This standard covers a range of basic competences that you need, to apply specified surface treatments on components. It will prepare you for entry into the engineering or manufacturing sectors, creating a progression between education and employment, or it will provide a basis for the development of additional skills and occupational competences in the working environment.

You will be expected to prepare for the surface treatment activities by obtaining all the necessary job instructions, materials, tools, equipment and any documentation that may be required.

You will be expected to use the specified techniques to prepare the surfaces in readiness for the application of the treatments. The treatment activities will include the application of surface treatments such as plating, anodising, powder coating, hot dip treatments and chemical treatments, as applicable to the task.

Your responsibilities will require you to comply with health and safety requirements and organisational policy and procedures for the surface treatment activities undertaken. You will need to report any difficulties or problems that may arise with the surface treatment activities, and to carry out any agreed actions. You will work under a high level of supervision, whilst taking responsibility for your own actions and for the quality and accuracy of the work that you carry out.

Your underpinning knowledge will provide an understanding of your work, and will enable you to apply appropriate surface treatment techniques and procedures safely. You will understand the preparation and surface treatment techniques used, and their application, and will know about the equipment, materials and consumables, to the required depth to provide a sound basis for carrying out the activities to the required specification.

You will understand the safety precautions required when carrying out the surface treatment activities, and when using the associated tools and equipment. You will be required to demonstrate safe working practices throughout. You will also understand your responsibilities for safety, and the importance of taking the necessary safeguards to protect yourself and others in the workplace.

Specific Standard Requirements

At least one of the finished surfaces must require a combination of different finishing techniques to be used: such as preparing the surface by degreasing, masking up areas that need to be protected from the treatment, and applying a finishing coat such as powder coating.

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1. work safely at all times, complying with health and safety legislation, regulations, directives and other relevant guidelines
2. prepare the work surfaces in readiness to receive the appropriate treatment
3. check that the finishing equipment and treatment solutions are at satisfactory operating conditions and levels
4. carry out the surface treatment process, using appropriate techniques and procedures
5. report any difficulties or problems that may arise with the surface treatment activities, and carry out any agreed actions
6. dispose of waste material safely and correctly, in line with organisational procedures
7. shut down the finishing equipment to a safe condition on completion of the surface treatment activities
8. leave the work area in a safe condition on completion of the surface treatment activities

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1. the specific health and safety precautions which must be taken when preparing surfaces and applying surface treatment processes (such as wearing protective clothing and protective equipment, using fume extraction equipment)
2. the hazards associated with preparing surfaces and applying surface treatments (such as using chemicals for cleaning and coating activities, fume inhalation, splashes from hot or corrosive treatment processes), and how they can be minimised
3. the personal protective equipment (PPE) that should be used (such as eye protection, overalls, face masks, breathing equipment); how to obtain it and check that it is in a safe and usable condition
4. the requirements for working in confined spaces and safe systems of work (including required air quantities (RAQs) and local exhaust ventilation (LEV)) to maintain safe conditions
5. the importance of ensuring that fume extraction equipment is operating effectively, and that good housekeeping and fire prevention procedures are observed
6. the importance of following job instructions and defined surface treatment procedures
7. the surface preparation methods and techniques to be undertaken prior to applying the treatments (such as stripping off old materials; using solvents to remove dirt and grease; masking surfaces to contain the deposits)
8. the specific surface treatment process to be carried out (such as powder coating, hot dip treatments, chemical treatments, phosphating, electroplating and anodising)
9. the pre-treatments to be carried out on the components prior to the surface treatment activities (such as cleaning/degreasing, pickling, pre-heating)
10. the visual checks to be made on the components prior to carrying out the surface treatment activities (such as checking that they are dry, have been pre-heated or are correctly masked up)
11. the need to make certain that all substrates and jigs are completely free of water or other solvents prior to immersing in a hot solution, and the potential consequences of failing to check this
12. the methods used to hold/secure components during the surface treatment process (such as wires, hooks, jigs)
13. the importance of monitoring the equipment settings and process solutions during the treatment process
14. the time intervals that the components need to be immersed, or the time required between coats, and why these must be adhered too
15. the problems that can occur with the surface treatment operations, and how these can be overcome
16. when to act on your own initiative and when to seek help and advice from others
17. the importance of leaving the work area and equipment in a safe and clean condition on completion of the surface treatment activities (such as returning tools and equipment to the designated location, cleaning the work area, and removing and disposing of waste)

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1. Carry out all of the following during the surface treatment activities:

   1. adhere to procedures or systems in place for risk assessment, COSHH, personal protective equipment (PPE) and other relevant safety regulations
   2. follow job instructions and surface treatment specifications and procedures
   3. check that the equipment is ready for the surface treatment operations being performed
   4. carry out handling/jigging of the component (where appropriate)
   5. clean all tools and equipment on completion of the surface treatment activities
   6. dispose of waste and excess materials, in line with agreed organisational procedures

2. Apply surface treatments to components, by carrying out one of the following treatment processes:

   1. powder coating          
   2. electroplating   
   3. chemical treatments
   4. hot dip treatments   
   5. anodising    
   6. phosphating

3. Apply surface treatments to one of the following substrates:

   1. mild steel     
   2. copper     
   3. previously plated substrates
   4. glass
   5. stainless steel    
   6. zinc based diecastings  
   7. plastics/composite material 
   8. aluminium
   9. brass         
   10. other specific material

4. Prepare the components for the surface treatment activities by carrying out one of the following:

   1. degreasing             
   2. rinsing      
   3. pre-heating
   4. cleaning              
   5. masking  
   6. pickling

5. Use one of the following methods for locating the work during the treatment process:

   1. wiring           
   2. jigging components, which are masked prior to processing
   3. specialised jigs             
   4. jigs with integral masking

6. Carry out the surface treatment activities, to include all of the following:

   1. confirm with the authorised person that the plant is ready for carrying out the treatment operations
   2. check that the components are correctly prepared for the required treatment activities (such as dry, at the correct temperature, correctly masked)
   3. load components safely into the treatment plant/solutions
   4. ensure that components are left for the required induction period (if applicable)
   5. remove the components from the plant/solution safely and correctly
   6. apply appropriate post treatment activities (such as curing, cooling, quenching)

7. Apply surface treatments to one of the following types of component:

   1. symmetrical shaped components 
   2. welded/joined components
   3. flat components
   4. irregular shaped components  
   5. hollow/tubular components  
   6. other specific components

8. Carry out surface treatment processes which comply with all of the following:

   1. the final surface finish is in line with the specification or job requirements
   2. the finished surface is free from defects
   3. the finished surface meets customer/company requirements

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​Additional Information

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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31 Mar 2020

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Current

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Original

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Semta

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SEMPEO1-34

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Engineering, Engineering and Manufacturing Technologies

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5221

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performing engineering operations; applying surface treatments; manufacturing; application of treatments; treatment activities; plating; anodising; powder coating; hot dip treatments; chemical treatments

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