities using the correct methods and techniques

6. produce components to the required specification
7. check that all the required operations have been completed to specification
8. deal promptly and effectively with problems within your control and report those that cannot be solved
9. complete relevant documentation in line with organisational procedures

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1. 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 using composite materials, consumables, tools and equipment, and how to minimise these in the work area

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 workshop environmental conditions the must be observed when producing marine composite mouldings (such as temperature, humidity, styrene levels to threshold limits, fume/dust extraction systems and equipment)
6. how to use and extract information from drawings and related specifications (to include symbols and conventions to appropriate BS or ISO standards) in relation to work undertaken
7. how to interpret first and third angle drawings, imperial and metric systems of measurement, workpiece reference points and system of tolerancing
8. quality procedures used in the workplace to ensure production control (in relation to currency, issue, meeting specification.) and the completion of the appropriate documents
9. conventions and terminology used for wet lay-up techniques (such as resin and fibre weights/volumes, material orientation, material identification, material tailoring, mixing ratios, gel times, exotherm, consolidation)
10. the different types of resins, reinforcement, catalysts, accelerators and additives used, and their applications
11. the different types of fibre materials, weave patterns, orientations, their combinations and applications
12. the visual identification systems of both raw and finished composite materials
13. the different types of tooling used for producing marine composite components
14. the identification and rectification of defects in marine mould tooling
15. methods of preparation for patterns, moulds and tooling, including the correct use of surface sealers and release agents
16. methods for handling and preparing the reinforcing fibres
17. calculations of resin volume/weight/ratios required to wet-out the reinforcing fibres
18. the mixing ratios for gel coats, resins, additives and catalysts, and the associated working times 
19. the methods used in the application of the resin/fibre during the lay-up activity
20. the tools and equipment used in the lay-up activities, and their care, preparation and control procedures
21. problems that can occur during the lay-up process (including defects such as contamination, resin/fibre rich areas, distortion, poor consolidation, under-cure and exotherm)
22. how defects can be overcome during the lay-up activity
23. procedures and methods used for removing mouldings from production tooling
24. the methods and techniques used to trim mouldings prior to release
25. how different materials can effect the selection of tip tool geometry when cutting composite mouldings
26. the identification of defects in the composite moulding (such as de-lamination, voids, contaminants)
27. the care and safe handling of production tooling and composite mouldings throughout the production cycle
28. the production controls used in the work area, and actions to be taken for unaccounted items
29. how the composite moulding relates to its own quality documents and the production tooling used
30. the extent of your own responsibility and whom you should report to if you have problems that you cannot resolve

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1. Carry out all of the following during the wet lay-up moulding activities:

   1. use the correct issue of production documentation (such as drawings, manuals, specifications, job cards)
   2. use relevant health and safety documentation (such as material data sheets, COSHH sheets, risk assessments)
   3. use the correct tools and equipment for the activity and ensure that they are safe to use
   4. keep the work area in a safe condition

2. Carry out all of the following activities when preparing the marine composite tooling:

   1. check that tooling is correct and complete        
   2. correctly apply sealers/release agents
   3. clean the tooling and remove resin build-ups        
   4. clean and store tooling suitably after use
   5. check for surface defects

3. Carry out all of the following activities to prepare the materials for production:

   1. obtain the correct materials for the activity            
   2. calculate the correct resin-to-fibre ratios
   3. check that materials are fit for purpose and `in life'  
   4. check the correct measure and mix of resin/catalyst
   5. cut materials to the correct size and shape          
   6. identify and protect materials in the work area
   7. check that quantities of resins  are available

4. Produce marine components, using four of the following application techniques:

   1. spray application of fibre/resin       
   2. roller application of fibre/resin
   3. use of vacuum bagging
   4. application of a gel coat            
   5. removal of voids and air pockets   
   6. by consolidation
   7. brush application of fibre/resin

5. Produce marine composite mouldings using wet lay-up techniques, to include: Either one of the following:

   1. hull                            
   2. superstructure    
   3. bulkhead          
   4. masts and spars
   5. cabins or wheel houses

Or four of the following types of marine components:
6. rudders                 
7. casings and covers    
8. berths               
9. vanity units
10. air intakes/vents     
11. davits                 
12. shower units    
13. steering equipment (wheel, tiller)
14. fairings                  
15. skegs               
16. seats            
17. radar/navigational domes
18. hatches                 
19. tanks                   
20. consoles
21. composite mould tools     
22. other specific marine components

6. Produce marine components incorporating two of the following in the lay-up:

   1. feathered joins                    
   2. orientated plies                            
   3. fixtures
   4. overlap joins                        
   5. inserts                                     
   6. butt joins

7. Produce marine components incorporating three of the following shape features:

   1. internal corner 
   2. double curvature   
   3. convex surface
   4. external corner     
   5. concave surface      
   6. vertical surface

8. Produce marine components, using appropriate techniques for two of the following types of resin:

   1. polyester                              
   2. epoxy resin
   3. vinyl ester                            
   4. phenolic resin

9. Produce marine components, using appropriate techniques for one of the following types of fibre:

   1. polyethylene                     
   2. aramid                         
   3. hybrid
   4. glass                            
   5. carbon

10. Produce marine components, using appropriate techniques for two of the following types of reinforcement:

    1. roving                                
    2. tapes                           
    3. continuous filament
    4. braids                            
    5. chopped strand     
    6. woven

11. Produce marine components, using appropriate techniques for two of the following types of core material:

    1. solid timber                       
    2. foam                          
    3. end grain balsa
    4. core mat                       
    5. honeycomb

12. Produce marine components which comply with one of the following standards:

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

13. Complete the relevant documentation in line
    with organisational procedures, to include one from the following and pass it to the appropriate people:

    1. build records
    2. quality/acceptance documentation
    3. system log
    4. job cards 
    5. work authorisation documents
    6. other specific reporting method

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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

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3

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29 Apr 2021

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Current

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Original

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Semta

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SEMME3143

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Marine Engineering Trades

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2122

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engineering; marine; produce; composite; components; wet lay-up; techniques; hulls; superstructures; masts; spars

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