Applying surface finishes to composite mouldings
Overview
This standard identifies the competences you need to apply surface finishes to composite mouldings (such as moulds, panels and components), in accordance with approved procedures. You will be required to use appropriate drawings, specifications and documentation to apply surface finishes, using the correct techniques.
You will apply finishes to composite mouldings using a range of techniques and processes. A variety of surface finishes will be applied to a range of resin and fibre materials.
Your responsibilities will require you to comply with organisational policy and procedures for the finishing activities undertaken, and to report any problems with the finishing 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 produce.
Your underpinning knowledge will be sufficient to provide a good understanding of your work, and will provide an informed approach to applying finishing techniques and procedures to composite mouldings. You will have an understanding of the finishing techniques used, and their application, in adequate depth to provide a sound basis for carrying out the activities, recognising faults and ensuring the work output is to the required specification.
You will understand the safety precautions required when carrying out the finishing operations 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
- ensure the material surfaces to be treated are suitably prepared for the finishing operations to be carried out
- check that the finishing equipment and treatment solutions are set up and maintained at satisfactory operating conditions and levels
- carry out the surface finishing process in accordance with operating procedures and the component specification requirements
- ensure that the treated work piece achieves the required characteristics and meets the finishing specification
- 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 finishing equipment in a safe condition on completion of the surface finishing 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 composite materials, consumables, tools and equipment, and how to minimise these and reduce any risks in the work area
- 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 environmental conditions the must be observed when applying surface treatments to composite mouldings (such as temperature, humidity, fume/dust extraction systems, equipment)
- how to extract and use information from engineering drawings and related specifications (to include symbols and conventions to appropriate BS, ISO or BSEN standards) in relation to work undertaken
- quality procedures used in the workplace to ensure production control (such as in relation to currency, issue, meeting specification), and the completion of appropriate documents
- conventions and terminology used for applying finishes (such as surface keying, finish thickness, matt finish, gloss finish, treatment reactions)
- different types of composite resin systems, fibres and reinforcements, and their merits
- different finishes applied to composites, and their application
- correct methods of storage, handling and disposal of finishing materials
- methods of preparation for applying different finishes
- the importance of having the correct mixing ratios when using surface treatments and the associated working times
- methods of application for different finishes
- problems that can occur during the finishing process, including defects such as contamination
- how defects can be overcome during the finishing activity
- tools and equipment used in finishing activities, and their care, preparation and control procedures
- the extent of your own authority and to whom you should report if you have problems that you cannot resolve
Scope/range
Scope Performance
Carry out all of the following during the finishing activities:
- obtain and use the appropriate documentation (such as job instructions, drawings, quality control documentation, material data sheets)
- adhere to procedures or systems in place for risk assessment, COSHH, personal protective equipment and other relevant safety regulations and procedures to realise a safe system of work
- maintain a safe working environment for the composite surface treatment activities
- confirm that all tools and equipment to be used are in a safe and usable condition
- follow safe practice/approved composite surface treatment techniques and procedures at all times
- segregate and dispose of waste materials using the correct procedure
- return all tools and equipment to the correct location on completion of the surface treatment activities
- leave the work area in a safe and appropriate condition on completion of the activities
- complete relevant production documentation
Carry out three of the following activities when preparing for the surface finishing activity:
- check that mouldings are correct and complete
- check for any defects in the mouldings
- check that equipment is suitable for use
- check availability of ancillary materials required
- identify and protect the moulding in the work area
Apply finishes to composite mouldings, using one of the following techniques:
- cloth application
- brush
- spray
- laying films
- roller
- other to be specified
Prepare surfaces of composite mouldings, using one of the following methods:
- surface masks
- peep ply
- abrading
- abrasive blasting
- etching
- water cleaning
- solvent cleaning
- priming
- other to be specified
Apply two types of finish to composite mouldings from the following:
- surface sealers
- top coats
- UV coatings
- speciality coatings
- primers
- adhesive films
- heatproof coatings
- flexible coatings
- other to be specified
Apply finishes to composite mouldings, using one of the following:
- one-part finishes
- multiple coatings
- solvent based
- water based
- single coatings
- two-part finishes
- combination coats
- adhesive based
- other specific finish
Use two of the following consumable materials during the finishing operations:
- abrasives
- masking films
- thinners
- stoppers
- sealers
- cutting compounds
- masking tapes
- polishes
- solvents
- fillers
- primers
- cleaning agents
- other specific consumable
Apply finishes to composite mouldings which are suitable for one of the following resin types:
- bio resin
- thermoplastic
- polyester
- vinyl ester
- epoxy
- phenolic
- bismaleimide
- cyanate ester
- other specific resin
Apply finishes to composite mouldings suitable for one of the following fibre types:
- natural fibre
- thermo plastic
- glass
- aramid
- carbon
- hybrid
- other specific fibre
Apply finishes to a range of mouldings, which comply with one of the following standards:
- BS, ISO or BSEN standards and procedures
- company standards and procedures
- customer standards and requirements
- recognised compliance agency/body standards