Level 2 Certificate in Boat Building, Maintenance and Support · Level 2 Certificate in Boat Building, Maintenance and Support 5 Assessment and quality assurance National standards

Level 2 Certificate in Boat Building, Maintenance and Support (2451) Qualification handbook

www.cityandguilds.com August 2003 Version 5.0 (June 2008)

About City & Guilds City & Guilds is the UK’s leading provider of vocational qualifications, offering over 500 awards across a wide range of industries, and progressing from entry level to the highest levels of professional achievement. With over 8500 centres in 100 countries, City & Guilds is recognised by employers worldwide for providing qualifications that offer proof of the skills they need to get the job done. City & Guilds Group The City & Guilds Group includes ILM (the Institute of Leadership & Management) providing management qualifications, learning materials and membership services and NPTC which offers land-based qualifications and membership services. City & Guilds also manages the Engineering Council Examinations on behalf of the Engineering Council. Equal opportunities City & Guilds fully supports the principle of equal opportunities and we are committed to satisfying this principle in all our activities and published material. A copy of our equal opportunities policy statement Access to assessment and qualifications is available on the City & Guilds website. Copyright The content of this document is, unless otherwise indicated, © The City and Guilds of London Institute 2005 and may not be copied, reproduced or distributed without prior written consent. However, approved City & Guilds centres and learners studying for City & Guilds qualifications may photocopy this document free of charge and/or include a locked PDF version of it on centre intranets on the following conditions: • centre staff may copy the material only for the purpose of teaching learners

working towards a City & Guilds qualification, or for internal administration purposes • learners may copy the material only for their own use when working towards a City & Guilds

qualification • the Standard Copying Conditions on the City & Guilds website. Please note: National Occupational Standards are not © The City and Guilds of London Institute. Please check the conditions upon which they may be copied with the relevant Sector Skills Council. Publications City & Guilds publications are available on the City & Guilds website or from our Publications Sales department at the address below or by telephoning +44 (0)20 7294 2850 or faxing +44 (0)20 7294 3387. Every effort has been made to ensure that the information contained in this publication is true and correct at the time of going to press. However, City & Guilds’ products and services are subject to continuous development and improvement and the right is reserved to change products and services from time to time. City & Guilds cannot accept liability for loss or damage arising from the use of information in this publication. City & Guilds 1 Giltspur Street London EC1A 9DD T +44 (0)20 7294 2800 www.cityandguilds.com F +44 (0)20 7294 2400 [email protected]

Level 2 Certificate in Boat Building, Maintenance and Support

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Contents Introduction.......................................................................................................................... 2 General information ............................................................................................................. 3 General structure ................................................................................................................. 3

Core units .......................................................................................................................... 3 Optional units ................................................................................................................... 3

Assessment and quality assurance ..................................................................................... 5 Course design....................................................................................................................... 6 Entry to qualification............................................................................................................ 6 Centre and scheme approval............................................................................................... 7 Assessment of optional units .............................................................................................. 8 Assignment templates ......................................................................................................... 8 Guidance for marking........................................................................................................... 8 Marking assignments........................................................................................................... 9 Recording marks and grades............................................................................................. 10 Underpinning knowledge questions for optional units ................................................... 10 Feedback ............................................................................................................................ 10 What centres need to do ................................................................................................... 11

Machinery, tools and equipment ................................................................................... 11 Producing assignments to assess optional units.......................................................... 11

Assessor's guidance notes......................................................................................... 11 Candidate's instructions............................................................................................. 11 Mark scheme............................................................................................................... 12

Submission of assignments............................................................................................ 12 Registration and certification......................................................................................... 13

Test specification ............................................................................................................... 16 Online exams .................................................................................................................. 16 Assignments ................................................................................................................... 17 Optional units ................................................................................................................. 17

Generic grading descriptor for assignments .................................................................... 19 Educational health and safety ........................................................................................... 19 Key Skills signposting ........................................................................................................ 20 Units .................................................................................................................................... 21

Unit 013 ........................................................................................................................... 22 Unit 014 ........................................................................................................................... 33 Unit 015 ........................................................................................................................... 39 Unit 003 ........................................................................................................................... 46 Unit 004 ........................................................................................................................... 52 Unit 005 ........................................................................................................................... 58 Unit 006 ........................................................................................................................... 67 Unit 007 ........................................................................................................................... 75 Unit 008 ........................................................................................................................... 82 Unit 009 ........................................................................................................................... 88 Unit 010 ........................................................................................................................... 95 Unit 011 ......................................................................................................................... 101 Unit 012 ......................................................................................................................... 107

Appendix: Centre devised assignment submission report ............................................ 111

Level 2 Certificate in Boat Building, Maintenance and Support 2

Level 2 Certificate in Boat Building, Maintenance and Support Introduction This award is aimed at candidates who • are following Modern Apprenticeship programmes • require evidence towards the underpinning knowledge of the NVQ • do not have access to an N/SVQ and wish to develop skills and knowledge • wish for career progression within the industry. The award is designed to contribute towards the knowledge and understanding for the N/SVQ(s) in Boat Production and Support Services while containing additional skills and knowledge which go beyond the scope of the National Occupational Standards. It provides a valuable alternative for those candidates who do not have access to the N/SVQ. The award is approved as a Technical Certificate.


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General information Certificates have been designed by City & Guilds to support government initiatives towards the National Qualifications Framework. They can contribute towards the knowledge and understanding required for the related N/SVQ while not requiring or proving evidence of occupational competence. General structure Certificates are made up of units expressed in a standard format. Each unit is preceded by details of • the structure of the unit • the aims and general coverage of the unit • the relationship of the unit to the appropriate N/SVQ National Occupational Standards • the outcomes • the assessment methods • signposting of opportunities to generate evidence for Key Skills. For the Level 2 Certificate in Boat Building Maintenance and Support the units are: Core units Unit 013 Developing self and working safely in a marine environment.(online) Unit 014 Marine technology (online) Unit 015 Marine engineering processes and principles (online) Optional units Unit 003 Yacht and boatbuilding assembly and sub assembly. Unit 004 Production of hulls and decks and structural components. Unit 005 Installation and fitting out of boats. Unit 006 Composites for marine construction. Unit 007 Servicing and maintenance of marine engines. Unit 008 Marine propulsion systems. Unit 009 Maintaining electrical equipment /systems. Unit 010 Principles of marine electrical systems. Unit 011 Prepare surfaces and marine coatings. Unit 012 Apply marine coatings. To gain the Level 2 Certificate in Boat Building, Maintenance and Support, candidates must undertake the following assessments:

• For the Boat Building route they need to complete core units 013 and 014 plus two optional units from 003 to 008 (complex 01).

• For the Marine Engineering route they need to complete core units 013 and 015 plus two

optional units from 003 to 010 (complex 03).

• For the Painting and Finishing route they need to complete core units 013 and 014 plus units 011 and 012 (complex 05).


In any of the routes, the candidate must complete four assessments:

• one online test for each of the core units

• one assignment for each of the two optional units.


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Assessment and quality assurance National standards and rigorous quality assurance are maintained by the use of • City & Guilds set and online test(s)

• Assignments, set and marked by the centre according to externally set marking criteria, with quality assurance provided by the centre and monitored by City & Guilds’ external verification system, to ensure that national standards are maintained.

Quality assurance includes initial centre approval, scheme approval, the centre's own procedures for monitoring quality and City and Guilds' ongoing monitoring by an External Verifier. Details of City & Guilds’ criteria and procedures, including roles of centre staff and External Verifiers can be found in Providing City & Guilds Qualifications - a guide to centre and scheme approval. There is an online test for each core unit to assess knowledge and understanding (see Registration and certification page 13). Assignments (one per unit) assess application of skills and knowledge. City & Guilds will provide an assignment template which details the range of practical tasks and underpinning knowledge to be covered. Assignments need to be approved by the centre devised unit. Assessment components are graded (Pass, Credit, Distinction). A Pass is the achievement level required for the knowledge and understanding in an NVQ and generally represents the ability to follow instructions and procedures. Credit and Distinction represent increasing levels of ability to adapt to changing circumstances and to independently resolve problems. Generic grading criteria for Pass, Credit and Distinction are given on page 9. Details of the availability of assessments and of the general regulations for their conduct are given in the ‘Directory of Assessments and Awards’. If there is any inconsistency between the scheme regulations in this pamphlet and the Directory of Assessments and Awards, the Directory shall prevail. For candidates with particular requirements, centres should refer to City & Guilds’ policy document Access to assessment, candidates with particular requirements. This also applies to candidates who wish to seek examinations in language other than English.


Course Design Tutors/assessors should familiarise themselves with the structure and content of the award before designing an appropriate course; in particular they are advised to consider the knowledge and understanding requirements of the relevant N/SVQ. City & Guilds does not itself provide courses of instruction or specify entry requirements. As long as the requirements for the award are met, tutors/assessors may design courses of study in any way that they feel best meets the needs and capabilities of the candidates. Units are broadly the same size and centres may deliver them in any order they wish. Centres may wish to introduce other topics as part of the programme which will not be assessed through the qualifications, eg to meet local needs. It is recommended that centres cover the following in the delivery of the course, where appropriate: • Health and safety considerations, in particular the need to impress to candidates that they

must preserve the health and safety of others as well as themselves.

• Key Skills (such as Communication, Application of Number, Information technology, Working

with others, Improving own learning and performance, Problem solving).

• Equal opportunities.

• Spiritual, moral, social and cultural issues.

• Environmental education, related European issues.

It is recommended that 250 guided learning hours should be allocated for the two core and two optional units required for certification. Entry to qualification No specific prior qualifications, learning or experience are required for candidates undertaking the qualification. However, centres will need to make an initial assessment of each candidate to ensure that the level of the scheme is appropriate. As this is a Certificate it is considered that candidates may have gained qualifications at a lower level. The nature of both the learning and assessment required for the qualification is such that candidates will need basic literacy and numeracy skills: ie the ability to read and interpret written tasks and to write answers in a legible and understandable form. Candidates will also need to be able to organise written information clearly and coherently, although they will not be assessed for spelling or grammatical accuracy unless this is part of the assessment criteria. There are no restrictions on entry for this award. City & Guilds recommend that candidates entering for a qualification of the same level and the same content as that of a qualification they already hold should not apply to take the qualification.


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Centre and scheme approval Centres wishing to offer City & Guilds qualifications must gain approval. New centres must apply for centre and scheme approval. Existing City & Guilds centres will need to get specific scheme approval to run this Certificate. Full details of the process for both centre and scheme approval are given in Providing City & Guilds qualifications - a guide to centre and scheme approval which is available from City & Guilds’ regional offices. City & Guilds reserves the right to suspend an approved centre, or withdraw its approval from an approved centre to conduct a particular City & Guilds scheme or particular City & Guilds schemes, for reasons of debt, malpractice or for any reason that maybe detrimental to the maintenance of authentic, reliable and valid qualifications or that may prejudice the name of City & Guilds. External verifiers act on behalf of City & Guilds to ensure that national standards are maintained. Full details of their role can be found in Providing City & Guilds’ Qualifications - a guide to centre and scheme approval.


Assessment of optional units In each optional unit there are a number of learning outcomes and each of these learning outcomes specifies a number of practical activities. Each optional unit should be assessed by the use of an assignment. The assignment should be produced by the centre in accordance with the template provided by City & Guilds. It will be made up of a number of practical tasks and one underpinning knowledge task. The resultant level of candidate achievement will be graded. Candidates must pass all tasks within an assignment. Assignments will provide opportunities for candidates to be assessed for a sample range of the practical activities required for the unit. Assignments will usually consist of several tasks. The range of assignments developed by the centre for each unit should ensure that all the practical activities for all the outcomes are assessed as the centre uses a range of assignments over a period of time. City & Guilds will provide assignment templates from which centres should produce the assignments for the units contained in this award. Centres are required to use the templates provided by City & Guilds. City & Guilds centre devised team must approve all assignments prior to use by the centre (see page 12). Assignment templates Detailed assignment templates for each optional unit are provided. Centres can access approved centre devised assignments in City & Guilds website www.cityandguilds.com The password to open the documents is available in the Walled Garden. Guidance for marking Grading of assignments is Pass, Credit and Distinction; grades of Credit and Distinction are intended to distinguish those candidates who show greater degrees of autonomy in the way they organise themselves, or apply reflective thinking and originality in the completion of tasks. Detailed marking and grading criteria are provided for each assignment in the Marking Criteria section of the assignment. The candidate must display satisfactory performance throughout the tasks. Failure to do so will result in the candidate requiring further training.

http://www.cityandguilds.com/


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Marking assignments Centres will be taking into account the following three aspects of candidate’s performance: • planning, preparation and recording

• practical activity

• underpinning knowledge.

Each aspect must be marked and awarded a Pass, Credit or Distinction. Specific guidance for marking is provided in the assignment template. Candidates must achieve a minimum of a Pass in each aspect of performance. The marks that should be awarded for planning, preparation and recording and underpinning knowledge are as follows: Marks Pass 1 Credit 2 Distinction 3

(Note: half marks are NOT available)

The marks that should be awarded for the practical activities are as follows:

Marks Pass 2 Credit 4 Distinction 6

(Note: these marks are NOT divisible ie, Pass candidates must be awarded 2 marks, Credit candidates 4 marks and so on)

The marks that should be awarded for the underpinning knowledge are as follows: Grading criteria Pass=1 mark Credit = 2 marks Distinction = 3 marks Pass 50–64% Credit 65–79% Distinction 80–100% To award an overall grade the number of marks given for each task are totalled and then a grade is applied as follows: Marks Grade 4-6 Pass 7-9 Credit 10-12 Distinction


Recording marks and grades To record candidate marks and overall grades for each completed assignment, assessors should enter details onto the appropriate Assignment Mark Sheet. For example, below is a completed Assignment Mark Sheet as it would appear in the candidates’ Assignment Guide. It shows how the overall grade was produced. Pass Credit Distinction Planning, preparation and recording

1

Practical activity 4 Underpinning knowledge 3

Total 8

Grade CREDIT

Underpinning knowledge questions for optional units Assignments for optional units must also include underpinning knowledge questions and are designed to sample the underpinning knowledge of the unit. The questions included in the assignments do not need to be taken in formal examination conditions, however, they should be taken under supervision as assessors need to ensure the answers to the questions are the candidate’s own work. To preserve the integrity and useful life of the questions, candidates should not be given their answer sheets. A candidate’s success in a written assessment should be recorded by a statement from the centre, quoting the relevant unit number or areas of knowledge assessed, which can then be used by candidates as evidence. Original completed answer sheets should be kept for auditing purposes by the assessor in their own assessment records of candidates’ performance. Please refer to City & Guilds’ General Regulations for confirmation of the period of time during which records should be maintained to meet regulatory requirements. Feedback The assignments are intended as a formal assessment of candidates’ practical skills. They are not designed as teaching aids and candidates should not be entered until they are ready. Should a candidate fail any of these tasks other than on health & safety grounds, as stated above, appropriate feedback should be given by the assessor both to the candidate and the tutor concerned. Assessors must ensure that candidates understand why a particular grade has been given for the award. If a candidate’s work is selected for verification, samples of work must be available to the appointed external verifier.


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What centres need to do Machinery, tools and equipment Centres must have access to sufficient equipment in the college, training centre or workplace to ensure candidates have the opportunity to cover all of the practical activities. It is acceptable for centres to use specially designated areas within a centre for some of the units: eg to train and assess the installation of compressed air systems, ventilation ducting, alignment and setting up of electric motors and driven devices (pumps, compressors generators etc). The equipment, systems or machinery must be of an industrial standard and be capable of being used under normal working conditions: eg hydraulic rigs must have a method of applying reasonable loads and not merely be connected up to show movement. Producing assignments to assess optional units The centre devised assignments must be made up of three sections: 1 Assessor’s guidance notes This section is intended for use by the assessor only. It should contain: • a health and safety statement • the location of where the assignment should be taken • the requirements for tools, equipment, materials and data • notes on the content of the assignment to include any preparatory work required by • the assessor/centre • details of evidence and recording requirements • time consideration. Any new assignments set must have the same time allocated to the completion of the assignment as set in the guidance note in the assignment template. 2 Candidate’s instructions The candidate’s instructions should contain: • general advice to candidates about the need to understand the assignment before

starting work and the need to seek guidance if clarification is required • guidance on the time limits • the importance of health and safety • an assignment brief which sets the scene or a scenario to contextualise the task(s) • clearly defined tasks covering a range of practical activities – an outline of each task should

be provided rather than a series of marking checklists • recording/report sheets for recording the progress of the activity • notes which refer to how the evidence they produce should be stored and labelled.


3 Mark scheme (see Guidance for marking section on page 9) NOTE: Where the use of drawings/specifications is essential for the activity, relevant pages can be photocopied form workshop manuals, etc – copyright and industrial confidentiality permitting. It is not usually necessary for such items to be copied out by the candidates, however, the use of sketches to show specific, important aspects of the work undertaken: eg points of wear, location of components within a system, alignment methods, etc should be encouraged. CAD and word processing packages can be used but time spent on the presentation should not be excessive. The final grade awarded will not necessarily depend upon presentation provided the candidates’ work is clear, neat and technically correct. Candidates generating evidence for IT Key Skills may wish to spend more time on this aspect of their work. Submission of assignments All assignments must be approved for use by City & Guilds. Each assignment should be submitted with a copy of the centre-devised assignment submission report. Centres must submit all centre devised assignments to: Centre Devised Unit City & Guilds 1 Giltspur Street London EC1A 9DD Six weeks before they intend to use the assignment if submitted electronically to the following email address: [email protected] Eight weeks before they intend to use the assignment if a paper based submission is made (three copies must be provided). A copy of the centre-devised assignment submission report is at the end of this handbook and should be submitted with the assignment.

mailto:[email protected]


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Registration and certification For the award of a certificate, candidates must successfully complete the following assessments:

• For the Boat Building route they need to complete core units 013 and 014 plus two optional units from 003 to 008 (complex 01).

• For the Marine Engineering route they need to complete core units 013 and 015 plus two

optional units from 003 to 010 (complex 03).

• For the Painting and Finishing route they need to complete core units 013 and 014 plus units 011 and 012 (complex 05).

Please see chart on page 15 Core units Assessment components required

Unit 013

Developing self and working safely in a marine environment

2451-01-013 2451-03-013 2451-05-013

Multiple choice online test

Unit 014

Marine technology 2451-01-014 2451-05-014

Multiple choice online test

Unit 015

Marine engineering processes and principles

2451-03-015 Multiple choice online test

Optional units Unit 003

Yacht and boatbuilding assembly and sub assembly

2451-01-003 2451-03-003

Assignment

Unit 004

Production of hulls and decks and structural components

2451-01-004 2451-03-004

Assignment

Unit 005

Installation and fitting out of boats 2451-01-005 2451-03-005

Assignment

Unit 006

Composites for marine construction 2451-01-006 2451-03-006

Assignment

Unit 007

Servicing and maintenance of marine engines

2451-01-007 2451-03-007

Assignment

Unit 008

Marine propulsion systems 2451-01-008 2451-03-008

Assignment

Unit 009

Maintaining electrical equipment /systems

2451-03-009 Assignment

Unit 010

Principles of marine electrical systems


Unit 011

Prepare surfaces and marine coatings


Unit 012

Apply marine coatings 2451-05-012 Assignment


• Candidates must be registered at the beginning of their course. Centres should submit

registrations using Form S (Registration), under the desired scheme/complex number.

• When assignments have been successfully completed, candidate results should be submitted

on Form S (Results submission). Centres should note that results will not be processed by

City & Guilds until verification records are complete.

• Online tests are available at any time of the year.

• Candidates achieving one or more assessment components will receive a Certificate of Unit

Credit listing the assessment components achieved. Candidates achieving the number and

combination of assessment components required for the Certificate will, in addition, be

issued a Certificate.

Full details on all the above procedures, together with dates and times of written tests will be found in the Directory of Vocational Awards published annually by City & Guilds. This information also appears on City & Guilds’ website http://www.cityandguilds.com

http://www.cityandguilds.com/


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Level 2 Certificate in Boat Building, Maintenance & Support (2451) routes and units

Unit no Title Level Type 013

Developing self and working safely in a marine environment

2

Mandatory (core)

014

Marine technology

2 Mandatory (core)

015

Marine engineering processes and principles

2

Mandatory (core)

003

Yacht and boatbuilding assembly and sub assembly

2

Optional

004

Production of hulls decks and structural components

2

Optional

005

Installation and fitting out of boats

2

Optional

006

Composites for marine construction

2

Optional

007

Servicing and maintenance of marine engines

2

Optional

008

Marine propulsion systems

2

Optional

009

Maintaining electrical/equipment systems

2

Optional

010

Principles of marine electrical systems

2

Optional

011

Prepare surfaces and marine coatings

2

Optional

012

Apply marine coatings

2

Optional

2451 Level 2

Core 013

Boat Building Painting and Refinishing

Marine Engineering

Core 014 Core 015 Core 014

Any two optional units from 003-008

Any two optional units from 003-010

Optional units 011 and 012


Test Specification Online tests The knowledge requirements will be assessed by an online test following test specifications: Core units Paper 013: Developing self and working safely in a marine environment Test duration: 45 minutes Total number of questions: 25 Unit Outcome No of questions

1 Describe the role of the marine industry within the UK

3

2 Understand boat and nautical terminology 7

3 Recognise requirements regarding health and safety

7

4 Recognise employee/employer roles and responsibilities

2

5 Contribute to self development and working relationships

3

013

6 Contribute to the effectiveness of boat production and support services

3

Paper 014: Marine technology Test duration: 45 minutes Total number of questions: 25 Unit Outcome No of questions

1 Identify boat construction materials 6

2 Interpret and use drawing and specifications 4

3 Identify tools and equipment used in boatbuilding

7

014

4 Understand the principles of boatbuilding processes

8

Paper 015 : Marine engineering processes and principles Test Duration : 45 minutes Total number of questions: 25 Unit Outcome No of questions 015 1 Identify marine construction materials 6 2 Interpret and use drawings and specifications 4 3 Identify tools and equipment used in

marine/electrical processes 7

4 Understand the principles of marine/electrical processes

8


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Assignments Optional units will be assessed by means of an assignment. This will be set by the centre within the guidelines set out. The assignment will test practical and underpinning knowledge requirements for each unit. The weightings indicate the minimum and maximum percentages of each outcome which will be covered in an individual assignment. Optional Units Assignment 003: Yacht and boat building assembly and sub assembly

Unit Outcome Percentage of assignment

1 Plan and implement boat assembly and sub assembly operations using drawing, instructions and specifications

40

2 Carry out operations correctly in a safe manner 40

003

3 Check the assembly and sub assembly components meet the quality standards

20

Assignment 004: Production of hulls and decks and structural components


1 Produce moulds and templates for components of boats

40

2 Cut and finish materials to form components of boats

20

004

3 Assembling components to form hulls and decks 40

Assignment 005: Installation and fitting out of boats


1 Prepare for installation of interior modules, joinery and marine fittings

20

2 Position and install/fix interior modules, joinery and marine fittings

30

3

Fix and secure interior modules, joinery and marine fittings

30

005

4 Complete, inspect and protect interior modules, joinery and marine fittings

20

Assignment 006: Composites for marine construction


1 Interpret drawings, instructions, Regulations and relevant codes of practice

10

2 Plan mould and lay up operations 40 3

Carry out operations correctly and in a safe manner

40

006

4 Check the finished product with the specification 10


Assignment 007: Servicing and maintenance of marine engines


1 Recognise the requirements for the safe servicing and maintenance of marine engines

30

2 Identify appropriate information, tools and materials needed for servicing operations

30

3 Undertake basic servicing and maintenance of marine engines

30

007

4 Record results and make appropriate recommendations

10

Assignment 008: Marine propulsion systems


1 Recognise the requirements for the safe servicing and maintenance of marine propulsion systems

30

2 Identify appropriate information, tools and materials needed for servicing operations

30

3 Understand basic principles of propulsion systems and servicing and maintenance procedures

30

008

4 Record results and make appropriate recommendations

10

Assignment 009: Maintaining electrical equipment/systems Unit

Outcome

Percentage of assignment

1 Prepare for maintaining electrical equipment/systems

30

2 Carry out the maintenance of electrical/systems 50

009

3 Reinstate the work area and apply safe working practices

20

Assignment 010: Principles of marine electrical systems

Unit

Outcome


1 Understand the functions of electrical systems/components

30

2 Understand electricity supply systems (12, 24 and 240 volt), protection and earthing

40

3 Understand the methods of storing electricity on board

15

010

4 Understand the requirements for installing instrumentation

15


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Assignment 011: Prepare surfaces and marine coatings

Unit

Outcome


1 Prepare marine material surfaces 50 011

2 Prepare marine coatings 50

Assignment 012: Apply marine coatings

Unit

Outcome


1 Apply marine coatings 60 012

2 Check and report minor surface defects 40

Generic grading descriptor for assignments Pass Credit Distinction In a practical activity involving some non-routine operations, the candidate demonstrated the use of skills in meeting the essential requirements of the outcomes of the unit.

In a practical activity involving some non-routine operations, the candidate demonstrated the use of skills in meeting the substantial majority of requirements of the outcomes of the unit.

In a practical activity involving some non-routine operations, the candidate demonstrated the use of skills in meeting the comprehensive requirements of the outcomes of the unit.

Educational Health and Safety The requirement to follow safe working practices is an integral part of all City & Guilds qualifications and assessments, and it is the responsibility of centres to ensure that all relevant health and safety requirements are in place before candidates start practical assessments. Should a candidate fail to follow health and safety practice and procedures during an assessment (eg practical assessment, assignment) the test must be stopped and the candidate advised of the reasons why. The candidate should be informed that they have failed the assessment. Candidates may retake the assessment at a later date.


Key Skills Signposting Identification of Key Skills summary relationship table

Unit No and Title Communication Application of Number

Information Technology

013 Developing self and working safely in a marine environment

C 2.1 C 2.2

N 2.1

014 Marine technology

C 2.2 N 1.1 N 1.2

015 Marine engineering processes and principles

003 Yacht and boat building assembly and sub assembly

C 2.2

004 Production of hulls and decks and structural components

C 2.2

005 Installation and fitting out of boats

C 2.2

006 Composites for marine construction

C 2.3 C 2.2

N 2.1 N 2.2

007 Servicing and maintenance of marine engines

C 2.2 C 2.3

N 2.2

008 Marine propulsion systems

N 2.2

009 Maintaining electrical equipment /systems

C 2.2 C 2.3

N 2.2

010 Principles of marine electrical systems

011 Prepare surfaces and marine coatings

C 2.2

012 Apply marine coatings

C 2.2


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Level 2 Certificate in Boat Building, Maintenance and Support (2451) Units

www.cityandguilds.com January 2007 Version 4.0


013 Developing self and working safely in a marine environment Rationale This is a mandatory unit. All candidates need to take this unit to obtain the qualification. This unit is concerned with safety awareness and communication skills needed to work effectively in the marine industry. It covers health and safety, interaction with other employees and an understanding of the terminology and structure of the industry. This unit covers six learning outcomes. The candidate will be able to: 1 describe the role of the marine industry within the UK 2 understand boat and nautical terminology 3 recognise requirements regarding health and safety 4 recognise employee/employer roles and responsibilities 5 contribute to self development and working relationships 6 contribute to the effectiveness of boat production and support services. Connection with other awards This unit combines and extends the knowledge contained in units: Unit 1 – Working safely in a boatbuilding/repair environment Unit 2 – Contributing to self development and working relationships Unit A – Contributing to the effectiveness of boat production and support services of the Level 2 NVQ in Boat Production and Support Services. Assessment The underpinning knowledge requirements are listed for each outcome. These will be assessed by a multiple choice online test covering the six outcomes.


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Outcome 1: Describe the role of the marine industry within the UK Underpinning knowledge The candidate will be able to: 1 describe the structure and role of organisations within the marine industry for example

the services that may be available in: a Boatyards, marinas and yacht basins:

i accommodation facilities providing toilets and showers ii environmental services such as water points, electrical hook-up,

waste and refuse disposal, pump-out facilities, and laundry room with washing machines and spin driers.

iii The range of products one may obtain in a Chandlery such as yacht fittings and fastenings, glues, ropes, charts, books, paint, chain, shackles, anchors, Yacht clothing and boots etc. and navigation equipment etc.

iv Mooring and storage arrangements to include types of mooring that may be available such as swinging or fixed moorings on piles or marina berth moorings.

v Storage cabins or lock-ups that may be available, mast and spar storage arrangements.

vi Fitting out, maintenance and lay-up facilities. b Boatbuilding facilities:

i hull and deck construction for wood, or metal hulls ii composite manufacture and repair for FRP hulls and decks iii engine installation and maintenance. iv fitting out or refit operations for joinery, plumbing, electrics.

c Equipment manufactures and suppliers for: i boat equipment and suppliers: ii timber merchants iii metal suppliers iv bottled gas v suppliers of stanchions vi boat davits vii handrails viii exhaust systems ix upholstery and drapes x sails and rigging etc.

d Marine services such as: i brokerages providing buying and selling of craft ii financial services iii insurance provision iv marine surveying services v leisure operators providing boat hire for holiday cruising.


2 recognise the basic shape and form of both leisure and commercial craft.

a Leisure craft such as: i listed ii motor cruisers iii sailing boats iv narrow boats.

b Commercial craft such as: i tankers ii tugs iii lighters iv cargo ships v container ships vi cruise liners etc.

3 recognise the application and methods used for providing services such as:

a servicing and maintaining systems such: i engines ii winches iii instruments iv electrical systems v gas systems vi toilet and waste systems etc.

b methods of moving boats afloat by engine power, rowing, towing, sailing and rafting. c methods of moving boats ashore by mobile hoists, cradle and slippery ways, rollers,

tractor and cradle on wheels, mobile Crane and fork lift truck. d carrying out inspections by noting the types of inspection used either by mechanical

means using testing equipment or making a visual inspection.


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Outcome 2: Understanding boat and nautical terminology. Underpinning knowledge The candidate will be able to: 1 identify common parts of a boat.

a Hull: i strakes ii keel iii bow iv stern v bilge vi gunwales vii risers viii transom ix floors. b Interiors: i bulkheads ii cockpit iii hatches iv coach roof v companionway vi bridge/wheelhouse. c Deck structures: i beams ii carlins iii kneels. 2 identify accommodation areas on boats. a Galley. b Saloon. c Sleeping areas. d Shower/wc. e Navigation/steering.


3 identify marine components and fittings.

a Cleats and bollards b Fairleads c Windlass d Anchor e Navigation lights f Masts g Sails h Safety equipment, life raft, horseshoes i Pullpit j Pushpit k Stanchions l Lifelines m Running rigging such as sheets halyards, running backstays. n Standing Rigging includes Stays and shrouds and the purpose of each. o Types of blocks to include a snatch block that has a hinged faceplate to allow

the bight of rope to be inserted rather than having to feed the ropes end through it.

p Propulsion systems (inboard, outboard) q Steering systems, tiller, rudder r Instrumentation systems, navigation/radar s Power supplies such as Battery, generators powered by fuel engines, wind or water

flow, solar panels and by shore power hook-up. t Utilities such as water supply waste water systems (holding tanks) Heating systems

and gas systems.


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Outcome 3: Recognise requirements regarding health and safety Underpinning knowledge The candidate will be able to: 1 recognise the basic regulations with regard to health and safety in the place of work: a Health and Safety at Work Act 1974 (HSWA) b Control of Substances Hazardous to Health (COSHH) c Lifting and Handling (LOLER 1998) d Provision and Use of Work Equipment Regulations 1998 (PUWER). 2 identify the range of Personal Protective Equipment (PPE) and the typical situations

where they should be used. a Hats, goggles, boots, masks, gloves b Safety harness, lifejacket, buoyancy aids. 3 recognise designated safety signs. a Warning. b Advisory. c Mandatory. d Prohibition. 4 understand how First Aid procedures operate. a Role of qualified first aides. b Location of facilities. 5 identify the procedures to be followed in the sounding of an emergency alarm. a Evacuation b Escape routes c Assembly points 6 recognise common causes of fire and preventative measures to reduce risk. 7 state the types of fire extinguisher and their application. a Water. b Foam. c Powder. d Gas.

8 clarity in the roles and responsibilities of a The Safety officer in a company is responsible for ensuring that Health and Safety in

the company is implemented. b A safety representative is generally a member of the workforce who sits on a safety

committee within the company. c Health and safety Inspectors are employed by the Health and Safety Executive and

are responsible for inspecting premises on HAS matters. d Environmental Health Officers are employed to investigate all matters which effect

health such as water pollution etc.


9 recognise potential hazards in the work environment. a Spillages and slippery surfaces. b Faulty electrical connections or damaged cables. c Faulty or incorrectly set up tools and equipment. d Pressure containers, gas bottles, cylinders. e Hazardous material, toxics, solvents, inflammables. f Dust and fumes. g Moving of loads. h Working at heights. 10 state good housekeeping measures. a Correct storage of tools, equipment and materials. b Maintaining access and egress. c Safe removal of waste. d Acceptable codes of behaviour and dress. e Appropriate lighting and ventilation. 11 state the reasons for risk assessment 12 state the procedures for reporting hazards 13 outline the safety factors for craft operating in harbours and inland waterways. a Permission to manoeuvre a boat. b Tide and weather conditions. c Effects of vessel shape, size, form and propulsion system on manoeuvring. d Safe transit during manoeuvre. e Requirements secure and safe mooring.


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Outcome 4: Recognise employee/employer roles and

responsibilities Underpinning knowledge The candidate will be able to: 1 list the main items for a contract of employment. a Job description. b Hours of work. c Pay. d Role and responsibilities. e Discipline. f Structure. g Terms of notice. h Employment Rights Act 2 identify the relevant legislation which relates to condition of employment. a Equal Pay Act 1970. b Sex Discrimination Act 1975. c Race Relations Act 1976. 3 state where to find the sources of information on employment rights and responsibilities. a Trades Unions b ACAS c Citizens Advice Bureau 4 list the roles and responsibilities in a typical organisation by being able to a describe or sketch a simple organisation chart showing the lines of authority b state the role of key personnel in a marine company such as the role of a manager, a

foreman, a charge-hand etc c describe the methods used in a marine company to communicate information such

as letters, memos, drawings, written and verbal work instructions, computers the Internet, videos, pictures manufactures instructions or guidance literature etc

d describe how to work effectively as a team member by being co-operative and responsive, good time keeping, obeying company rules and regulations, working safely, treat people (workmates and customers) with courtesy and respect etc


Outcome 5: Contribute to self-development and working relationships. Underpinning knowledge The candidate will be able to: 1 have a basic understanding of the factors in maintaining effective working relationships. a From Outcome 4.4c, be aware of communications methods in a marine company.

b The importance of listening skills, paying attention to work instructions and making sure that they understand what has been said by asking questions when unsure.

c By knowing where to seek guidance such as experienced reliable workmates, charge hands, foreman, managers. By not being afraid of seeking help when needed.

d As of Outcome 4d the importance of team work in achieving work objectives, working safely, good time keeping, good personnel hygiene, maintaining a high standard of work etc.

2 have an understanding of difficulties that can occur in working relationships.

a The conflict of personalities such as the friction that can occur between forceful characters compared with meek and shy people, uncouth behaviour, constant physical and verbal bullying, racial or sexual remarks etc. and the need for balanced dialogue for settling disputes.

b Understand the role or function of people in the workplace such as shipwrights, joiners, sawyers, marine engineers, painters, plumbers, welders, electricians, buyers, storekeepers, dock-master, riggers and charge hands, foremen managers, etc.

3 be able to identify action to be taken when dealing with difficulties in working

relationships. a As with 2b above, know who to go to for guidance and understand the procedures f or grievances and appeals etc. b Again as with 4.4a and 2b above, know the lines of authority within the company.

4 as with 1 above but also knowing why these are important such as:

a Absenteeism and bad timekeeping and its effects on work schedules, putting extra pressure on workmates and leading hands in getting the job done on time and its effects on people’s impression of you and your reliability and future employment

b By observing the rules, regulations and procedures it ensures that work is carried out in the correct way, to the correct standard and in a safe manner.

c Correct conduct and behaviour in the workplace helps to reduce tensions which might arise if people are rude and inconsiderate.

d Maintaining good relationships with colleagues, supervisors and managers are important for reducing tensions and creating an atmosphere of esprit-de-corps at work.

e Respect for the company’s property ensures plant and equipment remains in a safe and serviceable condition and reduces the costs of having to repair or replace it.

f As with b above. g Having a positive attitude to customers helps to maintain good relationships with

them and will give the customer a favourable opinion of the company and lead to return custom.


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Outcome 6: Contribute to the effectiveness of boat production and

support services. Underpinning knowledge The candidate will be able to: 1 understand the type of information required for company and customer records

including: a job instructions such as a description of the work location, special requirements

(tools) b requisition sheets will include the description of materials used such as timber,

screws and fastenings, adhesives, equipment such as cleats and other fittings etc. c test and quality information such as records of trials and running tests on equipment

etc. d time sheets giving the labour hours e sub-contracted work details.

2 Sources of information to complete records.

a As with 1 above, the sources would come from information within the company available in the form of; time sheets, requisition sheets, test records, drawings and specifications and outside the company in the form of Designers drawings and specifications, Regulation agencies such as Lloyds, Recreational Craft Directive, Marine safety Agency etc. material and equipment suppliers.

3 The importance of accuracy when completing records in terms of:

a preventing wrong information being recorded b enabling a true account of costs and time to be established c providing a log of what was done when and by whom d providing information for future planning and potential customers.

4 The problems that may occur if records are not maintained and completed accurately

like: a work may be done more than once b work that should be done may be missed or not completed c work may be done incorrectly or not up to the standard required or expected d the true cost of the work may not be recovered e the customer may be charged too much or too little f the reputation of the company may be.

5 State where and to whom the records are to be delivered, for example:

a staying with the job as in the building records required by the R.C.D. b being kept by workmates as in the general methods of doing the job by a charge

hand or team leader c being kept in the office or stores and given some form of a time scale before they

become out of date and obsolete.


6 list the steps required to safely, efficiently and effectively undertake boat production

operations as listed from a to h. a Checking instructions and specifications. b Checking work area for suitability and safe access. c Determining sequence of operations. d Selecting tools, equipment and materials. e Assessing the processes required. f Coordinating functions. g Carrying out the process safely. h Checking completed task meets specification.


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014 Marine technology Rationale This is a core unit. All candidates must take this unit to obtain the qualification. This unit is concerned with selection and use of materials, tools and equipment and their application in boat production maintenance and support. This unit covers four learning outcomes. The candidate will be able to: 1 Identify boat construction materials. 2 Interpret and use drawings and specifications. 3 Identify tools and equipment. 4 Understand the principles of boatbuilding processes. Connection with other awards This unit combines and extends the knowledge contained in: Unit C – Cutting and finishing materials to form components of boats. Unit D – Assembling components to form hulls and decks. Unit E – Cutting and finishing materials to form interior components of boats. Unit F – Manufacturing sub-assemblies for boats. Unit G – Installing sub-assemblies in boats. Unit H – Installing interior fittings in boats. Unit I – Repairing damaged boat components. Unit K – Producing and finishing FRP mouldings. Unit L – Repairing FRP moulds and mouldings. Unit M – Assembling/installing FRP components on boats. Unit N – Repairing FRP boats and components. Unit O – Installing deck and hull fittings and components. of the Level 2 NVQ in Boat Production and Support Services. Assessment The underpinning knowledge requirements are listed for each outcome. These will be assessed by a multiple choice online test.


Outcome 1: Identify boat construction materials Underpinning knowledge The candidate will be able to: 1 identify the common materials used in boat construction. a Timber. i hard wood ii soft wood iii manufactured boards. b Composites. i glass reinforced (GRP) ii fibre reinforced (FRP) iii plastics. c Metals. i ferrous, steel ii non ferrous, aluminium iii alloys. 2 list features that identify materials. a Colour. b Texture. c Density. d Magnetism. 3 state the meaning of properties of materials. a Tensile strength. b Hardness. c Toughness/brittleness. d Elasticity. e Ductility/malleability. f Corrosion resistance. 4 state the effects of oxidisation and electrolytic action on metals 5 list typical adhesives used in marine construction. a PVA. b Formaldehydes. c Epoxy resins. 6 list types of protective coatings used in marine construction. a Varnishes b Paints c Preservatives d Resins


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Outcome 2: Interpret and use drawings and specifications Underpinning knowledge The candidate will be able to: 1 interpret drawing conventions to ISO8888/2000 for lines, dimensions and setting out. 2 identify types of drawings. a First and third angle orthographic projections. b Oblique and isometric projections. c General layout and assembly drawings. d Exploded and sectional views. 3 identify common scales used for drawing. 4 interpret information from drawings used in the production of boats and in fitting out. a Lines. b Construction plans. c General arrangements. d Detailed drawings. 5 list the sources of marine installation information. a Instruction manuals. b Technical books. c Tables, charts, graphs, data sheets. d Reference materials. e Electronic sources.


Outcome 3: Identify tools and equipment used in boatbuilding Underpinning knowledge The candidate will be able to: 1 describe types, applications and operation of tools for: a Measuring and marking out: i rules ii micrometers iii squares, protractors iv gauges v scribes. b Cutting: i saws ii knives iii shears. c Drilling: i drills ii bits. d Shaping: i files ii planes iii grinders. e Assembling and fixing: i spanners ii wrenches iii screwdrivers iv hammers v pliers, grips. 2 describe typical materials and equipment and applications. a Fixing devices, screws, bolts, nails. b Adhesives, formaldehydes, PVA. c Resins, composites. d Plastics. e Glass, ceramics. 3 identify equipment for lifting and transporting loads. a Trolleys. b Skates, jacks. c Trucks pallet, fork lift. d Wall and overhead cranes. e Slings and pull lifts. f Docking equipment. 4 state the general rules for the maintenance of tools and equipment. a Safe storage. b Cleaning after use. c Sharpening, honing. 5 list the safety requirements in respect of power tools. a PPE. b Guards. c Low voltage systems.


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Outcome 4: Understand the principles of boatbuilding processes Underpinning knowledge The candidate will be able to: 1 state the units and derived units of: a length b area c volume d capacity e mass f pressure g temperature. 2 perform simple calculations in respect of the above in 1. 3 state the purpose of measurement and marking out. a Identify properties to be measured. i Length, flatness, parallelism, angle, profile, relative position ii Volume, area, weight iii Temperature iv Pressure. b Select equipment used in measuring. c List the factors affecting accuracy of measurement. i Condition of equipment, calibration. ii Correct positioning. d Explain the concept of dimensions and tolerances. e Select marking out equipment and describe its use. f Describe use of datum and centre lines. 4 describe the purpose of work holding. a Identify typical devices. i Vices. ii Clamps. iii Chucks. 5 describe the purpose of material removal and recognise types of operation. a Sawing: i cutting sheet materials ii roughing down to size iii cutting at angle. b Planing: i finishing to size ii end grain iii grooves, rebates or profiles. c Shaping/turning: i cutting out waste ii paring iii carving. d Drilling: i through holes ii counterbored iii countersunk holes.


6 describe the factors which effect material removal. a Cutting speed. b Material hardness c Lubricants.

7 describe the purpose of assembly joining/fixing and recognise types of operation. a Joining by heat for permanent joints, welding, adhesives. b Joining/fixing by screwthreads, pins, rivets staples. c State the type and effects of forces used in assembly. i Tensile, shear and compressive loads on screwthreads. ii Shear loads on pins. iii Effects of over tightening and distortion. d Select appropriate joining/fixing devices 8 describe the purpose of finishing and recognise types of operation. a Varnishes. b Paints. c Chemical treatments. 9 state the general principles for carrying out processes. a Preparation of work area, materials, tools and equipment: i extract information from instructions, specifications, drawings. ii select materials, tools and equipment. iii develop operations plan. iv obtain permission, permit to work or advise client. v comply with health and safety requirements. b Carryout operation/process: i set up equipment/machinery ii follow correct procedure for process c Complete process and check it has achieved outcomes: i check for accuracy against specification ii reinstate work area 10 list the general rules in respect of safety. a Use of personal protective equipment. b Relevant legislation. c Inspection of equipment, materials and tools. d Isolation of electrical equipment. e Removal of waste.


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015 Marine engineering processes and principles Rationale This is a mandatory unit. All candidates need to take this unit to obtain the qualification. This unit is concerned with the identification of materials used in marine construction, the interpretation of drawings along with the tools and equipment used. It also covers the principles of marine electrical processes. This unit covers four learning outcomes. The candidate will be able to: 1 Identify marine construction materials. 2 Interpret and use drawings and specifications. 3 Identify tools and equipment used in marine/electrical processes. 4 Understand the principles of marine/electrical processes. Connection with other awards This unit combines and extends the knowledge contained in units: Unit 116 – Cutting and shaping wooden components for yachts and boats using hand tools of the Level 2 NVQ in Boat Production and Support Services. Assessment The underpinning knowledge requirements are listed for each outcome. These will be assessed by a multiple choice online test.


Outcome 1: Identify marine construction materials Underpinning knowledge The candidate will be able to: 1 identify the common materials used in boat construction:

a Timber: i hard woods ii soft wood iii manufactured boards. b Composites: i glass reinforced (GRP) ii fibre reinforced (FRP) iii plastics. c Metals: i ferrous, steel ii non ferrous, aluminium iii alloys.

2 list features that identify materials. a Colour. b Texture.

c Density. d Magnetism. 3 state the meaning of properties of materials.

a Tensile strength. b Hardness. c Toughness/brittleness. d Elasticity. e Ductility/malleability f Corrosion resistance.

4 state the effects of oxidation and electrolytic action on metals 5 list typical sealants and mastics used in marine constructions 6 List types of protective coatings used in marine construction.

a Preservatives. b Sprays. c Coatings.


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Outcome 2: Interpret and use drawings and specifications Underpinning knowledge

The candidate will be able to:

1 interpret drawing conventions to 1808888/2000 for lines, dimensions and setting out. 2 identify types of drawings: a first and third angle orthographic projections b oblique and isometric projections c general layout and assembly drawings d exploded and sectional views.

3 identify common scales used for drawings 4 interpret information from drawings used in the production of boats and in fitting out: a circuit and wiring diagrams b general layout drawings c detailed drawings.

5 list the sources of marine engineering information. a Instruction manuals. b Technical books. c Tables, charts, graphs, data sheets. d Reference materials. e Electronic sources. f Specifications.


Outcome 3 Identify tools and equipment used in marine/electrical processes Underpinning knowledge


1 describe types, applications and operation of tools for: a measuring and marking out i Rules. ii Micrometers, verniers, height gauges. iii Squares, protractors. iv Gauges. v Scribes. b cutting/shaping i Saws. ii Knives. iii Shears. iv Hole saws. v Drills. vi Machine tools. vii Hand power tools. viii Grinders disc cutters. c test equipment i Multi meter. ii Timing light . iii Compression tester. iv Temperature gauge. v Alignment gauge. d assembling and fixing. i Spanners/wrenches. ii Torque wrenches. iii Screwdrivers. iv Hammers. v Pliers, grips. 2 describe typical materials, equipment and applications. a Fixing devices, screws, bolts b Adhesives c Resins, composites d Plastics 3 identify equipment for lifting and transporting loads. a Trolleys. b Skates, jacks. c Trucks: pallet, fork lift. d Wall and overhead cranes. e Slings and pull lifts. f Docking equipment.


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4 state the general rules for the maintenance of tools and equipment. a Safe storage. b Cleaning after use. c Sharpening and honing. 5 list the safety requirements in respect of power tools. a PPE. b Guards. c Low voltage systems.


Outcome 4: Understand the principles of marine/electrical processes Underpinning knowledge


1 state the units and derived units of: a length b area c volume d capacity e mass f pressure g temperature h Ohm’s Law i power units. 2 perform simple calculations in respect of the Outcome 4.1 3 state the purpose of measurement and marking out. a Select equipment used in measuring. b List the factors affecting accuracy, calibration. i condition of equipment ii correct positioning and connection c Explain the concept tolerances. 4 describe the purpose of work holding. a Identify typical devices: i vices ii clamps iii chucks. 5 describe the purpose of material removal and recognise types of operation. a Sawing: i cutting sheet materials ii roughing down to size iii cutting at angle. b Drilling: i through holes ii counterbored iii countersunk holes. c Describe the factors which effect material removal: i cutting speed/simple calculations ii material hardness iii lubricants.


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6 describe the process of assembly joining/fixing and recognition types of operation. a Joining by heat for permanent joints, welding, adhesives. b Joining/fixing by screw threads, pins, rivets, pop rivets. c State the type and effects of forces used in assembly. i Tensile, shear, and compressive loads on screw heads. ii Shear loads on pins. iii Effects of over tightening and distortion. d Select appropriate joining/fixing devices. 7 describe the purpose of finishing and recognise types of operation. a Varnishes. b Paints. c Chemical treatments. 8 state the general principles for carrying out processes. a Preparation of work area, materials, tools and equipment: i extract information from instructions, specifications, drawings ii select materials, tools and equipment iii develop operations plan iv obtain permission, permit to work or advise client. v comply with health and safety requirements. b Carry out operation/process: i set up equipment/machinery ii follow correct procedure for process. c Complete process and check it has achieved outcomes: i check for accuracy against specification ii reinstate work area. 9 list the general safety rules in a boatbuilding environment. a Use of personal protective equipment. b Relevant legislation. c Inspection of equipment, materials and tools. d Isolation of electrical equipment. e Removal of waste.


003 Yacht and boatbuilding assembly and sub assembly Rationale This is an optional unit. It covers the skills and knowledge associated with the building of boats and associated components. The content includes interpreting specifications, preparation, assembly and quality control. This unit covers three learning outcomes. The candidate will be able to:

1 Plan and implement boat assembly and sub assembly operations using drawing, instructions and specifications. 2 Carry out operations correctly and in a safe manner. 3 Check the assembly & sub assembly components meet the quality standards. Connection with other awards This unit combines and extends the knowledge contained in the following units: Unit C – Cutting and finishing materials to form components of boats Unit D – Assembling components to form hulls and decks Unit F – Manufacturing sub-assemblies for boats of the level 2 NVQ in Boat Production and Support Services Assessment The outcomes from this unit will be assessed using an assignment to cover the practical skills and the underpinning knowledge requirement.


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Outcome 1: Plan and implement boat assembly and sub assembly operations using drawings, instructions and specifications Practical activities The candidate will be able to: 1 interpret instructions to obtain materials, tools and equipment 2 plan sequence of operations and processes.

Underpinning knowledge The candidate will be able to: 1 identify and use sources of information relevant to boat assembly and sub assembly operations. a Codes of practice. b Lloyds and RCD rules & regulations. c Customer/client specifications. d BSS Boat safety scheme, inland waterways. e BS/EN standards applicable to the Marine Industry. 2 state the importance and purpose of drawings, specifications, data sheets and procedure sheets: a how to interpret information from line plans, working drawings and specifications b the current drawing standards ISO 8888/2000. 3 state the implications of BS/EN 4001. 4 identify the materials used in boat assembly and sub assembly and the inherent characteristics and physical properties. a Wood: i oak ii mahogany iii teak iv iroko v Baltic red pine vi white wood vii Douglas fir. b Composite/manufactured board: i GRP ii thermoplastics iii laminates iv marine ply v MDF. c Metal: i bronze ii copper iii brass iv stainless steel v galvanised steel vi aluminium.


5 state the factors influencing the choice of material. a Suitability. b Cost. 6 list the requirements of a safe working environment. a Environmental control. b Washing facilities. c Dust, and fume extraction. d Temperature and humidity control. e The handling and storage of hazardous materials. 7 state the function and safe use of hand tools. a Cutting tools, saws: i cross cut ii panel iii coping iv tenon and pad saws v hacksaws vi diamond vii tungsten tipped viii pull saws ix hole saws. b Material removal tools: i chisels ii planes iii spoke shaves iv drawknives v files vi rasps. c Assembly and joining tools: i drills ii screwdrivers iii spanners iv socket sets. d Measuring and marking out tools: i tapes ii rules iii squares iv gauges v scribes. e Special tools, workholding devices, jigs. 8 state the function and safe use of woodworking machinery: a saw, circular, band, cross cut b planes, over and under c mortises d spindle moulders e sanders. 9 state the function and safe use of other powered tools:

a hand held power tools b electrical drills c sanders d saws e grinders.


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10 identify and select applications for typical fastenings. a Screwthreads. b Bolts. c Adhesives. d Nails and pins. 11 read and interpret specifications to: a identify material required from the specification b select the correct tools to use for specific applications c identify and select the fittings and fixtures required for assemblies d describe the techniques used to transfer mould and template data to mould and template material (eg spiling) e describe the cutting and shaping methods used to produce moulds, templates and jigs. 12 identify material defects commonly found in timber and composite boards 13 state the importance of labelling components 14 describe the techniques used to align moulds, templates and jig components (dimensional orientation, horning in) 15 list the fastening methods used to secure moulds templates and jigs


Outcome 2: Carry out operations correctly in a safe manner Practical activities The candidate will be able to undertake assembly/sub assembly of boat components.

Underpinning knowledge The candidate will be able to: 1 state the related technology for mould and template manufacturing. a Lines plan and offsets. b CAD applications. 2 describe the techniques used to check alignment ie horning in, levelling, plumbing 3 state safety precautions to be observed in: a cutting components b using hand tools c using portable power tools d lifting and handling. 4 list the correct sequences in assembling boat components 5 recognise the need to comply with operation sheets and schedules 6 state the principle methods and techniques used in boat construction. a Wood: i construction of moulds and templates ii frame and jig assembly iii backbone, stems. b Composite: i construction of moulds ii waxing iii lay ups, spray iv laminating. 7 state the importance of correct and safe disposal of waste material 8 state safe methods for the use of lifting equipment. a Never exceed safe working load (SWL). b Avoid shock loading. c Never transport loads over people. d Avoid twisting of slings and ropes. 9 explain the importance of record keeping


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Outcome 3: Check the assembly and sub assembly components meet the quality standards Practical activities The candidate will be able to carry out quality checks on completed assembly/sub assembly components. Underpinning knowledge The candidate will be able to: 1 describe techniques and terminology for testing and checking alignment of jig moulds and formers 2 state basic techniques for a visual inspection of an assembly or sub assembly 3 describe how to evaluate test results 4 recognise common faults in construction materials: a wood and composite boards b metals c FRP structures. 5 state the use and application of protective coatings: a paint and varnishes b plastic coating c metallic coatings (galvanisers). 6 state the relevant regulations and safe working practices that apply to the work to be undertaken 7 state who to contact in the event of a problem 8 describe how to check that all operations have been completed 9 list correct operations to reinstate the work area


004 Production of hulls and decks and structural components Rationale This is an optional unit. This unit concerns the requirements for the successful production of components which make up the structure of boats. It includes the interpretation of lofted lines, drawings and specifications; the terminology and techniques needed to obtain the shape of moulds and templates and the skills required to mark, cut-out, assemble and finish the items which make up a boat. This unit covers three learning outcomes: 1 produce moulds and templates for components of boats 2 cutting and finishing materials to form components of boats 3 assembling components to form hulls and decks. Connections with other awards This unit combines and extends the knowledge and understanding contained in units: Unit B – Producing templates for components of boats Unit D – Assembling components to form hulls and decks of the level 2 NVQ in Boat Production and Support Services.

Assessment The outcomes of this unit will be assessed using evidence from an assignment covering practical and underpinning knowledge requirements.


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Outcome 1: Produce moulds and templates for components of boats Practical activities The candidate will be able to: 1 interpret instructions to obtain materials, tools and equipment 2 develop moulds/templates and transfer to appropriate material.

Underpinning knowledge The candidate will be able to: 1 identify and use sources of information relevant to production of hulls and decks a Codes of Practice b Lloyds and RCD rules and regulations c customer/client specification d BSS boat safety scheme, inland waterways e BS/EN standards applicable to the marine industry. 2 describe the basic concept of: a line plan b sheer plan or profile c half breath plan and body plan d water lines, buttock lines and diagonal lines. 3 state the importance and purpose of drawings, specifications, data and procedure sheets 4 recognise the range of materials used in the production of moulds and templates and their inherent characteristics. a Wood: i oak ii mahogany iii teak iv iroko v Baltic red pine vi white wood vii Douglas fir. b Composite/manufactured board: i GRP ii thermoplasctics iii laminates iv marine ply v MDF. c Template paper/card. d Metal: i ferrous ii non-ferrous.


5 describe the methods and procedures for developing the shapes of moulds and templates and transferring them onto the mould/template material. a Direct measurement. b Tracing/transfer. c Nail-head impressions. 6 state the function and safe use of hand tools. a Cutting tools, saws: i cross cut ii panel iii coping iv tenon and pad saws v hacksaws vi diamond vii tungsten tipped viii pull saws ix hole saws. b Material removal tools i chisels ii planes iii spoke shaves iv drawknives v files vi rasps. c Assembly and joining tools i drills ii screwdrivers iii spanners iv socket sets. d Measuring and marking out tools i tapes ii rules iii squares iv gauges v dividers vi scribes. 7 state the function and safe use of woodworking machinery: a saws, circular, band, cross cut b planes c sanders d routers. 8 state the function and safe use of other powered tools: a hand held power tools, electric drills, sanders, saws, grinders b thermal equipment. 9 identify defects in materials caused by: a poor selection b poor setting out c incorrect cutting/shaping d distortion (twisting and warping or heat distortion in the case of metals). 10 state the importance of minimising waste when marking and setting out moulds and templates


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Outcome 2: Cut and finish materials to form components of boats Practical activities The candidate will be able to produce components for boats. Underpinning knowledge The candidate will be able to: 1 identify the terms and names by which the components of a boat are known: a backbone items, stem, keel sternpost, deadwood b frames, knees, stringers, chines c types of planking, clinker, carvel, double diagonal, cold moulded, strip metals d beams and carlins and decks e ridged inflatable boat components. 2 identify the range of materials from which boat components are made. a Timbers, hardwoods and softwoods: i oak ii mahogany iii teak iv iroko v Baltic red pine vi white wood vii Douglas fir. b Plastics: i GRP ii thermosetting ii FRP. c Manufactured boards: i marine ply ii blockboard iii MDF. d Metals in the form of plate, bar, angle or section: i stainless steel ii galvanised steel iii aluminium iv brass v copper vi brass. 3 describe the techniques used for transferring shapes onto the component material. a Direct measurement. b Tracing/transfer. c Nail-head impressions. 4 select the correct cutting method for square, angular or curved profiles 5 describe procedures to set up and operate the cutting tools needed to profile the components 6 identify possible cutting defects in materials 7 state the correct finishing procedures applied to boat components


8 list the appropriate protective methods to apply to finished components 9 list techniques used to produce masts and spars. a) Solid spars. b) Hollow spars. c) Aluminium.


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Outcome 3: Assembling components to form hulls and decks Practical activities The candidate will be able to: 1 set up boat components 2 align and assemble components. Underpinning knowledge The candidate will be able to: 1 state the factors to be considered when preparing the work area. a Floor or bench space required. b Availability of material. c Tools and equipment. d Material handling facilities. 2 sescribe methods of setting up and bracing boat components 3 describe use of temporary fixing devices, cramps and clamps 4 select appropriate tools and equipment for assembly operations. a Levelling/alignment equipment. b Hand tools. c Portable power tools. d Thermal equipment (metal only). 5 describe the safe use of appropriate lifting equipment: a manual b mechanical. 6 state the correct alignment techniques when setting up components: a horning in b levelling c plumbing (vertical alignment). 7 list the problems which can occur when assembling boat components. a Blunt tools faulty equipment. b Level of skills and training of personnel. c Critical curing times of adhesives and mastics. d Delivery dates and penalty clauses 8 state the basic safety regulations applicable to hull and deck assembly. a HSaW. b COSHH. c Provision and Use of Work Equipment Regulations (PUWER 1998). d Need for risk assessment. e Correct disposal of waste. f Use of PPE.


005 Installation and fitting out of boats Rationale This optional unit is concerned with the installation of interior modules, joinery units, deck modules and consoles that contain fittings such as doors, apertures and drawers. It covers the preparation of the work area, the use of specifications and drawings, positioning and fitting modules of units, fixing and securing modules, joinery and marine fittings and the inspection of completed parts. The unit covers four learning outcomes. The candidate will be able to: 1 prepare for installation of interior modules, joinery and marine fittings 2 position and fit interior modules, joinery and marine fittings 3 fix and secure interior modules, joinery and marine fittings 4 complete, inspect and protect interior modules, joinery and marine fittings. Connection with other awards This unit combines and extends the knowledge and understanding contained in level 2 NVQ for Boat Production and Support Services, units G, H O and P. Assessment The outcomes from this unit will be assessed using evidence from an assignment which will cover practical and underpinning knowledge requirements.


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Outcome 1: Prepare for installation of interior modules, joinery and marine fittings Practical activities The candidate will be able to interpret instructions to identify materials, tools and equipment Underpinning knowledge The candidate will be able to: 1 identify and use sources of information relevant to fitting out boats. a Codes of Practice. b Lloyds and RCD rules and regulations. c Customer/client specifications. d BSS Boat safety scheme, inland waterways. e BS/EN standards applicable to the marine industry. 2 state the importance and purpose of drawings, specifications, data sheets and procedure sheets to obtain relevant information from: a instruction sheets b drawings c patterns and templates d manufacturer’s data sheets e company procedures. 3 state the importance of identifying the correct location and position for joinery and fitting by: a measurement b levelling c plumbing down d construction and datum lines e position of preinstalled components. 4 state the function and safe use of hand tools: a Cutting tools, saws: i cross cut ii panel iii coping iv tenon and pad saws v hacksaws vi diamond vii tungsten tipped viii pull saws ix hole saws. b Shaping tools: i planes ii spoke shaves iii chisels iv files v rasps.


c Fixing/joining tools: i drills ii screwdrivers iii spanners iv socket sets. d Measuring and marking out: i tapes ii rules iii squares iv gauges. 5 state the function and safe use of powered tools: a electric drills, sanders, saws, planes b compressed air equipment. 6 recognise and select applications for typical fastenings. a Screwthreads. b Bolts. c Adhesives. d Nails and pins. 7 recognise the major accommodation areas on boats and the typical fittings installed in each area. a Galley: i sinks and drainage fittings ii cooker and shut-off iii ice box/fridge iv storage lockers, hinges and locker catches v fire blanket vi water system and filters vii tanks – fresh and waste. b WC compartment: i toilet – black water holding tanks ii shower iii wash basin iv skin fitting for WC and wash basin v water system – hot and cold vi lighting and ventilation. c Navigation area: i seating ii chart table, lighting and vents iii navigation instruments and skin fittings (transducer) iv storage lockers and drawers, drawer hardware, catches. d Saloon: i seating – height/width conventions ii table – height/width conventions iii storage locker and drawers, drawer hardware, catches iv lighting and ventilation v heating systems. e Sleeping accommodation: i bunks and lee cloths ii lighting and ventilation iii hanging lockers and storage.


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8 list the checks to be carried out on joinery and fittings to ensure serviceability. a Visual checks. b Functional checks. 9 state the potential hazards and working problems that can affect fitting out. a Typical hazards that may be found in a work area: i ventilation ii fire hazards iii poor access. b Working problems: i interaction with other trades.


Outcome 2: Position and install/fit interior modules, joinery and marine fittings Practical activities The candidate will be able to select, position and fit interior modules. Underpinning knowledge The candidate will be able to: 1 state methods of identifying modules, joinery and fittings for installation. a Identification of codes and labels. b Bar coding. c Visual recognition. d Pattern or code numbers. 2 state means to find out approximate weight of modules, joinery and fittings for installation 3 describe methods of transporting and lifting modules, joinery and fittings to work area, and the related criteria. a Manual handling: i weight ii size iii safety considerations, sharp edges, shape. b Lifting equipment: i authorisation ii regulations iii lifting and slinging methods. 4 state methods of protecting and preventing damage to modules, joinery and fittings during transportation. a Covering and packing. b Padding. c Temporary supports. d Temporary surface coating 5 list the criteria to be met in preparing the work area for installation of modules, joinery and fittings. a Safe access, lighting and ventilation. b Area free from contamination and obstruction. c Level lines and position lines marked. d Temporary jigs and support equipment in place. e Inform other trades. f Prepare surface by: i cleaning ii abrading iii coating iv pre-greasing.


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6 Describe methods of accurately aligning and fitting modules, joinery and marine fittings. a Spile. b Cut, trim and fit. c Level and align. d Locate and temporarily fasten. e Temporarily secure using cramps, wedges, battens.


Outcome 3: Fix and secure interior modules, joinery and marine fittings Practical activities The candidate will be able to use a range of techniques to fix fittings. Underpinning knowledge The candidate will be able to: 1 state how positional accuracy is achieved 2 select appropriate fixing methods. a Mechanical fastenings: i screws ii bolts iii nails iv rivets. b Adhesives: i two-part epoxy ii phenal formaldehyde iii PVAs iv contact adhesive v urea formaldehyde vi cascein glue. c FRP bonding: i glass bonding ii polyester paste iii epoxy putty. d Sealants: i silicon (marine) ii polyurethane iii polysulphides iv oil based v acrylic vi jointing tape. 3 state the factors to be considered to ensure strength and security of fixed modules, joinery and marine fittings. a Backing pads and plates. b Load spreading methods. c Torque loadings. d Material breaking points. 4 select tools and equipment, procedures and safety precautions to undertake the following techniques: a drilling b reaming c countersinking d cutting e abrading.


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5 state the factors to be considered to avoid damage to the module, joinery and fittings during the fixing process. a Clean access adhesive/sealant. b Damage from tools and equipment. c Over-tightening fastenings. d Incorrect tool selection. 6 state the purpose of alignment checks and fixing quality by: a geometric accuracy b fit of joints c functional operation of fittings d leak test e alignment of screw/bolt heads.


Outcome 4: Complete, inspect and protect modules, joinery and marine fittings Practical activities The candidate will be able to carry out completion checks on installations. Underpinning knowledge The candidate will be able to: 1 describe methods of inspection and tests commonly used in installation. a Visual inspection: i surface defects ii twist and alignment iii fit of joints iv fixing damage. b Functional test: i correct operation ii water-tight iii no interference with other systems. c Dimensional control: i measurement ii geometric alignment. 2 give the reasons why it is important to protect completed modules, joinery and fittings 3 list common methods of protecting completed modules, joinery and fittings from damage. a Covering. b Labelling. c Wrapping. d Coating. 4 state the processes required to reinstate the work area following completion. a Clean and clear waste from work area. b Return tools, equipment and services. c Ensure protection and labelling in place. d Floors and access panels are replaced. 5 list the checks and recording required on completion of installation to include a record of hours b record of materials used c inspection checklist.


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006 Composites for marine construction Rationale This is an optional unit. This unit concerns the requirements for successful production of components in composite materials related to marine construction. It includes wet lay ups, use of pre-preg materials, interpretation of drawings, specifications, planning moulding and lay ups. It also covers operations required to produce components and safe working practices to complete composite construction. This unit covers four performance outcomes. The candidates will be able to: 1 interpret drawings, instructions, regulations and relevant codes of practice 2 plan mould and lay up operations 3 carry out operations correctly and in a safe manner 4 check the finished product with the specification. Connection with other awards This unit combines and extends the knowledge and understanding contained in units K, L, M, and N of the level 2 NVQ in Boat Production and Support Services. Assessment The outcomes from this unit will be assessed using evidence from an assignment which will cover both practical and underpinning knowledge outcomes.


Outcome 1: Interpret of drawings, instructions, regulations and relevant codes of practice Practical activities The candidate will be able to: 1 demonstrate knowledge and application of regulations, relevant codes of practice, Lloyds and RCD (Recreational Craft Directory) 2 perform simple experiments and tests on materials 3 extract information from working drawings, specification 4 demonstrate knowledge and application of the HASWA relating to a composite manufacturing work place. Underpinning knowledge The candidate will be able to: 1 select sources of information relevant to composite manufacture. a Regulations. b Codes of practice. c Lloyds and RCD rules. d Customer specifications. e BS/EN standards applicable. 2 identify the function of materials used 3 define the physical and working properties of materials used 4 state the standard BS/EN testing of material specimens 5 list the tests carried out to determine strength, resistance, hardness and flame retardation. 6 outline the pre-production test carried out on pre-preg materials 7 interpret and use working drawings 8 extract information from working drawings, specifications in order to compile material requirements. 9 state the requirements for a safe working environment. a Environmental controls. b Local exhausts ventilation (LEV systems). c Fume cabinets. d Washing facilities. e Dust proof lighting. f Dedicated dust and fume extraction. g Temperature control and humidity recording.


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10 Identify potential hazards when working with composites. a Curing agents. b Dust. c Broken fibres. d Solvents. e Resin vapours.


Outcome 2: Planning mould and lay up operations Practical activities The candidate will be able to: 1 identify materials, resins and additives required from job specification 2 select moulds, formers, templates, tools and equipment appropriate to material/application 3 select resin and catalyst systems 4 prepare and set up materials, moulds, machines and equipment 5 prepare operations sheet for one construction 6 use safe working practices. Underpinning knowledge The candidate will be able to: 1 describe the basic features of thermosetting plastics, GRP, FRP composite materials. 2 state the forms of supply of materials. a Dry cloth. b Pre-impregnated cloth (pre-preg). 3 state the types of fibre used in composites. a Glass. b Carbon. c Aramid. 4 identify the typical application of 2 and 3 related to the marine construction 5 identify the weave patterns used in cloth 6 state the reasons for different weave patterns 7 identify the formation of various combinations of glass fibre 8 describe methods used to check and monitor the resin/glass ratio 9 classify the different component construction used. a Contact moulding - wet lay ups. b Contact moulding - spray techniques. c Resin transfer moulding. d Use of pre-preg glass. e Sandwich construction, use of foam and wood.


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10 identify the resin catalyst systems used. a Polyester. b Vinylester. c Epoxy. 11 outline the mixing of resins in accordance with stated specifications 12 state the use of additives. a Colour pigments. b Thixotropic agents. c Fire retardants. d Fillers. 13 describe the materials/equipment required for wet lay ups. a Fibre glass cloth. b Resin. c Catalyst. d Accelerator. e Brushes, rollers. f Cleaning solvents. 14 identify the tools, machines, equipment used in working with composites 15 describe the preparation of moulds, formers including waxing and the application of release agents. 16 describe the use of templates for material preparations 17 explain the use of CNC machines for cutting out plies (reciprocating blade) 18 state the use of pre-preg materials 19 explain the reason for the use of a vacuum bag 20 state the purpose of the following components within a vacuum bag: a porous release film b absorption/bleeder cloth c non-porous release cloth d air breather. 21 explain the purpose of vacuum pressures 22 state the use of vacuum bag tape 23 describe the requirements of curing using heat and pressure 24 state how to prepare operation sheets for simple constructions 25 identify relevant legislation relating to safe working practices


Outcome 3: Carry out operations correctly and in a safe manner Practical activities The candidate will be able to: 1 use a range of moulds and formers 2 use lay up techniques 3 produce a component using a selected technique 4 use safe working practices 5 demonstrate safe handling techniques of materials and finished components by mechanical and manual means. Underpinning knowledge The candidate will be able to: 1 explain the related technology to mould and former design and construction 2 describe the treatment applied to moulds and formers. a Waxing. b Application of release agents. 3 state the choice of materials used in mould and former design with respect to heat and pressure. 4 describe the techniques and procedures required for: a wet lay ups b spray c pre-preg d sandwich construction - use of foam and wood. 5 describe the techniques for laminating flat and curved panels 6 explain plug and mould construction including: a incorporation of inserts for fixing b non skid surfaces c skin fitting d datum points for fixing internal fittings. 7 state the need for stiffening and cradling to support hulls 8 outline the construction of a vacuum bag for the accommodation of components 9 explain the proving of a vacuum bag 10 state the use of tools, equipment and machines 11 describe weighing and mixing of resins in accordance with stated specifications 12 state the important factors when using resins. a Cleanliness. b Weighing.


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c Mixing. d Pot life. 13 state safety precautions to be observed. a Use of resin and adhesives. b Mixing of resin and adhesives. c Machining composites. d Use of powered hand tools. e Disposal of waste. 14 state safe methods of transportation of jigs, moulds and components around the work place 15 identify safety regulations and rules for safe use of lifting equipment. a Never exceed the safe working load (SWL). b Avoid shock loading. c Never transport loads over persons. 16 name types of sling and their safe use. a Avoid twisting. b Never bend around sharp corners. c Importance of the angle between two slings (maximum 120o). 17 state safe use of portable electrical equipment. a Precautions against electric shock. b Legislation designed to reduce the risk of electric shock eg low voltage equipment. 18 identify safety regulations relating to machine tools including guarding


Outcome 4: Check the finished product with the specification Practical activities The candidate will be able to: 1 identify common flaws associated with composite construction 2 perform simple inspection techniques to ensure conformity with specification 3 interpret information from test/inspection results 4 use safe working practices at all stages. Underpinning knowledge The candidate will be able to: 1 identify common manufacturing defects/flaws associated with GRP/FRP construction 2 state the methods used for checking components. a Dimensional -measurement, jigs. b Profile, shape -templates, formers. c Surface finish-visual inspection. d Surface defects -visual inspection, tap test. 3 describe how to carry out visual inspection on a finished component 4 list NDT methods available for inspecting finished components 5 explain how to interpret results from 3 and 4 6 state repair techniques available for defective GRP/FRP components 7 list types of common damage that occur to composite construction. a Impact. b Erosion. c Scratches and gouges. d Water ingress. e Delamination. f Disbond. g Degradation. 8 identify the relevant legislation relating to safe use and inspection techniques


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007 Servicing and maintenance of marine engines Rationale This optional unit is concerned with the principles and procedures associated with the basic servicing and maintenance of marine engines. This unit covers four learning outcomes. The candidate will be able to: 1 recognise the requirements for the safe servicing and maintenance of marine engines 2 identify appropriate information, tools and materials needed for servicing operations 3 undertake basic servicing and maintenance 4 complete necessary actions and make appropriate recommendations where required. Connections with other awards This optional unit will be suitable for those undertaking a level 2 NVQ in Boat Production and Support Services or similar award where knowledge of marine engines is relevant. Assessment The outcomes from this unit will be assessed using evidence from an assignment covering both practical and underpinning knowledge requirements.


Outcome 1: Recognise the requirements for the safe servicing and maintenance of marine engines Practical activities The candidate will be able to: 1 access data for servicing and maintenance 2 identify marine engines systems and components. Underpinning knowledge The candidate will be able to: 1 identify the types of marine engines.

a Single cylinder: i spark ignition; two stroke, four stroke ii compression ignition; two stroke, four stroke.

b Multi cylinder: i cylinder layouts; in-line, horizontal, V ii spark ignition; two stroke, four stroke iii compression; two stroke, four stroke.

2 describe types of installation and application of engines. a Inboard. b Outboard. c Jet ski. 3 describe the operating principles of marine engines: a four stroke cycle for spark ignition and compression ignition b two stroke cycle for spark ignition and compression ignition

c combustion process for spark ignition and compression ignition. 4 identify the main components of a marine engine and state the purpose and operating characteristics. a Cylinder, cylinder block and crankcase. b Cylinder head. c Piston and piston rings. d Connecting rod and gudgeon pin. e Small and big bearings. f Crankshaft. g Main and thrust bearings h Sump. i Inlet and exhaust valves or ports. j Valve operating mechanisms. k Flywheel. l Crankshaft damper.


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5 identify the ancillary parts of a marine engine and state the purpose and operating characteristics. a Fuel systems: i tanks

ii piping iii filters iv pumps v injectors vi cleaners. b Cooling systems (air cooled and water cooled): i pumps ii thermostats iii hoses

iv pressure caps v sea inlet.

c Lubrication systems. d Ignition systems. e Starting systems. f Exhaust systems. 6 state the purpose of routine servicing and maintenance. a Improve efficiency.

b Extend engine life. c Reduce the chance of failure.

7 list the types of data required for servicing and maintenance. a Workshop manuals. b Manufacturer’s data and information sheets. c Service schedules. d Parts lists. e Trade Association check lists. f Legal and technical data reference books.

8 state how to access data using:

a computers b microfiche.

9 state the precautions required and the hazards associated in working with marine engines. a Use of Personal Protective Equipment (PPE); goggles, gloves, safety equipment. b Legislation; COSHH, HaSW, Codes of Practice. c Danger from power transmission systems rotating, reciprocating machinery and parts. d Lubricants and fuels: skin protection and ventilation. e Application and safe use of lifting equipment. f Electrical equipment and systems; isolation, low-voltage systems. g Fire risks, precautions with fuels. h Safe storage and disposal of materials. i Good housekeeping procedures and environmental awareness.


Outcome 2: Identify appropriate information, tools and materials needed for servicing operations Practical activities The candidate will be able to: 1 select appropriate data for servicing and maintenance operations 2 prepare for servicing and maintenance of marine engines. Underpinning knowledge The candidate will be able to: 1 describe the main elements of a maintenance programme. a Preventive and scheduled maintenance: i cleaning ii lubrication iii replenishment iv adjustment v checking vi overhaul vii replacement. b Corrective/emergency maintenance. 2 interpret technical data to compile a maintenance programme. 3 state the organisation and resources required for servicing and maintenance: a tools, test equipment, yard facilities and equipment

i hand tools: eg socket sets, screwdrivers, pliers, spanners, wrenches ii measuring equipment: eg feeler gauges, pressure gauges, test meters iii power tools iv lifting equipment v draining equipment

b spare parts, materials and consumables i filters, seals, gaskets, electrical connections ii lubricants

c reference data and documentation i technical information ii service manuals

d reporting systems i job sheets ii recommendations to other personnel.


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Outcome 3: Undertake basic servicing and maintenance of marine engines Practical activities The candidate will be able to identify procedures for servicing and maintenance. Underpinning knowledge The candidate will be able to: 1 describe the routine tests for a marine engine and its ancillary systems. a Engines:

i checking and adjustment of valve clearance ii examination for seals and gaskets for leak iii examination of cylinder head for coolant leaks iv cylinder power balance v examination of exhaust manifolds for leaks vi examination of engine mounting.

b Cooling: i pressure test for leaks ii testing thermostat iii checking drive belts for condition and tension iv checking cylinder and cowling for damage and cleanliness v antifreeze. c Fuel system: i condition of tank, fuel lines and unions ii checking pump iii checking injectors iv cleaning and replacing filters. d Lubrication system: i checking oil level ii checking for contamination iii cleaning and replacing filters. e Ignition system: i ignition timing ii condition of contact breaker and points iii condition of distributor iv condition of spark plugs v condition of leads and connections. f Inlet and exhaust systems: i checking manifold for leaks ii checking exhaust system for condition iii checking induction system for damage. g Starting system: i condition of leads and connections ii servicing of battery iii master switches.


2 describe general checks to be applied throughout and on completion of maintenance. a Safety checks: i electrical power, piping and connectors ii oil and coolant levels. b Performance checks: i engine running temperatures, pressure, leaks, alignment, vibration ii comparison of measured performance to specifications.


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Outcome 4: Record results and make appropriate recommendations Practical activities The candidate will be able to: 1 compare results of performance with manufacturers’ requirements 2 record results and make recommendations 3 access data from various sources. Underpinning knowledge The candidate will be able to: 1 state the methods of accessing data from:

a workshop manuals b manufacturer’s data and information sheets c service schedules d parts lists e Trade Association check lists f legal and technical data reference books.

2 state how to access data using: a computers b microfiche. 3 describe how to compare the results obtained from servicing and maintenance with manufacturer’s data:

a exhaust gas emissions testing S.I. and C.I. engines b compression testing (S.I. and C.I.) c cooling system testing d engine system testing with an electronic engine analyser.

4 record results obtained using:

a computers b manufacturer’s recording sheets c trade association recording sheets.

5 make and record appropriate recommendations resulting from inspections.

a Complete maintenance schedule as appropriate. b Report problems to higher authority.


008 Marine propulsion systems Rationale The unit is concerned with the principles and procedures associated with the basic servicing and maintenance of propulsion systems and auxiliaries engines. This unit covers four learning outcomes The candidate will be able to: 1 recognise the requirements for the safe servicing and maintenance of propulsion systems 2 identify appropriate information, tools and materials needed for servicing operations 3 understand basic servicing and maintenance procedures 4 record results and make appropriate recommendations where required. Connections with other awards This optional unit will be suitable for those undertaking a level 2 NVQ in Boat Production and Support Services or similar award where knowledge of marine propulsion systems is relevant. Assessment The outcomes from this unit will be assessed using evidence from an assignment covering practical and underpinning knowledge requirements.


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Outcome 1: Recognise the requirements for the safe servicing and maintenance of marine propulsion systems Practical activities The candidate will be able to: 1 access data for servicing and maintenance 2 identify marine propulsion systems and components. Underpinning knowledge The candidate will be able to: 1 identify the features of marine propulsion systems: a In board engines: i assembly fixtures ii transmission systems

iii fuel fixtures iv electrical connections v controls.

b Out board engines: i assembly and mounting ii control systems iii fuel fixtures iv electrical connections. 2 state the main components of propulsion systems and auxiliaries and state the purpose and operating characteristics of: a gearbox and reduction gear b drive systems, shafts c propellers d rudders e steering gear. 3 identify the ancillary parts of propulsion systems and state the purpose and operating characteristics. a Gearboxes: i cooling ii lubrication. b Drive systems: i hydraulic ii outdrive iii Z drive iv V drive. c Propellers: i couplings ii fittings. d Rudders. e Steering systems.


4 state the purpose of routine servicing and maintenance. a Improve efficiency. b Extend engine life. c Reduce the chance of failure. 5 list the types of data required for servicing and maintenance.

a Workshop manuals b Manufacturer’s data and information sheets c Service schedules d Parts lists e Trade Association check lists f legal and technical data reference books

6 state how to access data using

a computers b microfiche.

7 state the precautions required and the hazards associated in working with marine propulsion systems. a Use of Personal Protective Equipment (PPE): goggles, gloves, safety equipment. b Legislation: COSHH, HaSW, Codes of Practice. c Danger from power transmission systems rotating, reciprocating machinery and parts. d Lubricants and fuels: skin protection and ventilation. e Application and safe use of lifting equipment. f Electrical equipment and systems; isolation, low-voltage systems. g Fire risks, precautions with fuels. h Safe storage and disposal of materials. i Good housekeeping procedures and environmental awareness.


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Outcome 2: Identify appropriate information, tools and materials needed for servicing operations. Practical activities The candidate will be able to: 1 select appropriate data for servicing operations 2 compile a servicing schedule. Underpinning knowledge The candidate will be able to: 1 describe the main elements of a maintenance programme. a Preventive and scheduled maintenance: i cleaning ii lubrication iii replenishment iv adjustment v checking vi overhaul vii replacement. b Corrective/emergency maintenance. 2 interpret technical data to compile a maintenance programme 3 state the organisation and resources required for servicing and maintenance.

a Tools, test equipment, yard facilities and equipment: i hand tools; socket sets, screwdrivers, pliers, spanners, wrenches ii measuring equipment; feeler gauges, pressure gauges, test meters iii power tools iv lifting equipment v draining equipment.

b Spare parts, materials and consumables: i filters, seals, gaskets, electrical connections ii lubricants.

c Reference data and documentation: i technical information ii service manuals.

d Reporting systems: i job sheets ii recommendations to other personnel.


Outcome 3: Understand basic principles of propulsion systems and servicing and maintenance procedures Practical activities The candidate will be able to carry out basic maintenance. Underpinning knowledge The candidate will be able to: 1 describe the installation, construction and principles of operation for marine propulsion system and its ancillary systems: a gearboxes b transmission c rudders d steering systems. 2 describe the routine maintenance checks to be carried out on such systems 3 describe general checks to be applied throughout and on completion of maintenance. a Safety checks. b Performance checks. c Engine running temperatures, pressure, leaks, alignment, vibration. d Comparison of measured performance to specifications.


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Outcome 4: Record results and make appropriate recommendations Practical activities The candidate will be able to: 1 compare results of performance with manufacturers’ requirements 2 record results and make recommendations 3 access data from various sources. Underpinning knowledge The candidate will be able to: 1 state the methods of accessing data from: a workshop manuals b manufacturer’s data and information sheets c service schedules d parts lists e Trade Association check lists f legal and technical data reference books . 2 state how to access data using a computers b microfiche. 3 describe how to compare the results obtained from servicing and maintenance with manufacturer’s data 4 Record results obtained using

a computers b manufacturer’s recording sheets c trade association recording sheets.

5 Make and record appropriate recommendations resulting from inspections. a Complete maintenance schedule as appropriate. b Report problems to higher authority.


009 Maintaining electrical engineering equipment/systems Rationale This unit is concerned with the processes and equipment essential to the maintenance of 230 and 110 volt on board electrical equipment and systems. The candidate should develop an awareness of current regulations. The unit covers three performance outcomes. The candidate will be able to: 1 prepare for maintaining electrical equipment/systems 2 carry out the maintenance of electrical equipment/systems 3 reinstate the work area and apply safe working practices. Connection with other awards This unit combines and extends the knowledge contained in Unit 134 – Maintaining electrical equipment and systems of the N/SVQ (2251/2) in Performing Engineering Operations. Assessment The outcomes from the unit will be assessed by means of an assignment which will cover practical and underpinning knowledge.


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Outcome 1: Prepare for maintaining electrical equipment/systems Practical activities The candidate will be able to: 1 gather, read, and interpret manufacturers’ maintenance instructions 2 determine a suitable sequence of testing operations 3 devise suitable methods for the security of components removed during maintenance 4 obtain all the test equipment, consumables and tools required to carry out maintenance activities on different types of:

a electrical equipment b lighting circuits c power circuits d control circuits.

Underpinning knowledge The candidate will be able to: 1 state how to obtain the equipment circuit drawings and other related information and the procedures for their care and safe keeping including:

a manuals and/or circuit drawings b block diagrams c test schedules d manuals e safety guidance and job instructions f equipment and system specifications g specific fault diagnosis and testing instructions including advice on any special tools

that may be needed. 2 state the

a need to plan work activities b methods of producing work plans c information they must contain.

3 state how to correctly identify, label and store components and cables during disconnection. 4 state the range of tests and fault diagnosis documentation that can be used to aid fault diagnosis. 5 state the type of equipment used to check:

a voltage drop b continuity of main and supplementary equipotential bonding conductors c continuity of ring main conductors and protective conductors d insulation resistance between live conductors and each live conductor and earth e polarity f earth loop impedance g functional testing

i circuit


ii residual current device. 6 describe the typical faults that can occur with the equipment and circuits that are being checked and their probable causes.

a Open circuit. b Short circuit. c Resistance fault. d Mechanical component fault.

7 describe the range of tools used for maintenance and how to use them.

a Screwdrivers, pliers, cable strippers, side cutters. b Spanners and hammers. c Saws and files. d Drills. e Battery and 110 volt power tools (with particular reference to the dangers of using

230 volt tools in a marine environment). f Torches. g Soldering irons, solders and fluxes. h Cable terminating equipment. i Multimeter. j Insulation and continuity testers.

8 state the units of electrical measurements and their multiples and sub-multiples 9 state how to check test equipment is

a safe to use b suitable for the intended activities, c within current calibration approval dates and d can cover the range of values to be measured.

10 describe how to identify test points on the circuit from information given on the circuit diagrams and specifications 11 state how to take measurements 12 state how to select cables for different applications.

a Voltage and current carrying capacities. b Voltage drops in 12 and 24 volt systems. c Environmental requirements. d Cable selection for use in a marine environment and to meet classification society

standards. e Prevention of interference.

13 state methods of coding wires and components 14 state the use of component reference manuals to select equivalent components.


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Outcome 2: Carry out the maintenance of electrical equipment/systems Practical activities The candidate will be able to: 1 prepare to carry out maintenance.

a Complete any relevant Permit to Work documentation. b Perform safety checks before commencing work.

2 carry out maintenance:

a removing and storage covers and casings b identification marking and storing of disconnected or removed components c checking that replacement components meet:

i values ii tolerance iii polarity specification

d determining equivalent components when exact replacements are not available e identifying correct test points in the circuit and carrying out all testing in line with

defined procedures and relevant regulations f carrying out simple visual checks g carrying out fault finding h determining a course of action such as replacement or adjustment when repairing

equipment/circuit i completing all relevant test result documentation accurately and legibly j reconnecting the equipment.

3 carry out tests and adjustments to ensure that the fault has been cured and the equipment performs within the specification requirements after maintenance. 4 make decisions if problems occur. Underpinning knowledge The candidate will be able to: 1 state the need for permit to work systems. 2 state the importance of verifying power supply and integrity of fuses/circuit protection devices before proceeding further. 3 describe visual checks of the circuits and components for obvious signs of damage:

a broken connections b burnt or over heated casings c overheated contact surfaces cables or components d component or cable short circuits.

4 state methods of identifying components and cables to ensure correct replacement and reconnection. 5 describe where and how to connect instruments into the circuit.


6 state the need to

a isolate equipment b prove circuits are dead c use approved voltage testers, and suitably fused test probes.

7 describe how to

a take instrument readings and translate these into circuit-value measurements b compare test results obtained against specification requirements.

8 state the calculations necessary to assess the accuracy of the measurements (Ohm’s Law) 9 describe how to recognise the signals registered on test equipment such as current, voltage and resistance and interpret these measurements to determine the actions required 10 state how to use diagnostic aids.

a Circuit/wiring diagrams. b Equipment manuals. c Functional system charts. d Probability charts. e Maintenance/history records. f Equipment self diagnostics.

11 state the various fault finding techniques for tracing faults to block/unit/component level that are available such as:

a function testing b substitution c injection and sampling d half split technique e emergent problem sequence.

12 state how to decide whether

a the unit should be replaced b the fault be further traced to component level c identify if repair is it cost effective d identify if repair is a temporary measure whilst a new unit is ordered.

13 state how to use the information gained to determine the most likely causes of the fault 14 state how to use heat shunts/shields to prevent overheating components and cables on reassembly 15 describe the importance of recording faults, symptoms and their identified causes for future reference 16 describe the principal electrical termination methods and range of other devices used.

a Terminal blocks. b Crimped connections. c Junction boxes. d Glands. e Supports. f Clips. g Earthing devices.


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h Cable connectors. 17 state the types of faults that can occur and how they can be overcome.

a Open circuit. b Short circuit. c Resistance fault. d Mechanical component fault.

18 state how to deal with problems such as what to do when:

a fault finding procedures are not effective b the correct tools are not available c the equipment is damaged in some way d components cannot be removed as readily as expected e replacements required are not available f equipment cannot be re-commissioned.

19 state the need to check that:

a all disconnections have been remade b all components correctly orientated c fuses/protection devices are installed d equipment and systems are free from wire ends, solder blobs and screws which e could cause short circuits.

20 describe the tests required to check that the equipment or system is re-commissioned and operating to specification 21 describe the need to put tools and equipment into safe storage on completion of the activities, leaving the work area in a safe and tidy condition.


Outcome 3: Reinstate the work area and apply safe working practices Practical activities 1 wear personal protective equipment 2 identify and deal appropriately with potential hazards 3 comply with current regulations and organisational safety procedures 4 apply approved test procedures 5 commission or re-commissioning systems 6 record and comparing results against specifications 7 reinstate the work area. Underpinning knowledge The candidate will be able to: 1 state what might go wrong with the instruments, tools, equipment or installation activities and what to do if they occur 2 describe the isolation techniques used for the various equipment and systems 3 state the importance of recording faults, symptoms and their identified causes for future reference 4 state the responsibilities under regulations relevant to the work being undertaken 5 state the need for protective equipment:

a overalls b eye protection c gloves d barrier creams.

6 state the need for good housekeeping arrangements leaving work areas free of unused consumables

a cleaning down work areas b putting serviced instruments, tools and equipment into safe storage c keeping the work area free of waste/surplus materials, tools and equipment

labelling, and recording finished work.


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010 Principles of marine electrical systems Rationale This is concerned with the underlying principles that govern the electrical supply systems used on leisure and commercial small craft. Outcomes There are four outcomes to this unit. The candidate will be able to 1 understand the methods of generating electricity on board. 2 understand electrical supply systems (12, 24 and 240 volt), protection and earthing 3 understand the methods of storing electricity on board 4 understand the requirements for installing instrumentation. Assessment The outcomes from this unit will be assessed by a means of an assignment which will cover practical and underpinning knowledge.


Outcome 1: Understand the functions of electrical systems/components Practical activities The candidate will be able to: 1 investigate the components used in electrical systems on board yachts and motor cruisers. Underpinning knowledge The candidate will be able to: 1 describe the operation of shore power systems, including the purpose of:

a shore cables b deck plugs and sockets c consumer units d circuit breakers e consumer units f residual current devices g transformers h switched mode power supplies i inverters j internal 13Amp sockets k calorifiers.

2 describe the operation of propulsion engine driven generating systems, including the purpose of:

a engine driven alternators b supplementary high charge regulators c split charge relays d charge splitting diodes e isolators f changeover switches g state the need to correctly maintain belt tension in alternator systems.

3 describe the operation of wind driven generating systems.

a Advantaged and limitations of wind generators. b Placing wind generators for safety. c Avoiding noise and vibration. d Sizing wind generators for specific applications. e Regulating wind generators.

4 describe the operation of solar generating systems.

a Advantages and limitations of solar panels. b Portable solar generators. c Fixed solar generator systems. d Optimum positioning for maximum power, avoiding shadows and excessive wear. e Sizing solar panel installations for particular applications. f Regulating solar panels.


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5 describe the operation of separate engine driven generator units including: a constant running plant b battery demand operated plant c location of generator systems d automatic operation systems e sound and vibration proofing f special exhaust requirements.

6 state the purpose and application of on board electrical system components.

a Halogen lamp luminaries. b Fluorescent luminaries. c High energy LED luminaries. d Extraction fans and blowers. e Electrical winches. f Electrical toilets. g Bow thrusters. h Keel lifting mechanisms. i Water pumps. j Refrigeration and air conditioning.


Outcome 2: Understand electricity supply systems (12,24 and 240 volt), protection and earthing Practical activities The candidate will be able to: 1 investigate the mains electrical systems on board yachts and motor cruisers. Underpinning knowledge The candidate will be able to: 1 describe marine electricity supply systems consisting of low voltage and mains voltage systems.

a Distinguish between, and state the function of, low voltage (12 or 24 volt) and medium voltage (110 or 230 volt) on board supply systems.

b State the relationships between battery capacity, current demand, and recharge arrangements for on board systems.

c Identify the power generating needs for vessels when laid up, in commission, and permanently occupied.

d State the advantages and limitations of shore supplies. e State the safety implications of 110 and 230 volt systems on small craft. f State the requirements for and use of galvanic isolators.

2 describe typical supply systems.

a Draw simple diagrams to show the interconnection of engine and “ships” supplies for typical small craft.

b Draw simple diagrams to show the interconnection of low voltage and medium voltage supplies through inverters and transformers (including switched mode power supplies).

c Carry out calculations to determine current supplied to specific equipment. d Determine load currents in supply cables, and specify protective devices. e Determine voltage drops in circuits with particular reference to low voltage systems

delivering significant currents. f Determine correct cable sizes to minimize voltage drop in use. g Determine switching and protection requirements for circuits. h Identify special requirements for circuits and sockets exposed on deck. i Identify special circuit parameters for electrically powered winches, keel lifting

mechanisms and bow thrusters. j State the need to protect 110 and 230 volt supplies. k Identify the requirements for earthing and residual current devices in 110 and 230

volt systems. l Identify fusing/circuit breaker requirements for battery derived “ship supplies”. m State the pros and cons of fusing engine starter circuits. n State the need to provide lightning protection.


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Outcome 3: Understand the methods of storing electricity on board Practical activities The candidate will be able to: 1 investigate the battery storage requirements on board yachts and motor cruisers. Underpinning knowledge The candidate will be able to: 1 identify typical relationships between battery load, capacity and recharging requirements.

a State the suitability of automotive batteries, leisure batteries, semi traction batteries and Ni-cad batteries for particular on board applications.

b Identify appropriate battery sizes and arrangements for typical applications. c State the need for separating ni-cad and lead acid battery installations. d State the need to insulate battery terminals. e State the procedures involved in checking the condition of a battery and the readings

expected, the use of voltmeters, hydrometers and high current discharge testers. f Outline the procedures necessary to maintain a battery in good condition. g State the safety precautions required in relation to battery charging and battery

spaces. h State the need to secure batteries against movement.


Outcome 4: Understand the requirements for installing instrumentation Practical activities The candidate will be able to: 1 investigate the instrumentation requirements on board yachts and motor cruisers. Underpinning knowledge The candidate will be able to: 1 identify the supply, installation and interconnection requirements for typical on board instrumentation:

a wind instruments b logs c compasses d echo sounders e gps systems f chart plotters g radar sets h laptop computers i dedicated computers j on board entertainment systems k battery condition monitoring systems l vhf radio transceivers m MF radio transceivers n HF radio transceivers o “Ham” radio installations.

2 identify the requirements for installing transducers.

a Log impellors. b Echo sounder transducers. c Wind instrument sensors. d Electronic compasses (giro and fluxgate). e Magnetic compasses. f Radar transponders. g Aerials. h Ground plates. i Ammeter shunts.

3 identify the requirements for interfacing instruments.

a Identify interface standards (e.g. NMEA). b State the need to route signal cables separately. c State the need to shield signal cables. d State the need to incorporate standard length cables for radar and aerial cables. e State the need to use compatible instruments in interconnected systems.


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011 Prepare surfaces and marine coatings Rationale This is an optional unit. The unit covers the underlying technology and skills requirements for the successful preparation of surfaces to apply marine coatings. It includes the interpretation of instructions and specifications, the terminology and techniques needed to identify/prepare surfaces and to select the appropriate tools and equipment. This unit covers two learning outcomes. The candidate will be able to: 1 prepare all surface substrates 2 prepare coatings. Connection with other awards This unit combines and extends the knowledge and understanding contained in: Unit 99 Carry out patch preparations of material surfaces using hand and mechanical tools. Unit 105 Preparing marine coatings for application. Unit 101 Preparing holding primer for application. Assessment The outcome of this unit will be assessed using evidence from a practical assignment covering the practical activities and underpinning knowledge.


Outcome 1: Prepare marine material surfaces Practical activities The candidate will be able to: 1 obtain instructions and specifications 2 identify condition of surface 3 select appropriate tools and equipment 4 carry out preparation activities as per specification. Underpinning knowledge The candidate will be able to: 1 obtain instructions and specifications from: a manufacturers/suppliers technical data sheets and materials safety data sheet

b job cards c customer contractual specification, including technical and cosmetical criteria.

2 identify condition and type of surface and visually check the surface coating for defects including:

a flaking b peeling c erosion d scratches e scuffs f osmosis g stress cracks h star crazing i blistering j corrosion k chalking (gross loss of gloss) l adhesion m solvent testing n cracking/crazing o cissing p pinholing q sweating r wrinkling s adhesion t coating cure.

3 select appropriate tools and equipment. a Use appropriate personal protective equipment (PPE) for the activity.

b Select appropriate hand tools including: i rubbing blocks ii sponges iii leathers iv trimming knife v paint scraper vi plastic, rubber and metal applicators vii pneumatic and electric power tools


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viii filling blades. 4 carry out preparation activities as defined in job specification.

a Prepare surfaces by hand or power tools. b Clean all types of surface by use of manufacturers hand and power tools and

recommended cleaning agents.

5 identify the hazards associated with carrying out surface preparation activities, and with the materials and equipment used, how they can be minimised.

a Sparks. b Dust/debris. c Hearing damage. d Hand/arm vibration. e Working at heights f Fumes g Cutting tools such as grinders. h Allergic reactions.

6 list the reasons for carrying out surface preparation. a Promote adhesion. b Smooth surface. c Contamination. d Corrosion or blistering.

7 identify the effects on the final finishing activities if preparations are not carried out correctly. a Premature loss of gloss. b Premature loss of colour. c Premature corrosion or blistering.

8 identify the various types of substrate that may require preparing:

a painted surfaces b unpainted surfaces c ferrous d non ferrous e composite / GRP f wood g ferro cement.

9 list the types of tools, techniques and materials used in surface preparation. a Degreasing solvents. b Chemical paint remover. c Hand abrasives. d Brushes or vacuum cleaner. e Hand tools. f Power wire brush. g Power discs. h Grinders. i Vacuum blasters. j Flame cleansing. k High pressure washers.


10 identify the quality control techniques and tests used during preparation activities to check their compliance with the preparation specification. a Substrate surface profile. b Temperature/humidity. c Visual examination. d Testex press tape. e Swabs. f Surface profile comparators. g Adhesion test cross hatch test, dolly test. h Acid and solvent test. i Surface temperature. j Shore D hardness test. k Colour retention test.

11 identify how to dispose of waste materials safely:

a environmental impact b regulatory requirements c company procedures.


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Outcome 2: Prepare marine coatings Practical activities The candidate will be able to: 1 obtain required materials and check for quantity and quality 2 identify required preparation 3 carry out preparation using suitable equipment. Underpinning knowledge The candidate will be able to: 1 identify the hazards associated with carrying out coating material preparation activities,

and with the materials and equipment used and how they can be minimised. a Inhalation of fumes/dust.

b Fire and explosion. c Contact with solvents and other chemicals.

2 identify the characteristics of, and applications for marine coating products. a Water based epoxies. b Solvent based epoxies.

c Conventional alkyd or silicone alky. d Acrylic urethane.

e Polyester polyurethane.

3 identify/list the storage requirements for marine coating products and solvents. a Containment arrangements b Environmental regulated conditions such as temp/humidity c Explosion proof storage container.

4 identify factors to obtain an estimate of the product volume. a Estimation of areas to be covered. b Theoretical and practical paint consumption.

c Loss factors. d Application method e.g. pads, brush, roller, spray or other. 5 identify containers appropriate to defined products and usage.

a Non metallic (plastic) for water based coatings. b Metallic for solvent based coatings. c As per manufacturers instructions.

6 identify preparation requirements for marine coatings. a Pot/shelf life. b Induction times. c Temperature conditioning requirements. d Compatibility of underneath laying coating. e Solvents requirements. f Coating interval times.


7 state the importance of stirring single pack paints and epoxys and use of thinners, for

marine coating products. a Adding of solvents improves flow characteristics of the paint film and enhances the

cure cycle. b Achieve homogeneous mixture of coating ingredients. c To achieve maximum coating performance. d To achieve correct coating cure cycles.

8 state the importance of mixing ratios for two-pack products.

a To achieve maximum coating performance. b To achieve correct coating cure cycles. c To achieve homogeneous mixture of coating ingredients.

9 identify the appropriate procedures for: a disposal of redundant materials and non-re-usable containers b cleaning of re-usable containers c contain and to clear away spillages d disposal of the arisings.

10 identify the quality control requirements and techniques to be followed when preparing marine coatings:

a manufacturers recommendations b company procedures c national/international standards d customer contractual acceptance criteria and specifications e local environmental rules and regulations.

11 identify the importance of the maintenance of records for paint and solvent consumption: a Gov legislation – VOC b Owners requirements c Insurance approval requirements d Quality Assurance and Control program e coating manufacturers requirements for product liability.


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012 Apply marine coatings Rationale This is an optional unit. The unit covers the underlying knowledge and skills requirements for the successful application of a range of marine coatings. It includes the techniques and procedures for application of coatings manually and using spray methods and the checking of the finished coating to identify minor surface defects. This unit covers two learning outcomes. The candidate will be able to: 1 apply marine coatings 2 check and report minor surface defects. Connection with other awards This unit combines and extends the knowledge and understanding contained in units: Unit 106 Carry out the manual application of marine coatings Unit 107 Carry out the application of marine coatings using spray methods Unit 102 Applying holding primer by spray methods Unit 110 Applying fairing, filling etc. Assessment The outcome of this unit will be assessed using evidence from a practical assignment covering the practical activities and underpinning knowledge.


Outcome 1: Apply marine coatings Practical activities The candidate will be able to: 1 prepare work area and surroundings 2 prepare coating equipment 3 apply coatings by hand and spray.

Underpinning knowledge The candidate will be able to: 1 obtain instructions and specifications from: a manufacturers’/suppliers’ technical data sheets and manufacturers’

Safety Data Sheet b job cards c customer requirements d technical application manual or paint appendix e coating insurance requirements.

2 identify the characteristics of, and the applications for, marine coating’s products:

a solvent based epoxies b alkyds/silicone alkyds c water based acrylics d water based epoxies e solvent based acrylic urethanes f solvent based polyester polyurethanes g water based polyurethanes.

3 identify the reasons for ensuring that substrates have been prepared correctly for the

coatings to be applied: a clean, smooth and free of welding and grinding debris, weld spatter b free of grease, fat, oil, waxes, dust c correct surface profiles d compatibility with shop or holding primers.

4 identify the time intervals that are required between coats, and why these must be adhered to:

a cure cycle b avoid solvent entrapment c ensure adhesion in between coatings d maximum coating performance.

5 identify manual application equipment, to suit the materials and the finish required as per

specification. a Brushes. b Rollers. c Paint pads.

6 identify spray applied application equipment to suit the materials and the finish required as

per specification: a conventional spray b airless spray


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c air-assisted spray d electro-static equipment. 7 state the importance of stripe coating an extra coat of materials usually applied by brush to

build up thickness along edges of beams, around nuts and bolts and in less accessible areas

8 state the correct use of stripe coating: a corners/outside corners b obscured corners and edges c edges d welds/structural joints e slot welds.

9 identify the requirements for working afloat, on outer/hull bottoms, and at heights. a Scaffolding. b Shrink foil. c Covers. d Safety harness. e Helmets. 10 identify the procedures to contain and to clear away spillages and the safe and

appropriate disposal of waste materials: a company procedures b environmental procedures c regulatory procedures.


Outcome 2: Check and report minor surface defects

Practical activities The candidate will be able to:

1 visually check coated surface 2 identify minor surface defects and their cause 3 report minor surface defects.

Underpinning knowledge

1 identify faults in application, and their causes:

a pinholes b runs, sags, drips c solvent entrapment d coating cure cycle.

2 identify visual inspection techniques and methods. a Angles. b Lighting. c Mirrors. d Magnifying glass.

3 recognise surface defects:

a contamination b runs c sags d drips e inclusions f fish-eyes g pin-holing h sweating.

4 identify the quality assurance/control requirements and techniques to be followed when

applying marine coatings: a manufacturer’s recommendations b company procedures c national/international standards d customer contractual acceptance criteria and specifications e local environmental rules and regulations.

5 identify the techniques required to avoid defects arising from the

application of marine coating products to a variety of surfaces. a Correct film thickness.

b Correct banding/surface overlap. c Complete surface coverage. d Smooth surface free of defects, contamination and inclusions. e Correct coating cure cycle.


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2451 Level 2 Certificate in Boat Building, Maintenance and Support

Centre devised assignment submission report Part A – To be completed by centre BOX 1

Centre details Date sent to City & Guilds (dd/mm/yyyy)

Centre number Sub centre

Centre name

Name of Examinations Office contact Telephone number Fax number e-mail Name of author of question paper Telephone number

Assignment details BOX 2

Assignment component number

2 4 5 1 -

Component title

Please complete the following checklist:

The assignment submitted Yes No* Covers all practical activities from the assignment’s template

Will take a minimum of TEN hours to complete

Can be marked according to the grading criteria provided

Includes the required underpinning knowledge questions * Please provide justification for the assignment NOT meeting the set criteria (add separate sheets if required


Please attach a copy of the proposed assignment to this Assignment Submission Form BOX 3

The centre confirms that the assignment contains: 1 Assessor’s guidance notes including:

A health and safety statement

The location where the assignment will take place

The requirements for tools, equipment, materials and data

Notes on the content of the assignment

Notes on preparatory work required by the assessor

Details of evidence and recording requirements

Time considerations

2 Candidate’s instructions include:

An assignment brief setting the scene or giving a scenario

General guidance notes advising candidates to check they understand requirements

Time consideration

The importance of health and safety

Clearly defined tasks – covering all practical activities from the assignment template

Recording/reporting sheets to record progress through the tasks

Notes advising candidates on how their evidence should be stored

Any required engineering drawings provided to current standards

Note the centre should allow 6 weeks from the date of submission by e-mail for City and Guilds to agree the assignment

Name (block capitals) Date Signed

Please e-mail to [email protected] Centres which are unable to submit via e-mail must post THREE copies of the proposed assignment to City & Guilds, Centre Devised, 1 Giltspur Street, London, EC1A 9DD. This must be sent EIGHT weeks before intended use.

mailto:[email protected]


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SP-02-2451

Documents

Level 2 Certificate in Boat Building, Maintenance and Support · Level 2 Certificate in Boat Building, Maintenance and Support 5 Assessment and quality assurance National standards