Finishing surfaces by applying treatments
Overview
This standard covers a broad 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 finishing activities by obtaining all necessary information, documentation, materials, tools and equipment, and to plan how you intend to carry out the required finishing activities.
You will be required to prepare the appropriate equipment to use, based on the surface treatment process and materials to be applied, and the surface area to be covered. You will be expected to use the specified or appropriate techniques to prepare the surfaces in readiness for the application of the treatments. The surface treatment activities will include the application of 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 preparation and surface treatment activities undertaken. You will need to take account of any potential difficulties or problems that may arise with the surface treatment activities, materials and equipment, and to seek appropriate help and advice in determining and implementing a suitable solution. 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 preparation and surface treatment techniques and procedures safely. You will understand the preparation and 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 operations, and when using the associated tools and equipment. You will be required to demonstrate safe working practices throughout, and will understand your responsibility for taking the necessary safeguards to protect yourself and others in the workplace.
Performance criteria
You must be able to:
- work safely at all times, complying with health and safety legislation, regulations, directives and other relevant guidelines
- plan the surface treatment activities before you start them
- prepare the work surfaces in readiness to receive the appropriate treatment
- check that the surface treatment equipment and solutions are set up and maintained at satisfactory operating conditions and levels
- carry out the surface treatment process, using appropriate techniques and procedures
- check that the finished surface achieves the required characteristics and meets the surface treatment specification
- deal promptly and effectively with problems within your control, and seek help and guidance from the relevant people if you have problems that you cannot resolve
- shut down the surface treatment equipment to a safe condition on completion of the activities
- leave the work area in a safe condition on completion of the surface treatment activities
Knowledge and Understanding
You need to know and understand:
- 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)
- 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
- the personal protective equipment (PPE) to be used; how to obtain it and check that it is in a safe and usable condition (such as eye protection, overalls, face masks, breathing equipment)
- 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
- the importance of ensuring that fume extraction equipment is operating effectively, and that good housekeeping and fire prevention procedures are observed
- the importance of following job instructions and defined surface treatment procedures
- 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)
- the specific surface treatment process to be carried out, and the types of application for which they are best suited (such as powder coating, hot dip treatments, chemical treatments, phosphating, electroplating and anodising
- the basic principles of operation of the specific surface treatment process being carried out
- the pre-treatments to be carried out on the components prior to the surface treatment activities (such as cleaning/degreasing, pickling, pre-heating)
- the visual checks to be made on the components prior to carrying out the surface treatment activities (such as checking they are dry, have been pre-heated or are correctly masked up)
- 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
- the methods used to hold/secure components during the surface treatment process (such as wires, hooks, jigs)
- the setting up of the surface treatment plant and equipment, and the operation and locations of emergency shutdown stops
- the importance of monitoring the equipment settings and process solutions during the treatment process
- the time intervals that the components need to be immersed, or time required between coats, and why these must be adhered to
- how to identify surface treatment processing faults (including blistering, missed deposits, dull deposits, contamination and poor adhesion)
- how to check and assess the finished work (such as for appearance, colour, coating thickness, coverage and adhesion)
- the problems that can occur with the surface treatment operations, and how these can be overcome
- when to act on your own initiative and when to seek help and advice from others
- 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)
Scope/range
Scope Performance
Carry out all of the following during the surface treatment activities:
- adhere to procedures or systems in place for risk assessment, COSHH, personal protective equipment (PPE) and other relevant safety regulations
- follow job instructions and surface treatment specifications and procedures
- ensure that the equipment is correctly prepared for the treatment operations being performed
- carry out handling/jigging of the component (where appropriate)
- clean all tools and equipment on completion of the surface treatment activities
- dispose of waste and excess materials, in line with agreed organisational procedures
Apply surface treatments to components by carrying out one of the following processes:
- powder coating
- electroplating
- chemical treatments
- hot dip treatments
- anodising
- phosphating
Apply surface treatments to two different substrates from the following:
- mild steel
- zinc based diecastings
- plastics/composite material
- stainless steel
- aluminium
- glass
- brass
- previously plated substrates
- copper
- other materials (specify)
Prepare the components for the surface treatment activities, by carrying out three of the following:
- degreasing
- rinsing
- pre-heating
- cleaning
- masking
- pickling
Use one of the following methods for locating the work during the surface treatment process:
- wiring
- jigging components, which are masked prior to processing
- specialised jigs
- jigs with integral masking
Carry out the surface treatment activities, to include carrying out all of the following:
- start up the surface treatment equipment, using approved procedures
- confirm with the authorised person that the plant is ready for carrying out the surface treatment operations
- ensure that the equipment settings and process solutions are set and adjusted to maintain the correct specification (such as time, levels, temperature, current)
- check that the components are correctly prepared for the required treatment activities (such as dry, at the correct temperature, correctly masked)
- load components safely into the treatment plant/solutions
- ensure that components are left for the required induction period (if applicable)
- remove the components from the plant/solution safely and correctly
- apply appropriate post treatment activities (such as curing, cooling, quenching)
Apply surface treatments to two different types of component from the following:
- irregular components with multiple surfaces
- hollow/tubular components
- welded/joined components
- flat components
Carry out checks on the treated surfaces, to include four of the following:
- freedom from damage
- adhesion of deposit to substrate
- freedom from contamination
- porosity of coating
- overall coverage/completeness of the coating operations
- deposit hardness
- thickness of deposit/coating
- brittleness of deposit
- appearance of deposits (such as colour, brightness)
- abrasion resistance
- bend test (such as manual or mechanical)
- corrosion testing
- surface roughness checks
Carry out surface treatment processes which comply with all of the following:
- the final surface finish is in line with the specification or job requirements
- the finished surface is free from defects
- the finished surface meets customer/company requirements
Scope Knowledge
Values
Behaviours
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