Elements and Performance Criteria

This competency unit includes the use of equipment and materials to form composite products using hand layup processes. It includes the operation of all relevant additional equipment where that equipment is integral to the hand layup process.

Procedures means all relevant workplace procedures, work instructions, temporary instructions and relevant industry and government codes and standards.

The processes covered by this unit include, but are not limited to:
setting up moulds
preparation of resins, including mixing as required
preparation of fibre reinforcement, including cutting and trimming
use of composites materials including gel coats, resins and fibres
application of composite materials to the mould by hand lay up.

This competency includes tools and equipment such as:
open moulds for composite products
hand mixing equipment and stirrers
knives and cutters to trim fibres
hand application tools, rollers, trowels, etc.
relevant personal protective equipment.

Typical hazards include:
hazardous materials and vapours
manual handling hazards
knife hazards.

Typical problems include:
cracks, dents or imperfections of the mould
variations in materials, colour, consistency or mix
contamination of materials.

All operations are performed in accordance with procedures.

Essential knowledge and enterprise requirements
Application of knowledge of the materials, equipment and process sufficient to recognise out of specification products, process problems and materials faults.
Knowledge of the enterprise's procedures and relevant regulatory requirements along with the ability to implement them within appropriate time constraints and work standards.

Competence includes the ability for the practical completion of the job to:
apply and/or explain:
impact of incorrect or faulty materials
production workflow sequences and materials demand
properties of the materials required to form a composite structure of the required strength and surface finish, including properties of gel coat and bonding
pot-life of the resins used
hazards of the materials and process and appropriate hazard control procedures
distinguish between causes of faults such as:
wrong raw materials/additives/catalyst
incorrect quantity of materials/additives/catalyst
contaminated materials/additives/catalyst.

Critical aspects
It is essential that competence is demonstrated in the ability to:
recognise the importance of material properties and qualities
apply approved procedures
take appropriate action to resolve faults or report faults to appropriate personnel
explain and implement emergency shutdown procedures.

Consistent performance should be demonstrated. In particular look to see that:
composites production standards are met consistently
upstream and downstream communication is timely and effective
operating procedures and work instructions are read and interpreted correctly
problems are identified and appropriate action is taken (i.e. the problem is fixed or reported)
all safety procedures are followed.

Language, literacy and numeracy requirements
This unit requires the ability to read and interpret typical product specifications, job sheets, procedures, material labels and safety information as provided to operators.
Writing is required to the level of completing workplace forms.
Numeracy is required to the level of reading tables of figures and graphs (and applying the resultant information), using formula percentages/ratios to determine the required mass of an additive (catalyst, pigment, etc.) for a given amount of resin, and similar manipulations and interpretation.

Assessment method and context
Competence in this unit may be assessed:
on an operating plant allowing for operation under all normal and a range of abnormal conditions
by use of a suitable simulation and/or a range of case studies/scenarios
by a combination of these techniques.

In all cases it is expected that practical assessment will be combined with targeted questioning to assess the underpinning knowledge and that the theoretical assessment will be combined with appropriate practical/simulation or similar assessment.

Resource implications
This section should be read in conjunction with the range of variables for this unit of competency. Resources required include suitable access to an operating plant or equipment that allows for appropriate and realistic simulation. A bank of case studies/scenarios and questions will also be required to the extent they form part of the assessment method. Questioning may take place either in the workplace, or in an adjacent, quiet facility such as an office or lunchroom. No other special resources are required.