Bonding marine composite components
Overview
This standard identifies the competences you need to bond marine composite components and assemblies, such as the hull, bulkhead, superstructure, masts, spars, air intakes/vents, fairings, casings/coverings, rudders, skegs, internal mouldings, tanks and davits, in accordance with approved procedures. You will be required to use appropriate drawings, specifications and documentation, and to use the correct techniques to bond composites materials.
You will produce a range of bonded composite components and assemblies, incorporating a variety of features and using a range of techniques and processes. Bonded components and assemblies produced will include a range of resin, fibre and adhesive materials.
Your responsibilities will require you to comply with organisational policy and procedures for the bonding 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 bonding techniques and procedures. You will understand the bonding 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 produced is to the required specification.
You will understand the safety precautions required when carrying out the composite bonding 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 bonding procedure specification and job instructions
- check that the materials to be bonded and bonding agents comply with the specification
- correctly prepare the parent materials and bonding agents in line with the bonding specification
- carry out the bonding operations using the specified processes and techniques to position and bond the materials in their correct locations
- ensure that any equipment used to maintain surface contact during the bonding activities is set up and used correctly
- achieve bonds of the required quality and within the specified dimensional accuracy
- deal promptly and effectively with problems within your control and report those that cannot be solved
- complete relevant documentation in line with organisational procedures
Knowledge and Understanding
You need to know and understand:
- 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
- how to recognise and deal with emergencies and the procedures to be followed (such as methods of safely evacuating and closing down of compartments in the case of fire or other major incident, first aid, fire fighting and resuscitation of personnel)
- the hazards associated with bonding composite materials, and with the consumables and tools and equipment used, and how to minimise these in the work area
the protective equipment (PPE) that is needed for personal protection 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 bonding marine mouldings (such as temperature, humidity, styrene levels to threshold limits, fume/dust extraction systems and equipment)
- 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
- how to interpret first and third angle drawings, 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 completion of appropriate documents
- conventions and terminology used for bonding (such as gel points, cure times, bond thickness, bond strength, peel strength)
- different types of composite resin and adhesive systems, fibres, reinforcements, and their merits
- different bonding agents, and their applications
- correct methods for storage and handling of bonding agents
- methods of preparation for bonding different materials
- mixing procedures and ratios for two-part pastes, and the associated working times
- methods of application for different bonding and adhesive systems
- the different methods of retaining the bond during curing
- tools and equipment used in bonding activities, and their care, preparation and control procedures
- the identification and rectification of bond defects
- problems that can occur during the bonding process (including defects such as contamination, distortion, disbonds and under-cure)
- how defects can be overcome during the bonding activity
- 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 composite bonding activities:
- use the correct issue of production documentation (such as drawings, manuals, specifications, job cards)
- 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 ensure they are safe to use and suitably stored
- keep the work area in a safe and tidy condition
Carry out all of the following when preparing for the bonding activity:
- check that mouldings are correct and complete
- check availability of ancillary materials required
- check for any defects in the mouldings
- select the correct equipment for the activity
- check that bonding/laminating materials are `within life'
- check that the equipment is suitable for use
- identify and protect the moulding, bonding/laminating materials in the work area
- check that bonding/laminating materials are correct and complete
Bond composite components using two of the following resins or adhesives:
- polyurethane
- polyester
- epoxy
- phenolic
- bismaleimide
- cyanate ester
- vinyl ester
- acrylic
- rubber
- silicones
Prepare bonding surfaces using four of the following methods:
- peel plies
- abrading
- water cleaning
- dry fitting
- priming
- templates
- bead/grit blasting
- solvent cleaning
- acid etching
- surface masks
- gel planer
Bond composite components, using five of the following methods and techniques:
- dry fitting
- wetting-out by brush
- curing by ambient temperature
- laminating
- applicator gun
- oven curing
- shimming materials
- hand tool applicator
- heated press
- mixing adhesives
- laying film adhesives
- heated lamps/mats
During curing, retain the bond using two of the following:
- weighting down
- pinning joins
- press
- vacuum bagging
- bonding jigs
- clamping
- mechanical fasteners
Bond composite mouldings, using techniques for three of the following:
- sandwich panels
- overlap joins
- return joins
- feathered
- staggered
- butt joins
- joggle joins
Bond composite components, using techniques for two of the following:
- flat surfaces
- internal surfaces
- shaped surfaces
- external surfaces
Bond composite components in two of the following positions:
- horizontal
- vertical
- overhead
Use techniques for bonding three of the following materials to the composite moulding:
- plastics
- metals
- wood-based materials
- ceramics
- other composites
Bond composite mouldings, using adhesives suitable for two of the following fibre types:
- polyethylene
- carbon
- glass
- hybrid
- aramid
Bond a range of mouldings, which comply with one of the following standards:
- BS, ISO or BSEN standards and procedures
- customer (contractual) standards and requirements
- company standards and procedures
- recognised compliance agency/body's standards
Complete the relevant documentation in line with organisational procedures, 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
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