Elements and Performance Criteria

This competency unit includes the application of gel coat to specification using manual application or spray equipment. It involves the application of gel coat to a mould former as part of a manufacturing process. Where gel coating is not part of the manufacturing process, but a similar process occurs, then this unit should be customised to suit a similar coating process.

It is not intended to cover repairs or patching work to the gel coat surface of products.

It includes the operation of all relevant additional equipment where that equipment is integral to the process of applying gel coat.

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

This competency includes tools and equipment such as:
measurement devices, such as measuring flasks, containers, weighing machines, scales or meters.
hand application equipment including brushes
hand application by 'slushing'
spray application
relevant personal protective equipment.

Typical hazards include:
hazardous materials and vapours
manual handling
stationary and moving machinery, parts and components.

Typical problems include:
gel coat mix, colour and additives
equipment problems, including spray blockage/buildup and wear and breakage
poor mixing
over or undermeasurement of components.

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:
operation of gel coat application equipment and components
function of gel coat in the composite products being manufactured
importance of gel coat application to the standard of the finished work
production workflow sequences and materials demand
approved hazard control and safety procedures and the use of PPE in relation to handling materials, equipment operation and clean up
potential effects of variations in raw materials and equipment operation in relation to quality of product
waste management and importance of reusing non-conforming products wherever possible
correct selection and use of equipment, materials, processes and procedures
plan own work including predicting consequences and identifying improvements
monitor equipment operation and product quality
identify when the operator is able to rectify faults, when assistance is required and who is the appropriate source for assistance
identify and describe role and role of others involved directly in the process
identify factors which may affect product quality or production output and appropriate remedies
use PPE, safely handle products and materials, read relevant safety information and apply safety precautions appropriate to the task
pause equipment, or shut down equipment in abnormal circumstances
distinguish between possible causes of routine gel coating faults such as:
base materials and additives
cure time and conditions
spray equipment.

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:
gel coating production standards are met consistently
upstream and down stream 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.
Basic numeracy is required, e.g. to determine that two 25 kg bags are needed for 50 kg.

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
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.