Level 2 Diploma in Boatbuilding (Foundation

Level 2 Diploma in Boatbuilding (Foundation
Level 2 Diploma in
Boatbuilding (Foundation)
(2473-02)
Version 1-1(January 2017)
Qualification Handbook
Qualification at a glance
Subject area
Marine
City & Guilds number
2473
Age group approved
16-19, 19+
Entry requirements
Assessment types
Approvals
None
Multiple Choice; Short Answer; Assignment
Qualification approval
Support materials
Qualification handbook; Assessment pack; Exemplar
assignment; Centre-devised recording forms
Registration and certification
Consult the Walled Garden/Online Catalogue for last
dates
Title and level
GLH
TQT
City & Guilds
qualification
number
Ofqual
accreditation
number
Level 2 Diploma in Boatbuilding
(Foundation)
460
502
2473-02
603/0348/7
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
2
Contents
Qualification at a glance
2
Contents
3
1
4
Introduction
Structure
Total Qualification Time
2
Centre requirements
Approval
Resource requirements
Learner entry requirements
Age restrictions
3
Delivering the qualification
Initial assessment and induction
Support materials
4
Assessment
Summary of assessment methods
Assessment strategy
5
5
6
6
6
7
7
8
8
8
9
9
12
5
Grading
15
6
Units
16
Structure of the units
16
Unit 201
Introduction to the marine industry
17
Unit 202
Principles of boatbuilding technology
31
Unit 203
Business improvement techniques
43
Unit 204
Yacht and boatbuilding assembly and sub-assembly
47
Unit 205
Production of external boat components
59
Unit 206
Interior installation and fitting out of boats
69
Unit 207
FRP manufacture for marine construction
79
Appendix 1
Sources of general information
89
Appendix 2
Useful contacts
91
Dummy Front Matter Cha pter Title - please do not include in out put
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
3
1
Introduction
This document tells you what you need to do to deliver the qualification:
Area
Description
Who is the qualification for?
This qualification is aimed at learners aged 16 and above
who would like to gain the basic knowledge and skills
required during their initial training to become a
Boatbuilder, either as part of their Apprenticeship or as
full time students.
What does the qualification cover?
Learners will be introduced to the scope and
opportunities offered within the wider boatbuilding and
marine sector.
They will develop the range of transferable skills over a
cross section of production, manufacturing, service and
construction sectors which are valued by employers and
therefore increase their employability skills.
Learners will also gain the skills to work competently with
at least two different types of materials, including wood,
composites and metals.
All the above will enable learners to progress into further
training to become a Boatbuilder.
What opportunities for progression
are there?
Upon completion of this qualification learners will have
developed most of the basic skills and knowledge
required during their foundation phase of the
Apprenticeship and will enable them to progress into
further training to become a Boatbuilder.
Who did we develop the qualification
with?
This qualification has been developed in collaboration
with the Boatbuilder trailblazer group which is led by
organisations including: Berthon Boat Company Ltd,
Sunseeker International, Princess Yachts, Pioneer Sailing
Trust, Pendennis Shipyard, Fairline Loats, Broom Boats,
Green Marine, English Harbour Yachts, Windboats,
Cockwells and the British Marine Federation.
Is it part of an apprenticeship
framework or initiative?
Yes, this qualification has been developed to be included
within the foundation phase of the new Apprenticeship
Standard for Boatbuilders, which will replace the current
Level 2 and Level 3 Marine, Construction, Systems
Engineering and Maintenance (Boatbuilding) SASE
Frameworks.
The qualification can also be used for full time students
who would like to gain the basic knowledge and skills that
will enable them to progress into further training to
become a boat builder.
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
4
Structure
To achieve the Level 2 Diploma in Boatbuilding (Foundation), learners must achieve mandatory
units 201, 202 and 203 and two optional units from units 204-207.
City & Guilds unit
number
Unit title
GLH
Mandatory
201
Introduction to the marine industry
100
202
Principles of boatbuilding technology
100
203
Business improvement techniques
50
204
Yacht and boatbuilding assembly and sub-assembly
140
205
Production of external boat components
140
206
Interior installation and fitting out of boats
70
207
FRP manufacture for marine construction
160
Optional
Total Qualification Time
Total Qualification Time (TQT) is the total amount of time, in hours, expected to be spent by a
Learner to achieve a qualification. It includes both guided learning hours (which are listed
separately) and hours spent in preparation, study and assessment.
Title and level
GLH
TQT
Level 2 Diploma in Boatbuilding
(Foundation)
460
502
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
5
2
Centre requirements
Approval
To offer these qualifications, all centres will need to gain both centre and qualification approval.
Please refer to the Centre Manual - Supporting Customer Excellence for further information.
Centre staff should familiarise themselves with the structure, content and assessment requirements
of the qualifications before designing a course programme.
Resource requirements
Resources
This qualification should be delivered in the workshops and classrooms of a centre with full facilities
for boatbuilding activities, with all the equipment, machines, relevant tools and consumables for
working safely with boatbuilding materials appropriate to each unit.
Centre staffing
Staff delivering these qualifications must be able to demonstrate that they meet the following
occupational expertise requirements. They should:
 be occupationally competent or technically knowledgeable in the area[s] for which they are
delivering training and/or have experience of providing training. This knowledge must be to the
same level as the training being delivered
 have recent relevant experience in the specific area they will be assessing
 have credible experience of providing training.
See also the qualification page on the City & Guilds website for the latest version of the assessment
strategy on the role of supervisors and managers in the assessment process.
Centre staff may undertake more than one role, eg tutor and assessor or internal quality assurer,
but cannot internally verify their own assessments.
Assessors and Internal Quality Assurers
Registered centres must have effective quality assurance systems to ensure optimum delivery and
assessment of qualifications. Quality assurance includes initial centre registration by City & Guilds
and the centre’s own internal procedures for monitoring quality. Centres are responsible for
internal quality assurance and City & Guilds is responsible for external quality assurance.
Standards and rigorous quality assurance are maintained by the use of:
 internal quality assurance
 City & Guilds external quality assurance.
In order to carry out the quality assurance role, Internal Quality Assurers must have appropriate
teaching and vocational knowledge and expertise. Assessor/Verifier (A/V) units are valued as
qualifications for centre, but they are not currently a requirement for the qualification.
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
6
Learner entry requirements
City & Guilds does not set entry requirements for these qualifications. However, centres must
ensure that candidates have the potential and opportunity to gain the qualifications successfully.
Age restrictions
City & Guilds cannot accept any registrations for learners under 16 as these qualifications are not
approved for learners under 16.
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
7
3
Delivering the qualification
Initial assessment and induction
An initial assessment of each candidate should be made before the start of their programme to
identify:
 if the candidate has any specific training needs
 support and guidance they may need when working towards their qualifications
 the appropriate type and level of qualification.
We recommend that centres provide an induction programme so the candidate fully understands
the requirements of the qualification, their responsibilities as a candidate, and the responsibilities of
the centre. This information can be recorded on a learning contract.
Support materials
The following resources are available for these qualifications:
Description
How to access
Assessment pack
Exemplar assignment
Developing centre devised
assessments – guidance for centre
based assessment writers (GM1)
www.cityandguilds.com
Centre-devised recording forms
Recording documents
Candidates and centres may decide to use a paper-based or electronic method of recording
evidence.
City & Guilds endorses several ePortfolio systems, including our own, Learning Assistant, an easy-touse and secure online tool to support and evidence learners’ progress towards achieving
qualifications. Further details are available at: www.cityandguilds.com/eportfolios.
City & Guilds has developed a set of Recording forms including examples of completed forms, for
new and existing centres to use as appropriate. Recording forms are available on the City & Guilds
website.
Although new centres are expected to use these forms, centres may devise or customise
alternative forms, which must be approved for use by the external quality assurer, before they are
used by candidates and assessors at the centre. Amendable (MS Word) versions of the forms are
available on the City & Guilds website.
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
8
4
Assessment
Summary of assessment methods
Candidates must successfully complete:



one multiple-choice test for each of the mandatory units 201 and 202
one externally set, internally marked short-answer question assessment for unit 203
one assignment and one externally set, internally marked short-answer question assessment
for each chosen optional unit
Available assessments/assignments
City & Guilds has written the following assessments to use with this qualification:
 evolve multiple-choice tests to be delivered on-screen
 externally set, internally marked short-answer questions
 exemplar assignment and underpinning knowledge questions for unit 205
Centre set and marked assignments
City & Guilds has provided separate guidance for writers of centre based assessments which should
be read in conjunction with this document, entitled, ‘GM1 - Developing centre-devised
assessments – guidance for centre based assessment writers’.
A set of generic recording forms is also provided as follows:










Assessment tasks (AD1)
Assessment grading criteria (AD2)
Assessment sign off form (AD3)
Evidence recording form (GF1)
Assessment unit front and mark sheet (GF2)
Assessment task front sheet (GF3)
Assessment unit mark sheet (GF4)
Assessment feedback and action plan form (GF5)
Qualification assessment tracking form (GF6)
Group assessment tracking form (GF7)
A full explanation of the use of these forms can be found in the centre-devised assessment writing
guidance. All of these materials are available to download from the qualification page of the City &
Guilds website.
Approval process for centre set assignments
Centre set assignments must be approved by the external quality assurer before use. For each
assignment, the Assessment sign off form (AD3) must be completed and be made available to
the EQA for inspection.
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
9
Assessment Types
Unit
Title
Assessment
method
Where to obtain assessment
materials
2473-201
Introduction to the
marine industry
Multiple-choice
online test
2473-201
www.walled-garden.com
The assessment
covers all the
outcomes in this unit
2473-202
Principles of
boatbuilding
technology
Multiple-choice
online test
2473-202
www.walled-garden.com
The assessment
covers all the
outcomes in this unit
2473-203
Business
improvement
techniques
Short-answer
questions
2473-203
www.cityandguilds.com
The assessment
covers all the
outcomes in this unit
2473-204
Yacht and
boatbuilding
assembly and subassembly
Centre-devised
practical assignment
and
Short-answer
questions
2473-204
www.cityandguilds.com
These assessments
cover all the
outcomes in this unit
2473-205
Production of
external boat
components
Centre-devised
practical assignment
and
Short-answer
questions
2473-205
www.cityandguilds.com
These assessments
cover all the
outcomes in this unit
2473-206
Interior installation
and fitting out of
boats
Centre-devised
practical assignment
and
Short-answer
questions
2473-206
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
www.cityandguilds.com
10
Unit
Title
Assessment
method
Where to obtain assessment
materials
These assessments
cover all the
outcomes in this unit
2473-207
FRP manufacture for
marine construction
Centre-devised
practical assignment
and
Short-answer
questions
2473-207
www.cityandguilds.com
These assessments
cover all the
outcomes in this unit
Time constraints
The following must be applied to the assessment of this qualification:
 candidates must finish their assessment within six months
 all assessments must be be completed within the candidate's period of registration
 assignments should take no longer than 8 hours. If they do, centres should consider why this is,
and make sure that they are not trying to gather too much evidence.
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
11
Assessment strategy
Test Specifications
The way the knowledge is covered by each test is laid out in the tables below:
Assessment title: Introduction to the marine industry
Assessment type: Multiple-choice online test
Assessment conditions: Invigilated examination conditions
Grading: X/P/M/D
201
Duration: 75 minutes
Number of
marks
%
01: Understand the range of services
available within the global marine industry
8
16
02: Understand the terminology used to
recognise boats and equipment
6
12
03: Understand the environmental, Health
and Safety rules and regulations applicable
to the marine industry
17
34
04: Understand employment roles and
responsibilities
4
8
05: Know how to contribute to selfdevelopment and create and maintain
effective working relationships
7
14
06: Know how to contribute to the
effectiveness of boat production and
support services
8
16
50
100
Learning Outcome
Unit 201
Total
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
12
Assessment title: Principles of boatbuilding technology
Assessment type: Multiple-choice online test
Assessment conditions: Invigilated examination conditions
Grading: X/P/M/D
202
Duration: 60 minutes
Number of
marks
%
01: Know how to identify boat building
materials, their reaction to the
environment and their properties
14
31
02: Know how to interpret drawings,
specifications and installation
requirements
6
13
03: Know how to use tools and equipment
safely when boatbuilding
7
16
04: Understand boatbuilding operations
18
40
45
100
Number of
marks
%
01: Know what is meant by continuous
improvement
29
29
02: Understand what is meant by
workplace organisation
14
14
03: Know what is meant by visual
management
15
15
04: Understand problem solving
techniques
42
42
45
100
Learning Outcome
Unit 202
Total
Assessment title: Business improvement techniques
Assessment type: Multiple-choice online test
Assessment conditions: Invigilated examination conditions
Grading: X/P/M/D
203
Duration: 120 minutes
Learning Outcome
Unit 203
Total
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
13
Recognition of prior learning (RPL)
Recognition of prior learning means using a person’s previous experience, or qualifications which
have already been achieved, to contribute to a new qualification.
For this qualification, RPL is not allowed.
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
14
5
Grading
Grading of individual assessments
Individual assessments will be graded Pass/Merit/Distinction.
For the units to be achieved, candidates must achieve a minimum of Pass in each assessment, as
per marking scheme provided for each assessment.
Pass reflects the minimum requirements that are expressed in the unit, with Merit and Distinction
showing progression in the depth and breadth of the learner’s knowledge, as well as in the type of
cognitive operations learners demonstrate.
Grading of qualification
The Boatbuilder Employer Group has taken the decision to grade this qualification
Pass/Merit/Distinction, through the aggregation of the individual assessment graded
Pass/Merit/Distinction.
All assessments must be achieved at a minimum of Pass for the qualification to be awarded. All
assessments graded Pass/Merit/Distinction contribute equally to the overall qualification grade.
For full details on how to grade the qualification, refer to the Assessment Pack available on the
qualification page of www.cityandguilds.com.
Overall qualification grades must be entered using one of the following overall grading modules on
the Walled Garden:



901 Pass
902 Merit
903 Distinction
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
15
6
Units
Structure of the units
These units each have the following:
 City & Guilds reference number
 Title
 Level
 Guided learning hours (GLH)
 Assessment type
 Learning outcomes, which are comprised of a number of assessment criteria
Centres must deliver the full breadth of the range. Specialist equipment or commodities may not be
available to all centres, so centres should ensure that their delivery covers their use. This may be
covered by a practical demonstration (eg video). For the practical assessments for this qualification,
centres should ensure that there are sufficient resources to complete the task but are not required
to use all the equipment or commodities in the range.
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
16
Unit 201
Introduction to the marine industry
Unit level:
GLH:
Unit aim:
Assessment type
Level 2
100
This mandatory 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.
Multiple-choice online test
Learning outcome
The learner will:
1
Understand the range of services available within the global marine industry
Assessment criteria
The learner can:
1.1
1.2
1.3
1.4
1.5
1.6
1.7
describe what boatyards, marinas and yacht basins are
list the facilities and services that are found in boatyards, marinas and yacht basins
describe the services of boatbuilding to the UK and global markets
describe the purpose of boatyards, marinas and yacht basins
describe methods for moving boats
identify personnel responsible for providing services
list ancillary marine services provided within the marine industry
Range
(AC1.2) Facilities:
 new build
 fit out
 maintenance
 repair and lay up facilities
 painting
 finishing facilities
 moorings:
o swinging or fixed
o marina pontoons
o on piles
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
17

(AC1.2)
(AC1.3)
(AC1.4)
(AC1.5)
accommodation facilities:
o toilets
o showers
o laundry room (washing machines, spin driers)
 storage cabins or lock-ups
 mast and spar storage arrangements
 pump-out facilities
 fuelling facilities
 workshops
 storage facilities
 materials storage facilities
 machinery and equipment
 launching and recovery
 slipway services
 crane services
Services:
 water points
 electrical hook-up
 waste and refuse disposal
 material storage
 gas bottles
 fuel
Services of boatbuilding to the UK and global markets:
 new build
 fit out
 repair
 sales and after sales
 warranty
 customer service and support
 parts
Purpose of boatyards, marinas and yacht basins:
 building, repairing and fitting out of boats to include hull and deck construction in
wood, metals and composites
 engine and mechanical installation and maintenance
 electrical and electronic diagnostic maintenance and installations
 fit out or refit operations for joinery
 electrics
 preparation, painting and finishing
 boat valeting
 berthing of boats
 boat lifting
 storage ashore
 shower and laundry services
Methods for moving boats:
 afloat by:
o engine power
o sailing
o towing
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
18
o rowing
o rafting
 ashore by:
o mobile self-propelled hoists
o mobile self-propelled boat movers
o telehandler
o coupled boat movers cradle
o railed slipway
o slippery ways
o rollers
o tractor and cradle on wheels
o mobile crane
o static crane
o fork lift truck
o dry stack
(AC1.6) Personnel responsible for providing services:
 shipwrights, boatbuilders, joiners and sawyers:
o boatbuilding boat repair and refit operations
 laminators:
o FRP hull and deck mouldings
o gel and FRP repairs
 composite technician:
o FRP hull and deck mouldings
o gel and FRP repairs
o post curing
o vacuum bagging techniques
o materials selection
 marine engineers and fitters:
o engine and generator installations, maintenance, winterising and commissioning
o stern gear
o propulsion systems
o hydraulics
o winches
o machining
o fabricating and welding
 welders:
o metal fabrication activities and welding
 marine electricians and electronic engineers:
o electronic and electrical installations, diagnostics and repair
 marine plumbers and gas installers:
o installation and maintenance of wash basins, showers, toilet and waste water
systems
o LPG gas installations
 refrigeration engineer:
o install and maintain AC and refrigeration units
 riggers:
o splicing
o rope work
o install stays
o dress and undress masts
o step and unstep masts
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
19
o manufacture and repair rigging
o lifeline/safety lines
o set/tune rig
 sail-makers:
o make, repair and launder sails
 painters and finishers:
o preparation for boat painting
o filling and fairing
o boat spraying
o painting and finishing operations
 upholsterers:
o cabin décor
o furnishings activities
o external covers and awnings
 boat mover:
o boat moving operations on water and ashore
o lifting
o pressure washing and blocking off
o forklift and tractor operations
 naval architect:
o plans all parts of boat
 marine surveyor:
o inspects and examines boats and equipment on board to report on condition (can
be for sale or insurance purposes)
 marina manager:
o manages the marina, operations and dock masters
 yacht broker:
o sells new and second hand boats on behalf of the owner
o finds potential buyers
o manages the sale
 project manager:
o leads and manages a project from start to finish
o oversees the build or refit of a vessel
o manages staff and subcontractors and liaises with owner
 chandler:
o supply of yacht fittings and fastenings, glues, ropes, charts, books, paint, chain,
shackles, anchors, yacht clothing, boots and navigation equipment
 buyers
 storekeepers
 boat valets
(AC1.7) Ancillary marine services:
 harbour master
 skippers
 crew
 financial services
 insurance provision
 leisure operators
 boat haulage
 material and product supply chain
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
20

water taxi
Learning outcome
The learner will:
2
Understand the terminology used to recognise boats and equipment
Assessment criteria
The learner can:
2.1
2.2
2.3
2.4
use basic terms to describe types of leisure and commercial craft
describe the terms used to identify boat locations and dimensions
identify common marine components and fittings
identify marine systems terminology
Range
(AC2.1) Terms:
 leisure craft:
o yachts
o motor cruisers
o dinghies
o river and canal boats
o rigid inflatable boats (RIBS)
o personal watercraft (PWC)
o super yachts
 commercial craft:
o tankers
o tugs
o lighters
o passenger boats
o pilot boats
o dredgers
o ferries
o lifeboats
o military boats
o fishing vessels
(AC2.2) Locations:
 port
 starboard
 forward
 aft
 bow
 stern
 transom
 quarter
 aloft
 below
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
21











steering (helm) position
upper steering position
coach roof
wheelhouse
engine room
tank space
tiller flat
lazerette
forepeak
chain locker
accommodation areas on boats:
o galley
o saloon
o cabins
o heads
o shower
(AC2.2) Dimensions:
 length waterline (lwl)
 length overall (loa)
 beam
 draught
 freeboard
(AC2.3) Marine components and fittings:
 cleats
 bollards
 fairleads
 windlass
 anchor
 winch
 wheel
 tiller
 navigation equipment
 masts/spars and booms
 sails
 furlers
 tracks
 safety equipment:
o life rafts
o life belts
o lifelines
o pulpit
o pushpit
o stanchions
o guardwires
o handrails
 running rigging:
o sheets
o halyards
o running backstays
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
22

standing rigging:
o stays
o shrouds
 types of blocks
 davits
 through hull penetrations
 skin fittings
 stern gear
 A-brackets
 P-brackets
 stern tube
 shaft log
 shaft
 propeller
 rudder
 rope cutters
 anodes
(AC2.4) Marine systems terminology:
 main engines
 propulsion systems
 couplings and drives:
o Z
o V
o sail drive
o outdrive
o outboard
o wet jet
 steering systems:
o mechanical
o hydraulic
 instrument systems
 navigation systems
 power supplies:
o batteries
o generators powered by engines
o wind or water flow
o solar panels
o shore power hook-up
 bow thrusters
 stern thrusters
 heating
 air conditioning
 fresh water systems
 reverse osmosis water makers
 refrigeration
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
23
Learning outcome
The learner will:
3
Understand the health, safety and environmental rules and regulations applicable to the
marine industry
Assessment criteria
The learner can:
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
3.11
3.12
identify the health, safety and environmental regulations in the marine industry
identify the range of personal protective equipment (PPE)
identify when PPE is used in the marine industry
identify safety signs in use within the marine industry
describe the role of qualified first aiders and the re-qualification period
explain evacuation procedures in the event of an emergency
identify common causes of fire
describe preventative measures to reduce risk of fire
identify types of fire extinguishers
explain the purpose of a risk assessment
identify potential hazards in the work environment
identify good housekeeping procedures
Range
(AC3.1) Health, safety and environmental regulations:
 Health and Safety at Work Act 1974 (HSWA)
 Control of Substances Hazardous to Health (COSHH)
 Lifting and Handling 1998 (LOLER)
 Provision and Use of Work Equipment Regulations 1998 (PUWER)
 Portable Appliance Testing Regulations (PAT)
 Personal Protective Equipment at Work Regulations
 Supply of Machinery Regulations
 Manual Handling Operations Regulations
 Work at Height Regulations
 Safe Working in Confined Spaces Regulations and Code of Practice
 Supply of Machinery Regulations
 Biocidal Products and Chemicals (appointment of Authorities and Enforcement)
Regulations 2013
 Carriage of Dangerous Goods and the Use of Transportable Pressure Equipment
Regulations 2009
 Control of Major Accident Hazards Regulations 2015
 CRC Energy Efficiency Scheme Order 2013
 Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR)
 Environmental Permitting (England and Wales) Regulations 2010
 Environmental Protection Act 1990
 Registration, Evaluation, Authorisation & restriction of Chemicals (REACH) (EC)
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
24
(AC3.2)
(AC3.3)
(AC3.4)
(AC3.6)
(AC3.7)
 Recreational Craft Regulations 2004
 The Hazardous Waste (England and Wales) (Amendment) Regulations 2016
 The Hazardous Waste (Miscellaneous Amendments) Regulations 2015
 Waste (England and Wales) Regulations 2011
 Waste Batteries and Accumulators Regulations 2009
Personal Protective Equipment (PPE):
 hard hats
 goggles
 boots
 gloves
 safety harness
 lifejacket
 buoyancy aids
 overalls
 ear attenuators and defenders
 wet weather gear
 respiratory protection equipment (RPE):
o masks
o air feed hoods
When PPE is used in the marine industry:
 operating machinery
 working at height
 working on board
 working on water
 working in noisy environments
 working with hazardous substances:
o chemicals
o paints
Safety signs:
 warning or cautionary signs
 prohibition signs
 mandatory signs
 safety signs
 COSHH signs
Evacuation procedures:
 fire alarm
 escape routes
 assembly points
 fire drills
Common causes of fire:
 electrical faults
 fuels
 oils
 exotherming chemicals
 solvents and paints
 hot works without permitting
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
25
(AC3.9) Types of fire extinguisher:
 water
 foam
 powder
 CO2 gas
 fire blankets
 fire suppression system
(AC3.11) Potential hazards:
 spillages and slippery surfaces
 faulty electrical connections or damaged cables
 faulty, blunt or incorrectly set up of tools and equipment
 faulty or missing machine guards or interlocks
 faulty material handling or transportation
 risk of explosion
 dust and fumes
 moving loads
 suspended loads
 working at heights
 untidy work habits
 weather conditions
 air pressure systems
 confined spaces
 moving machinery
 working on water
 noise
 vibration
 chemicals
(AC3.12) Good housekeeping procedures:
 5S technique of good housekeeping:
o sort
o set
o standardise
o shine
o sustain
 correct storage of tools, equipment and materials
 maintaining access and egress to:
o work stations
o walkways
o emergency exits
o fire doors
 safe removal of waste and methods of waste disposal:
o burning
o landfill
o recycling
o chemical breakdown
 the acceptable codes of behaviour and dress
 following instructions
 walking not running
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
26

appropriate lighting and ventilation
Learning outcome
The learner will:
4
Understand employment roles and responsibilities
Assessment criteria
The learner can:
4.1
4.2
4.3
list the main aspects of a contract of employment
identify relevant legislation about conditions of employment
state sources of information on employment rights and responsibilities
Range
(AC4.1) Aspects of a contract of employment:
 job description
 hours of work
 rates of pay
 role and responsibilities
 disciplinary and grievance procedure
 organisational structure
 terms of notice
 holiday entitlement
 policies and procedures
(AC4.2) Relevant legislation:
 Equality Act 2010
 Employment Rights Act 1996
 Working Time Regulations
(AC4.3) Sources of information:
 trade unions
 ACAS
 Citizens Advice Bureau
 employer/contract of employment
 gov.uk websites
 company policies and procedures
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
27
Learning outcome
The learner will:
5
Know how to contribute to self-development and create and maintain effective working
relationships
Assessment criteria
The learner can:
5.1
5.2
5.3
5.4
5.5
5.6
identify the methods of communication used to manage information within the organisation
explain how to maintain effective working relationships
explain the difficulties that can occur in working relationships
identify the relevant persons to contact when information is not clear or sufficient
state the importance of asking for help when required
identify appropriate listening, questioning, recording and presentation techniques
Range
(AC5.1) Methods of communication:
 memos
 drawings and sketches
 diagrams
 written and verbal work instructions
 videos
 pictures
 manufacturers’ instructions or guidance literature
 noticeboards
 emails
 intranet
 job sheets
 technical datasheets
 safety datasheets
 risk assessments
 method statements
 mobile technology
 short wave radios
(AC5.2) Effective working relationships:
 the importance of listening skills
 pay attention to work instructions
 ensure understanding by asking questions to confirm understanding
 avoid abusive or offensive behaviour
 personal hygiene
 willing co-operation with all levels of organisation
 good time keeping
 obey company rules and regulations
 work safely
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
28
 treat people (workmates and customers) with courtesy and respect
 be reliable and trustworthy
 adhere to current regulations and legislation
 maintain a positive attitude
(AC5.3) Difficulties:
 disrespectful behaviour
 direct and indirect discrimination
 victimisation
 harassment
(AC5.4) Relevant persons:
 experienced and reliable colleagues
 charge-hands
 foreman
 managers
 team leaders
 mentors
 the company hierarchy
Learning outcome
The learner will:
6
Know how to contribute to the effectiveness of boat production and support services
Assessment criteria
The learner can:
6.1
6.2
6.3
6.4
6.5
identify the principles of costing, budgeting, pricing and hours
state the types of information to be used and recorded during a job
state sources of information for boat production and support services
state the importance of accuracy when completing records
state the importance of maintaining records for disposal of waste in an environmentally
responsible way
Range
(AC6.2) Types of information:
 description of the work
 location of work
 temperature and humidity
 special requirements (tools)
 time sheets stating labour hours
 sub-contracted work detail
 requisition sheets
 test and quality information
 calibration certificates
 materials and quantities
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
29

measurements:
o weight
o ratio
 batch numbers
 safety requirements
(AC6.3) Sources of information:
 internal:
o past records
o new build specifications
o scantlings lists
o time sheets
o requisition sheets
o test records
o drawings and specifications
o tool records
o calibration records
o application records
o risk assessments
o methods statements
 external:
o designers’ drawings and specifications
o regulation agencies
o Recreational Craft Directive (RCD)
o technical data and information
o safety data sheets
o health and safety regulations and information
o compliance organisations and regulations
(AC6.4) Importance of accuracy:
 prevent re-work and warranty claims
 prevent wrong information being recorded
 enable a true account of costs and time to be established
 provide a log of what was done when and by whom
 provide information for future planning, efficiency and potential customers
(AC6.5) Importance of maintaining records:
 legal requirement
 social responsibility
 company policy
 stock control
 warranty
 continuous improvement
 safety
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
30
Unit 202
Principles of boatbuilding technology
Unit level:
GLH:
Unit aim:
Assessment type
Level 2
100
This mandatory unit is concerned with the selection and use of
materials, tools and equipment and their application in boat
building maintenance and support operations.
Multiple-choice online test
Learning outcome
The learner will:
1
Know how to identify boatbuilding materials, their reaction to the environment and their
properties
Assessment criteria
The learner can:
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
identify the common materials used in boatbuilding
list the properties that identify materials
identify the properties of materials
identify storage requirements of materials
describe the difference between oxidation, electrolytic and galvanic corrosion and
hydrolysis
identify types of permanent, semi-permanent and temporary bonds
identify types of protective coatings used in marine applications
state the factors influencing the choice of materials in boatbuilding assembly and subassembly
Range
(AC1.1) Materials:
 timbers and veneers:
o hard woods (oak, elm, teak, iroko, mahogany, sapele, balsa)
o soft woods (douglas fir, pitch pine, European redwood, spruce)
o manufactured boards (plywood, MDF, honeycomb boards, foam cores, chipboard,
OSB, blockboard, marine plywood)
 composites:
o glass reinforced plastic (GRP)
o fibre reinforced plastic (FRP)
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
31
o plastics
 metals:
o ferrous (steel)
o non-ferrous (lead, aluminium, copper)
o alloys (brass, bronze)
 filler and filler compounds:
o colloidal silica
o talc and calcium carbonate
o glass microfibres
 resins:
o polyester
o vinylesters
o epoxy
 cloth:
o reinforcing fibres
o fibre reinforcement
o pre-impregnated
 bedding:
o silicon
o rubber
o PTFE
o polyurethane
 solvents:
o acetone
o thinners
 organic peroxides
o catalyst
(AC1.2) Properties that identify materials:
 metal:
o weight
o density
o colour
o magnetism
 wood:
o colour
o grain
o texture
o smell
o weight
 composite:
o colour
o orientation
o identifier strand
 cloth:
o fibre orientation
o weight
o identifier strand
 filler and filler compounds:
o texture
o colour
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
32
o hardness
o weight
(AC1.3) Properties of materials:
 metal:
o tensile strength
o hardness
o toughness/brittleness
o compressive/sheer strength
o ductility/malleability
o corrosion resistance
 wood:
o tensile strength
o hardness
o toughness/brittleness
o erosion resistance
o elasticity
o durability
o moisture content
o compressive/sheer strength
o workability
 composite:
o tensile strength
o hardness
o toughness/brittleness
o ductility/malleability
o compressive/sheer strength
o elasticity
 pre-impregnated:
o tensile strength
o hardness
o toughness/brittleness
o ductility/malleability
o compressive/sheer strength
o elasticity
 resins/organic peroxides:
o pot life
o shelf life
o temperature
o humidity
o mix ratio (weight, volume)
o viscosity
 cloth:
o weight
o fibre length
o fibre direction
o weave
o pattern
o colour
 filler and filler compounds:
o size
o viscosity
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
33
(AC1.4) Storage requirements of materials:
 timber:
o drying rack
o undercover
o flat
o air circulation
 composites:
o dry condition
o humidity control
o clean
o separate from catalysts
o flat
 pre-impregnated:
o refrigerated
 metals:
o dry
o purpose built rack
 resins/thinners:
o COSHH cabinet
 filler and filler compounds:
o dry
o clean
o humidity control
 organic peroxide:
o COSHH cabinet separate from flammables
(AC1.6) Permanent bonds:
 welding
 resins
 glue
 PVA
 formaldehydes
 epoxy resins
 polyurethanes
 polyester resin
 mastics
 Resorcinol glue
 contact adhesive
 chemical locks/locking adhesive
 fibre glassing
 methylmethacrylate adhesives
(AC1.6) Semi-permanent bonds:
 nails
 nuts
 bolts
 screws
 rivets
 fast mounts
 rivnuts
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
34
(AC1.6) Temporary bonds:
 split pins
 R clips
 polyurethane
 hot glue
 circlips
 nails
 pins
(AC1.7) Protective coatings:
 varnishes
 paints (including anti-fouling)
 preservatives
 resins
 plastic sheathing
 metallic coatings (eg galvanising and anodising)
 powder coating
 vinyl wrapping
(AC1.8) Factors:
 suitability based on:
o location
o cost
o weight
o durability
o stability/longevity
o availability
o customer requirements
Learning outcome
The learner will:
2
Know how to interpret drawings, specifications and installation requirements
Assessment criteria
The learner can:
2.1
2.2
2.3
2.4
identify drawing conventions to ISO8888/2000 for lines, dimensions and setting out
identify types of drawings used in the production of boats and fitting out
identify common scales used for drawing
list the sources of marine installation information
Range
(AC2.1) Lines, dimensions and setting out:
 centre lines
 water line
 datum lines
 station lines
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
35
 forward perpendicular (FP)
 aft perpendicular (AP)
 visible outline
 dimension lines
 hidden detail
(AC2.2) Types of drawings:
 first and third angle orthographic projections
 oblique and isometric projections
 general layout and assembly drawings
 exploded and sectional views
 lines plans and table of offsets
 construction plans
 general arrangements
 detailed drawings
(AC2.4) Sources:
 instruction manuals
 technical books
 tables
 charts
 graphs
 data sheets
 electronic sources
 regulatory bodies:
o Lloyd's
o Recreational Craft Directive (RCD)
o Maritime and Coastguard Agency (MCA)
Learning outcome
The learner will:
3
Know how to use tools and equipment safely when boatbuilding
Assessment criteria
The learner can:
3.1
3.2
3.3
3.4
identify typical hand tools, machine tools and equipment used in boatbuilding, outfitting and
finishing activities
identify the equipment for lifting and transporting loads
state the general rules for the maintenance of tools and equipment
describe the safety requirements for using power tools
Range
(AC3.1) Hand tools, machine tools and equipment:
 cutting tools:
o saws (cross cut, panel, coping, tenon, pad, hacksaws, diamond, tungsten tipped,
pull, hole)
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
36











material removal tools:
o chisels
o planes (block, smoothing, jack, try, bollow, moulding, rebate, bullnose, granny’s
tooth)
o spoke shaves
o drawknives
o files
o rasps
o adze
assembly and joining tools:
o drills
o screw drivers
o spanners
o socket sets
o torque wrench
o impact drive
hammers:
o claw
o ball pein
o cross pein
o maul
o lump
o soft blow
o mallet
measuring and marking out tools:
o tapes
o rules
o squares
o gauges (bevel, spar)
o scribes
o templates
o ‘Shepherds crook’
o tick stick
o joggle sticks
o spiles and spieling battens
o water level
o levels
o laser measures and levels
o 3D scanner
o plumb bob
o spirit level
drilling tools
shaping tools
sharpening systems
coating application tools
surface preparation tools
special tools:
o jigs
o formers
o saddles
work-holding devices:
o grips
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
37
o vices
o chucks
o ‘G’ cramps
o sash cramps
o quick-release cramps
o lever cramps
 adhesive tapes
 dust sheets
 protective coatings
 electrical leads
 lead lights
 airlines
 local exhaust ventilation (LEVs)
(AC3.2) Equipment for lifting and transporting:
 transporting:
o boat hoist
o boat mover
o tug
o tractor
o trailer
o trolleys
o skates
o jacks
o pallet truck
o fork lift
o telehandler
o cranes (wall, mobile, telescopic, static, overhead)
o slings and pull lifts
o docking equipment
o slipways
o winch
o mobile boat lifts
o sliding ways
o launches
 lifting accessories:
o chains
o blocks
o ropes
o trops
o shackles
o slings
(AC3.3) General rules:
 safe storage
 cleaning after use
 sharpening
 honing
 before use checks
 shadow boards
 safe working loads
(AC3.4) Safety requirements:
 use of correct PPE
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
38








ensure use and correct settings for guides and guards
use of low voltage system
pneumatic, mains or battery operated tools
LEVs
health surveillance for those exposed to hazardous substances or working practices
logging trigger times and measuring vibration of power tools
exposure action and limit values (EAL/ELV) extraction requirements
work at height and work on water procedures
Learning outcome
The learner will:
4
Understand boatbuilding operations
Assessment criteria
The learner can:
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
4.11
4.12
identify construction methods used in boatbuilding
state the units and derived units used to perform simple calculations
convert between units and derived units
identify the factors to be considered when measuring and marking out
list the factors affecting accuracy of measurement
identify the types of work-holding devices
describe the methods of material removal
describe the factors which affect material removal
describe the types of assembly joining/fixing
describe the principles of lofting
describe the purpose of finishing
identify the sequence of operations which maximise efficiency when carrying out
boatbuilding, outfitting and finishing activities
Range
(AC4.1) Construction methods:
 clinker
 carvel
 double diagonal
 cold moulding
 strip planking
 stitch and glue
 composite male and female moulding
 steel and aluminium
(AC4.2) Units and derived units:
 length
 area
 volume
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
39
(AC4.4)
(AC4.5)
(AC4.6)
(AC4.7)
 mass
 weight
 density
 relative density
 force
 imperial and metric
Factors:
 length
 flatness
 parallelism
 angle
 profile
 relative position
 capacity
 levelling and declivity
Factors:
 condition of equipment
 calibration
 correct positioning
 dimensions
 tolerances
 temperature
 humidity
Work-holding devices:
 vices
 clamps
 chucks
 jigs
Material removal:
 sawing:
o cutting sheet materials
o roughing down to size
o cutting at angle
 planing:
o finishing to size
o working on end grain
o producing grooves
o rebates or profiles
 shaping/turning:
o cutting out waste
o paring
o carving
o routing
o honing
o grinding
o sanding
o chiselling
o filing
o scissoring of cloths
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
40

drilling:
o through holes
o counter-bored holes
o counter-sunk holes
o boring bar
 sheet metal cutting:
o oxy/acetylene
o plasma cutter
o water jet
(AC4.8) Factors which effect material removal:
 dryness of material
 location of material
 cutting speed
 material hardness
 grain direction and structure/timber
 use of lubricants
 cutting compounds and friction reducing substances such as candle wax or bees wax
(AC4.10) Principles of lofting:
 lofting grid made up of:
o forward and after perpendiculars
o station lines
o water lines
o buttock lines
o diagonal lines
 table of offsets to produce a line plan containing:
o sheer plan or profile half breath plan
o body plan
(AC4.11) Purpose of finishing:
 customer requirements
 safety
 protection
 appearance
 feel
 to meet a quality standard
 functionality
 durability
 vessel use/end use requirement
(AC4.12) Sequence of operations:
 planning and set up:
o review and verify designs and plans
o finalise time and cost of the work to be done
o identify and source equipment, machinery, tools and materials
o make, produce and use jigs and templates as required
o set up tools and machinery
 manufacture and assemble/disassemble and repair components:
o manufacture/repair components to required specification
o move components using the appropriate safe methods
o check components for robustness, fit and tolerances
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
41




o analyse problems with machinery, equipment, tools and material,
proposing/implementing solutions where appropriate
o move, shape and manipulate components to achieve best fit
o select and use appropriate methods for holding materials and components in
place during assembly, and for the connecting, fixing and assembly of materials
and components
o safeguard materials and components during assembly
o select suitable methods for fault finding and analysis
o make repairs whilst safeguarding the integrity of components and the surrounding
area
o identify, mark, store and organise dismantled parts for reassembly
fit out:
o install and fix components using the most appropriate method and materials
o ensure the joins are made and treated
o position and fit items
o finalise fit out for deck hardware
finish:
o check joins are sealed and fit for purpose
o prepare surfaces, treat suitability and ensure all are free from defects and
protected
o soften or suitably finish edges
o assess quality of work
commissioning and sea trials:
o assess fixtures and fittings for quality and stability
o commission the boat
o assemble required documentation
reinstate work area
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
42
Unit 203
Business improvement techniques
Unit level:
GLH:
Unit aim:
Assessment type
Level 2
50
This unit aims to provide the learner with the knowledge of lean
business process and quality improvement in order to effectively
monitor and make enhancements to production, manufacturing
and maintenance processes.
Short-answer questions
Learning outcome
The learner will:
1
Know what is meant by continuous improvement
Assessment criteria
The learner can:
1.1
1.2
1.3
1.4
explain the meaning of continuous improvement
outline the benefits of applying continuous improvement techniques
define each stage of the Plan – Do – Check – Act (PDCA) improvement cycle
define the different categories of waste
Range
(AC1.2) Benefits:
 reduced cost (eg production)
 improved quality (eg reduced defects)
 improved safety (eg safe to use)
 improved working practices (eg reduced operator motion)
 improved delivery (eg reduced transportation time, reduced lead time)
 reduction of waste (eg over-processing, excess inventory)
 resource utilisation (eg reduced waiting time)
 improved customer satisfaction (eg meeting customer requirements)
(AC1.4) Categories of work:
 value added
 non-value added
 waste
(AC1.4) Categories of waste:
 transport
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
43







inventory
motion
waiting
over-production
over-processing
defects
skills/unrecognised people potential
Learning outcome
The learner will:
2
Understand what is meant by workplace organisation
Assessment criteria
The learner can:
2.1
2.2
2.3
2.4
explain the meaning of workplace organisation
outline the benefits of having an organised working environment
describe the effect an unorganised work environment may have
explain the importance of Standard Operating Procedures (SOPs) within workplace
organisation
Range
(AC2.3) Effects:
 poor quality
 increased costs
 reduced efficiency
 poor delivery times
 poor morale/teamwork
 poor health and safety
Learning outcome
The learner will:
3
Know what is meant by visual management
Assessment criteria
The learner can:
3.1
3.2
3.3
explain the meaning of visual management
describe the benefits of applying good visual management
describe different types of visual management
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
44
Range
(AC3.2) Good visual management:
 accurate and relevant
 eye-catching
 simple
 greater ownership
(AC3.3) Visual management:
 shadow boards
 PDCA worksheets
 colour coding
 floor footprints
 storyboards
 gauges
 photographs/pictures
 labelling
 lights
 schedule boards
 Kanban (pull systems)
 graphs
 management boards
 other area specific types of visual management
Learning outcome
The learner will:
4
Understand problem solving techniques
Assessment criteria
The learner can:
4.1
4.2
4.3
4.4
explain what is meant by a problem within a work environment
describe the benefits of solving work related problems
outline different techniques used for identifying and analysing problems
explain the importance of applying the appropriate corrective action and eliminating the
root cause of a problem
Range
(AC4.3) Techniques:
 tally charts
 flowcharts
 histogram/Pareto chart
 benchmarking
 process mapping
 correlation diagram
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
45










run diagram
Statistical Process Control
control charts
Gantt charts
root cause paths
value stream maps
Ishikawa diagrams (cause and effect, fishbone)
brainstorming
mind mapping
5 Why analysis
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
46
Unit 204
Yacht and boatbuilding assembly and subassembly
Unit level:
GLH:
Unit aim:
Assessment type
Level 2
140
This optional unit is concerned with yacht and boatbuilding
assembly and sub-assembly. It covers the specifications, tools,
equipment and materials required, carrying out assembly and
sub-assembly and understanding quality standards.
Centre-devised practical assignment and short-answer questions
Learning outcome
The learner will:
1
Know the specifications, tools, equipment and materials required for boat assembly and subassembly operations
Assessment criteria
The learner can:
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
use sources of information relevant to boat assembly and sub-assembly operations
interpret specifications to produce assembly and sub-assembly operations
select the materials used in boat assembly and sub-assembly
identify material defects commonly found in timber, composite boards and metal
use hand tools and equipment in boatbuilding assembly and sub-assembly safely
identify and operate the woodworking machinery used in boatbuilding assembly and subassembly
operate the hand held power tools used in boatbuilding assembly and sub-assembly
identify appropriate types of permanent, semi-permanent and temporary bonds
use protective coatings for assembly and sub-assembly operations
Range
(AC1.1) Sources of information:
 codes of practice
 rules and regulations:
o Lloyd's
o RCD
 surveyor’s report
 manufacturers’ specifications
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
47
 technical datasheets
 safety data sheets
 scheme of work
 customer/client specifications
 Boat Safety Scheme (BSS) (Inland Waterways Association)
 Inland Waterways
 BS/EN standards applicable to the marine industry
 line plans
 working drawings
 designer’s specifications
 current drawing standards ISO 8888/2000
(AC1.2) Interpret specifications:
 identify material required from the specification
 select the correct tools to use for specific applications
 identify and select the fittings and fixtures required for assemblies
 describe the techniques used to transfer mould and template data onto mould and
template material (eg nail-head impressions)
 describe the cutting and shaping methods used to produce:
o moulds
o template
o jigs
(AC1.3) Materials:
 timbers and veneers:
o hard wood (oak, elm, teak, iroko, mahogany, sapele, balsa)
o soft wood (douglas fir, pitch pine, European redwood, spruce)
o manufactured boards (plywood, MDF, honeycomb boards, foam cores, chipboard,
OSB, blockboard, marine plywood)
 composites:
o glass reinforced plastic (GRP)
o fibre reinforced plastic (FRP)
o plastics
 metals:
o ferrous (steel)
o non-ferrous (lead, aluminium, copper)
o alloys (brass, bronze)
 filler and filler compounds:
o colloidal silica
o talc and calcium carbonate
o glass microfibres
 resins:
o polyester
o vinylesters
o epoxy
 cloth:
o reinforcing fibres
o fibre reinforcement
o pre-impregnated
 bedding:
o silicon
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
48
o rubber
o PTFE
o polyurethane
 solvents:
o acetone
o thinners
 organic peroxides:
o catalysts
(AC1.4) Material defects:
 wood, composite board:
o natural defects (shakes, knots, types of rot)
o seasoning defects (hardening, twisting, warping)
o voids
o water damage
o woodworm
o UV reaction
o working reaction
o colour changes
 metal:
o corrosion (galvanic, electrolytic stray current)
o metal fatigue
o de-zincification
o oxidation
o crevice corrosions
o welding imperfections and cracks
 FRP:
o under cured resin
o gel coat contamination
o incorrect mixing and application of materials
o incorrect workshop conditions (humidity, temperatures)
o voids
o pin holes
o delamination
o osmosis
o gel streak
o gel coat cracking
o star crazing
(AC1.5) Hand tools and equipment:
 cutting tools:
o saws (cross cut, panel, coping, tenon, pad, hacksaws, diamond, tungsten tipped,
pull, hole)
 material removal tools:
o chisels
o planes (block, smoothing, jack, try, bollow, moulding, rebate, bullnose, granny’s
tooth)
o spoke shaves
o drawknives
o files
o rasps
o adze
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
49

assembly and joining tools:
o drills
o screw drivers
o spanners
o socket sets
o torque wrench
o impact driver
 hammers:
o claw
o ball pein
o cross pein
o maul
o lump
 measuring and marking out tools:
o tapes
o rules
o squares
o callipers
o gauges (bevel, spar)
o scribes
o templates
o ‘Shepherds crook’
o tick stick
o spieles and spieling battens
o water level
o levels
o laser levels
o 3D scanner
o plumb bob
o spirit level
 work-holding devices:
o grips
o vices
o chucks
o ‘G’ cramps
o sash cramps
o quick-release cramps
o lever cramps
 special tools:
o jigs
o formers
o saddles
(AC1.6) Woodworking machinery:
 saws:
o circular
o band
o cross cut
o rip/tenon
o fret/coping
 planer/thicknesser (over and under)
 mortisers
 spindle moulders
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
50
 bench sanders
 routers
 linisher
 pillar drill
 CNC controlled routers
 panel saw
 press
 bobbin sander
 table saw
 extraction systems
 spoke shaves
 chisels/gouges
 braces
(AC1.7) Hand held power tools:
 electrical and battery operated drills
 sanders
 saws:
o jig
o ’Skil’
o chain
 grinders
 routers
 power planes
 pneumatic sanders
 die grinders
 whizzers
(AC1.8) Permanent bonds:
 welding
 resins
 glue
 PVA
 formaldehydes
 epoxy resins
 polyurethanes
 polyester resin
 mastics
 Resorcinol glue
 contact adhesive
 chemical locks/locking adhesive
 fibre glassing
 acrylic adhesives
(AC1.8) Semi-permanent bonds:
 nails
 nuts
 bolts
 screws
 rivets
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
51
 fast mounts
 rivnuts
(AC1.8) Temporary bonds:
 split pins
 R clips
 polyurethane
 hot glue
 circlips
 nails
 pins
 tapes
(AC1.9) Protective coatings:
 paint
 varnishes
 metallic coatings:
o galvanising
o anodising
o powder coating
 vinyl wrapping
 nylon dipping
Learning outcome
The learner will:
2
Know how to carry out yacht assembly and sub-assembly operations safely
Assessment criteria
The learner can:
2.1
2.2
2.3
2.4
2.5
2.6
2.7
list the requirements of a safe working environment
identify safe methods for the use of lifting and handling equipment
identify the principal parts used for making assembly and sub-assembly components for
boat construction
use sources of information for mould and template manufacturing
explain the importance of complying with operation sheets and schedules
list the sequence of operations and processes needed to carry out assembly and subassembly operations
identify terminology and techniques used to set up moulds, templates, jig components and
check alignment
Range
(AC2.1) Requirements of a safe working environment:
 risk assessment
 safe systems of work
 method statement
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
52
 safety data sheets
 noise regulations
 environmental control
 washing facilities
 dust and fume extraction
 well maintained walkways
 effective access and egress
 safe and correct disposal of waste material
 temperature and humidity control
 Work at Height Regulations (2005)
 Manual Handling Operations Regulations
 Control of Substances Hazardous to Health (COSHH)
 Lifting and Handling 1998 (LOLER)
 Provision and Use of Work Equipment Regulations 1998 (PUWER)
(AC2.2) Safe methods:
 never exceed safe working load (SWL)
 avoid shock loading
 never transport loads over people
 avoid twisting of slings and ropes
 follow LOLER regulations
 balance load
 appreciate centre of gravity
(AC2.3) Principal parts:
 wood:
o moulds and templates
o keel
o hog
o stern knee
o horn timber
o deadwood
o transom
o stem and apron
o frames and timbers (grown, laminated, bent)
o floors (grown, laminated, plate, angle)
o stringers
o chine
o gunwales/inwales
o mast clamp
o mast step
o breast hook
o quarter knees
o planking
o beams
o carlins
o hanging knees
o lodging knees
o hatch and side coamings
o companion ways
o doghouse
o cockpit
o coach roof
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
53
o wheelhouse
o decks
o fly bridges
o radar chairs and hoops
o chain plates
o main brackets
o P-brackets
o A-brackets
 composite:
o male and female moulds
o laminates
o resins
o core materials
 metal:
o bulkheads
o engine beds
o steel and aluminium keel beds
o handrails
o push pit
o pull pit
o masts
o booms
o A-brackets
o P-brackets
o shaft lock
o shaft
o rudders
o rigging
(AC2.4) Sources of information:
 lines plan and offsets
 technical drawing
 designer’s drawings and specs
(AC2.5) Importance of complying:
 reduce errors
 prevent re-working
 prevent waste
 ensure quality
 standardised working
(AC2.6) Sequence of operations:
 planning and set up:
o review and verify designs and plans
o finalise time and cost of the work to be done
o identify and source equipment, machinery, tools and materials
o make, produce and use jigs and templates as required
o set up tools and machinery
 manufacture and assemble/disassemble and repair components:
o manufacture/repair components to required specification
o move components using the appropriate safe methods
o check components for robustness, fit and tolerances
o analyse problems with machinery, equipment, tools and material,
proposing/implementing solutions where appropriate
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
54
o move, shape and manipulate components to achieve best fit
o select and use appropriate methods for holding materials and components in
place during assembly, and for the connecting, fixing and assembly of materials
and components
o safeguard materials and components during assembly
o select suitable methods for fault finding and analysis
o make repairs whilst safeguarding the integrity of components and the surrounding
area
o identify, mark, store and organise dismantled parts for reassembly
 fit out:
o install and fix components using the most appropriate method and materials
o ensure the joins are made and treated
o position and fit items
o finalise fit out for deck hardware
 finish:
o check joins are sealed and fit for purpose
o prepare surfaces, treat suitability and ensure all are free from defects and
protected
o soften or suitably finish edges
o assess quality of work
 commissioning and sea trials:
o assess fixtures and fittings for quality and stability
o commission the boat
o assemble required documentation
 reinstate work area
(AC2.7) Terminology and techniques:
 plumb
 level
 dimensional orientation
 horning in
 bracing
 use of templates and jigs
 visual inspection
 sub-assembly datums
 correct ‘hand’ of component is used
 using cramps and clamps
 drilling holes
 securing components using correct/appropriate fastenings
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
55
Learning outcome
The learner will:
3
Understand quality standards for assembly and sub-assembly components
Assessment criteria
The learner can:
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
state the relevant regulations and compliance bodies that apply to checking the assembly
and sub-assembly operations
describe the reasons for inspections and tests used in assembly and sub-assembly
operations
describe how to prepare for final finish inspection
identify the relevant persons to contact in the event of a problem
use checks that ensure that all components have been completed according to plan
explain why it is important to protect completed components and what methods are used
describe the records and checks required on completion
describe how to reinstate the work area following completion
Range
(AC3.1) Regulations and compliance bodies:
 Lloyd's
 Recreational Craft Directive (RCD)
 Boat Safety Scheme (Inland Waterways Authority)
 Marine Safety Agency
 Bureau Veritas
 BS EN and ISO standards
 American Bureau of Shipping (ABS)
 Maritime Coastguard Agency (MCA)
 American Boat and Yacht Council (ABYC)
(AC3.2) Reasons for inspection and tests:
 visual inspection:
o surface defects
o twist and alignment
o fit of joints
o fixing damage
 functional test:
o correct operation
o water-tight
o no interference with other systems
 dimensional control:
o measurement
o geometric alignment
 coding requirements:
o welding
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
56
(AC3.3) Final finish inspection:
 final polish
 wiping down
 vacuuming
 oiling
 gap filing
 smoothing and sanding
 painting
 soften or suitably finish edges
 check joins
 check fastenings, rattles and squeaks
(AC3.4) Relevant persons to contact:
 charge-hand
 team leader
 foreman
 manager
 designer
 quality controller
(AC3.5) Checks:
 dimensional accuracy is within specification
 installed structures are correctly aligned, level and secure
 shape of the frame/hull is to template
 all plank fastenings line up with frames/beams
 specified type and quantity of fastenings are used and are correctly spaced out
 scarfs and joints are fitted with no gap in the interface
 seams and butts are evenly caulked watertight with no internal splitting
 cosmetic appearance is to specification
 functionally operative
 commissioning
 basin trials
 sea trials
(AC3.6) Methods to protect components:
 covering with cloth or cardboard
 wrapping with bubble wrap
 coating
 storing in secure, dry location until required
 correct labelling
 restrict access
(AC3.7) Records and checks:
 recording of hours
 recording of materials used
 inspection checklist and records
 quality control records
 owner’s RCD installation manual
 project plan
 batch numbers
 boat file
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
57
 quality panels
(AC3.8) How to reinstate the work area:
 5s approach
 clear away all waste and discarded material
 return all tools and equipment to the stores or tool boxes/shadow board
 dismantle or return all jigs and templates to storage areas
 clean and sharpen all tools ready for the next job
 ensure the area is safe and free from dangers (risk assessment)
 ensure protection and labelling in place
 floors and access panels are replaced
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
58
Unit 205
Production of external boat components
Unit level:
GLH:
Unit aim:
Assessment type
Level 2
140
This optional unit is about the requirements for the successful use
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.
Centre-devised practical assignment and short-answer questions
Learning outcome
The learner will:
1
Be able to produce moulds and templates for external boat components
Assessment criteria
The learner can:
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
1.11
use sources of information relevant to the production of moulds and templates for
components of boats
state the importance and purpose of drawings, specifications, data and procedure sheets
identify the materials used in the production of moulds and templates
identify characteristics of the materials used in the production of moulds and templates
state the importance of mould preparation
produce shapes of moulds and templates and transfer them onto the mould/template
material using a variety of techniques
identify techniques for mould release
use hand tools and woodworking machinery safely
explain the function and safe use of powered tools and equipment
identify the causes of defects in materials when marking, setting out and cutting materials
for moulds and templates
state the importance of minimising waste when marking, setting out and cutting materials
for moulds and templates
Range
(AC1.1) Sources of information:
 codes of practice
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
59

(AC1.3)
(AC1.4)
(AC1.6)
(AC1.7)
(AC1.8)
rules and regulations
o Lloyd’s
o RCD
 customer/client specifications
 surveyor’s report
 manufacturers’ specifications
 safety data sheets
 scheme of work
 Boat safety scheme (BSS) (Inland Waterways Association)
 BS/EN standards applicable to the Marine Industry
 lines plans
 working drawings and designer’s specifications
 current drawing standards ISO 8888/2000
 construction plan and scantlings list
 sail and rigging plan
Materials:
 template paper and card
 solid timber
 manufactured boards
 composites
 metals
 plastics
Characteristics:
 stability
 ease of use
 cost effectiveness
Techniques:
 direct measurement
 tracing/transfer
 nail-head impressions
 CNC
 lasers
 placement technology
Techniques for mould release:
 compressed air
 power washer
 wax
 chemical
 Teflon
 mechanical (wedges and hammer)
Hand tools:
 cutting tools:
o saws (cross cut, rip, coping, tenon, pad, hacksaws, diamond, tungsten tipped, pull,
hole)
o sheers
 material removal tools:
o chisels (firmer, mortise, bevel edged)
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
60
o planes (smoothing, jack, try, rebate, shoulder, bollow, moulding)
o spoke shaves
o drawknives
o files
o rasps
o adze
 assembly and joining tools:
o drills
o screwdrivers
o spanners
o socket sets
o long boards
o glue guns
 measuring and marking out tools:
o tapes
o rules
o squares
o gauges
o dividers
o scribes
o bevel board
o lasers
o water level
o spirit level
(AC1.8) Woodworking machinery:
 saws:
o circular
o band
o cross cut
o panel
 planer/thicknesser (over and under)
 sanders
 routers
 mortisers
 spindle moulders
 CNC routers
 lathe
 local exhaust ventilation (LEV)
(AC1.9) Powered tools and equipment:
 hand held power tools both electric and pneumatic:
o drills
o sanders
o saws
o grinders
o planers
o guillotine
o sheers
 thermal equipment:
o blow torches
o heat mats for vacuum moulding
o soldering irons
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
61
o welding (MIG, TIG, MMA)
 high pressure power washers
 compressors
(AC1.10) Causes of defects in materials:
 incorrect selection
 incorrect setting out
 incorrect cutting/shaping
 distortion (twisting and warping)
 heat distortion in metals
 incorrect labelling
Learning outcome
The learner will:
2
Be able to cut and finish materials to form external boat components
Assessment criteria
The learner can:
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
identify external boat components
identify materials used to make boat components
describe the techniques used to transfer shapes onto the component material
select the correct cutting technique for square, angular or moulded profiles
set up and operate cutting tools needed to profile the components
identify possible cutting defects in materials
follow surface finish procedures for boat components
list the protective methods to apply to finished boat components for storage and transport
Range
(AC2.1) External boat components:
 hatches
 garage
 companionway
 boards
 coamings
 gratings
 vent boxes
 navigation light boxes
 rudders
 tillers
 masts
 spars
 oars
 grab rails/hand rails
 toe rails
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
62
(AC2.2)
(AC2.3)
(AC2.4)
(AC2.6)
 rubbing strakes
 fender
 deck
 keel
 coachroof
 doghouse
 centreboards
 dagger boards
 keels
Materials:
 timbers:
o hardwoods
o softwoods
 composites
 manufactured boards
 metals
Techniques:
 direct measurement
 tracing/transfer (use of 'dummy sticks')
 nail-head impressions
 templates
 laser placement technique
Cutting technique:
 hand saws:
o pad
o keyhole
o reciprocating
o oscillating
o hacksaw
o powered hacksaw
o chop saw
 adjustable table on band or dimension saws
 adjustable base plate on jig and power saws
 portable routers
 spindle moulders
 disc cutter
 drills
 power planer
 lather
 grinders
 flame cutting
 plasma cutting
 hole saws
Cutting defects:
 saw tooth marks
 planer ripple marks
 burn marks from blunt cutters on routers
 warping
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
63
 denting
 scratching
 scoring
 break out
 gel chips
 cracks
 damaged fibre
 burred edges
 heat damage
 surface blemishes
 dulling
(AC2.7) Surface finish:
 painting
 varnishing
 staining and polishing
 antifouling
 plastic coating
 gel coat
 vinyl wrap
 anodising
 powder coating
 galvanising
 burnishing
 zinc plating
 chrome plating
 nano surface technology
(AC2.8) Protective methods:
 plastic covering
 bubble wrap
 peelable coatings
 cardboard
 paper
 hardboard
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
64
Learning outcome
The learner will:
3
Be able to assemble external boat components
Assessment criteria
The learner can:
3.1
3.2
3.3
3.4
3.5
3.6
3.7
list the safety regulations applicable to producing external boat components
prepare the work area prior to commencing assembly operations
describe methods of setting up external boat components
describe temporary and permanent fixing devices required for assembly operations
select and use tools and equipment for assembly operations
use lifting and transporting equipment safely
identify the problems which can occur when assembling boat components
Range
(AC3.1) Safety regulations:
 Health and Safety at Work Act 1974 (HSWA)
 Control of Substances Hazardous to Health (COSHH)
 Provision and Use of Work Equipment Regulations(PUWER)
 need for risk assessment
 correct disposal of waste
 use of PPE
 lifting and handling regulations (LOLER, manual handling regulations)
(AC3.2) Prepare the work area:
 floor or bench space required
 availability of material, tools and equipment
 material handling facilities
 adequate lighting, ventilation/extraction dust and fume (LEV)
 floor and surface protection
(AC3.3) Methods of setting up:
 levelling
 plumbing and ‘horning in
 bracing and shoring
 declivity
 wedging
 gauges
 reference points
 datums
(AC3.4) Temporary fixing devices:
 cramps
 clamps
 gripes
 nails
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
65
 hot glue gun
 press
 vice
 shores and braces
 jigs
 weights
 screws
 bottle screws
 jacks
(AC3.4) Permanent fixing devices:
 welding
 resins
 glue
 PVA
 formaldehydes
 epoxy resins
 polyurethanes
 polyester resin
 mastics
 Resorcinol glue
 contact adhesive
 chemical locks/locking adhesive
 fibre glassing
(AC3.5) Tools and equipment:
 levelling/alignment equipment
 hand tools
 portable power tools
 basic welding
 brazing and soldering equipment
(AC3.6) Lifting and transporting equipment:
 boat mover
 tug
 tractor
 trailer
 trolleys
 skates
 jacks
 pallet trucks
 fork lift
 cranes:
o wall
o mobile
o telescopic
o static
o overhead
 slings and pull lifts
 docking equipment
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
66





slipways
mobile boat lifts
sliding ways
launches
lifting accessories:
o chains
o ropes
o strops
o shackles
o slings
(AC3.7) Problems:
 blunt tools
 faulty tools and equipment
 inexperience of personnel
 poor planning and quality control
 components not to specification
 inadequate stock control
 inadequate working practices
 quality control issues
Learning outcome
The learner will:
4
Know how to complete, inspect and protect external boat components
Assessment criteria
The learner can:
4.1
4.2
4.3
4.4
4.5
describe how to prepare for final finish inspection
describe the reasons for inspections and tests used in the assembling of boat components
explain why it is important to protect completed external boat components and what
methods are used
describe the records and checks required on completion
describe how to reinstate the work area following completion
Range
(AC4.1) Final finish inspection:
 final polish
 wiping down
 vacuuming
 oiling
 gap filing
 smoothing and sanding
 painting
 soften or suitably finish edges
 check joins
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
67
(AC4.2)
(AC4.3)
(AC4.4)
(AC4.5)
 check fastenings, rattles and squeaks
Reasons for inspection and tests:
 visual inspection:
o surface defects
o twist and alignment
o fit of joints
o fixing damage
 functional test:
o correct operation
o water-tight
o no interference with other systems
 dimensional control:
o measurement
o geometric alignment
 coding requirements:
o welding
Methods:
 covering with cloth or cardboard
 wrapping with bubble wrap
 coating
 storing in secure, dry location until required
 correct labelling
 restrict access
Records and checks:
 recording of hours
 recording of materials used
 inspection checklist and records
 quality control records
 owner’s RCD installation manual
 project plan
 batch numbers
 boat file
 quality panels
How to reinstate the work area:
 5s approach
 clear away all waste and discarded material
 return all tools and equipment to the stores or tool boxes/shadow board
 dismantle or return all jigs and templates to storage areas
 clean and sharpen all tools ready for the next job
 ensure the area is safe and free from dangers (risk assessment)
 ensure protection and labelling in place
 floors and access panels are replaced
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
68
Unit 206
Interior installation and fitting out of boats
Unit level:
GLH:
Unit aim:
Assessment type
Level 2
70
This optional unit is about 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.
Centre-devised practical assignment and short-answer questions
Learning outcome
The learner will:
1
Be able to prepare for installation of interior modules, joinery and marine fittings
Assessment criteria
The learner can:
1.1
1.2
1.3
1.4
1.5
1.6
1.7
use sources of information relevant to fitting out of boats
state the importance and purpose of drawings, specifications, data and procedure sheets
use hand tools and powered hand tools safely
identify fastenings required
describe the fittings installed in the accommodation areas on boats
describe the checks to be carried out on joinery and fittings to ensure serviceability
describe the working problems and potential hazards that can affect fitting out activities
Range
(AC1.1) Sources of information:
 codes of practice
 rules and regulations:
o Lloyd’s
o RCD
 customer/client specifications
 surveyor’s report
 manufacturers’ specifications
 safety data sheets
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
69
 scheme of work
 Boat Safety Scheme (BSS) (Inland Waterways Association)
 BS/EN standards applicable to the marine industry
 line plans
 working drawings and designer’s specifications
 current drawing standards ISO 8888/2000
(AC1.2) Drawings, specifications, data and procedure sheets:
 designer’s drawings and specifications
 instruction sheets
 patterns and templates
 construction plan and scantlings list
 sail and rigging plan
 engine and equipment installation plans
 manufacturers’ data sheets and specifications
 customer’s specifications
(AC1.3) Hand tools:
 cutting tools:
o saws (cross cut, panel, rip, coping, tenon, pad, hacksaws, diamond, tungsten
tipped, pull, hole)
o knives
o scissors
 shaping tools:
o chisels (firmer, mortise, bevel edged)
o planes (smoothing, jack, try, rebate, shoulder, bollow, moulding, block)
o spoke shaves
o drawknives
o files
o rasps
o sheers
 fixing/joining tools:
o drills
o bits and augers
o screwdrivers
o spanners
o socket sets
 measuring and marking out tools:
o tapes
o rules
o squares
o gauges
o dividers
o scribes
o spiles or ‘dummy sticks’
o levels
(AC1.3) Powered hand tools:
 drills
 sanders
 saws:
o reciprocating
o oscillating
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
70
o jigsaws
 planes
 routers
 grinder
 sheers
(AC1.4) Fastenings:
 screws
 bolts
 nails
 pins
 adhesives
 hook and loop
 welding
 rivets
 rivnuts
 fibre glass
 pop rivets
 big heads
(AC1.5) Fittings:
 sinks and drainage fittings
 cooker and shut-off
 ice box/fridge
 storage lockers
 hinges and locker catches
 fire blanket
 crockery and cutlery stowage
 fiddle
 gimble
 water system and filters
 water tanks:
o fresh
o waste (grey and black)
 water systems:
o fresh (hot and cold)
o grey and black water
 bilge:
o pump
o filter
o skin fitting
 shower, including:
o tray
o pump
o filter
 toilet
 wash basin
 skin fitting for WC and wash basin
 lighting and ventilation
 seating
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
71





chart table
navigation instruments and skin fittings
transducer
storage lockers and drawers
drawer hardware:
o catches
o furniture
 table
 heating/air conditioning systems
 wet bar
 bunks
 pilot berths
 lee boards or cloths
 hanging lockers and storage
 fire systems
 gas bottles
 gas locker
 gas alarm
(AC1.6) Checks to ensure serviceability:
 visual
 functional
 operational
 accessibility
(AC1.7) Working problems and potential hazards:
 working problems:
o sequence of activities
o access for other trades
o limited access
o availability of resources (physical, human)
 hazards:
o lack of ventilation
o fire
o access and egress
o inadequate lighting
o poor housekeeping
o dust
o fumes
o working at height
o working on water
o confined spaces
o electricity
o chemical hazards (COSHH)
o manual handling
o noise at work
o lifting
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
72
Learning outcome
The learner will:
2
Be able to position and fit interior modules, joinery and marine fittings
Assessment criteria
The learner can:
2.1
2.2
2.3
2.4
2.5
2.6
2.7
describe methods of identification of the modules, joinery and fittings to be installed
describe methods used to identify the approximate weight of the modules, joinery and
fittings for installation
describe methods to transport and lift modules, joinery and fittings to the work area
describe the criteria for choosing transporting and lifting methods for modules, joinery and
fittings
describe how to protect and prevent damage to modules, joinery and fittings during
transportation
describe how to prepare the work area for the installation of modules, joinery and fittings
align and fit modules, joinery and marine fittings
Range
(AC2.1) Methods of identification:
 identification of codes and labels
 part number
 bar coding
 visual recognition
 pattern
 catalogue or code numbers
 drawing specifications
(AC2.2) Methods used to identify the approximate weight:
 measurement and calculation
 approximation
 manufacturer’s information
 labels
(AC2.3) Methods used to transport and lift:
 lifting equipment:
o trolleys
o skates
o jacks
o pallet truck
o fork lift
o wall and overhead cranes
o slings and pull lifts
o goods lifts
o blocks and tackle
 transporting equipment:
o trolleys
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
73
(AC2.4)
(AC2.5)
(AC2.6)
(AC2.7)
o skates
o pallet truck
o forklift
 manual handling
Criteria:
 manual handling considerations:
o weight
o size safety considerations (sharp edges, awkward shape)
o available personnel
o access/transport route
 lifting equipment considerations:
o authorisation
o regulations
o lifting and slinging methods
o safe working loads
How to protect and prevent damage:
 covering and packing
 padding
 temporary supports
 temporary surface coating
Prepare the work area:
 the correct procedure for preparing the work area:
o safe access
o lighting and ventilation
o area free from contamination and obstruction
o level lines and position lines marked
o temporary jigs and support equipment in place
o inform other trades
 prepare surface by:
o cleaning
o abrading
o coating
o de-greasing
Align and fit:
 use of ‘dummy sticks’ for spiling and scribing
 use of spile boards
 locate and temporarily fasten
 temporarily secure using:
o cramps
o wedges
o battens
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
74
Learning outcome
The learner will:
3
Be able to fix and secure interior modules, joinery and marine fittings
Assessment criteria
The learner can:
3.1
3.2
3.3
3.4
3.5
3.6
describe the methods to ensure the positional accuracy of modules, joinery and marine
fittings
use fixing methods on interior modules, joinery and marine fittings
describe how to ensure the strength and security of fixed modules, joinery and marine
fittings
use hand tools and powered hand tools safely
describe the techniques used to avoid damage to the module, joinery and fittings during the
fixing process
carry out alignment and fixing quality checks
Range
(AC3.1) Methods to ensure positional accuracy:
 dimensional checks against specifications
 levelling and measuring equipment
 drawings and datum lines
 level, plumb and horning in checks
 visual checks
 relationship to other components
 declivity
(AC3.2) Fixing methods:
 mechanical fastenings:
o screws
o bolts
o nails
o rivets
o rivnuts
o big heads
o quick-release fastenings
o locknuts
o captive nuts
o nylocks
o welding
o split pins
o castle nuts
o roll pins
o R clips
o lockwire
o sheerpin
o chemical thread lock
o circlip
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
75
o e-clips
 adhesives:
o two-part epoxy
o phenol formaldehyde
o PVAs
o contact adhesive
o urea formaldehyde
o casein glue
o polyurethane (PU)
 FRP bonding:
o glass bonding
o polyester paste
o epoxy putty
o methacrylates
 sealants:
o silicon (marine)
o polyurethane
o polysulphides
o oil based
o acrylic
o jointing tape
 hook and loop, dual lock
(AC3.3) How to ensure the strength and security:
 backing pads and plates
 load spreading methods
 torque loadings
 material breaking points:
o cross braces
o knees
o webs
(AC3.4) Use hand tools and powered hand tools safely:
 fixing hand tools:
o spanners
o screwdrivers
o sockets
o ratchets
o torque wrench
o pop rivet gun
o rivnut gun
o bedding gun
o hot glue gun
o staple gun
o hammers
 powered hand tools:
o impact driver
o nut runner
o battery drill
o pop rivet gun
o staple gun
o nail gun
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
76
(AC3.5) Techniques used to avoid damage:
 maintain clean and clear working access
 clean away excess of adhesive/sealant
 avoid over-tightening fastenings
 select and use correct tools
 protective coverings
(AC3.6) Alignment and fixing quality checks:
 dimensional and geometric accuracy
 fit of joints
 functional operation of fittings (fit for purpose)
 leak test
 alignment of screw/bolt heads
 visual
 length of thread
 specification and drawings
Learning outcome
The learner will:
4
Know how to complete, inspect and protect modules, joinery and marine fittings
Assessment criteria
The learner can:
4.1
4.2
4.3
4.4
4.5
describe how to prepare for final finish inspection
describe the reasons for inspections and tests used in the installation and fitting out of
boats
explain why it is important to protect completed modules, joinery and fittings and what
methods are used
describe the records and checks required on completion of installation
describe how to reinstate the work area following completion
Range
(AC4.1) Final finish inspection:
 final polish
 wiping down
 vacuuming
 oiling
 gap filing
 smoothing and sanding
 painting
 soften or suitably finish edges
 check joins
 check fastenings, rattles and squeaks
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
77
(AC4.2) Reasons for inspection and tests:
 visual inspection:
o surface defects
o twist and alignment
o fit of joints
o fixing damage
 functional test:
o correct operation
o water-tight
o no interference with other systems
 dimensional control:
o measurement
o geometric alignment
 coding requirements:
o welding
(AC4.3) Methods:
 covering with cloth or cardboard
 wrapping with bubble wrap
 coating
 storing in secure location until required
 correct labelling
 restrict access
 floors and access panels are replaced
(AC4.4) Records and checks:
 recording of hours
 recording of materials used
 inspection checklist and records
 quality control records
 owner’s RCD installation manual
 project plan
 batch numbers
 boat file
 quality panels
(AC4.5) How to reinstate the work area:
 5s approach
 clear away all waste and discarded material
 return all tools and equipment to the stores or tool boxes/shadow board
 dismantle or return all jigs and templates to storage areas
 clean and sharpen all tools ready for the next job
 ensure the area is safe and free from dangers (risk assessment)
 ensure protection and labelling in place
 floors and access panels are replaced
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
78
Unit 207
FRP manufacture for marine construction
Unit level:
GLH:
Level 2
160
Unit aim:
This optional unit is about the requirements for successful
production of components in FRP related to marine construction.
It includes wet lay ups, use of pre-impregnated materials,
interpretation of drawings, specifications, planning moulding and
lay ups. It also covers the operations required to produce
components and safe working practices to complete FRP
construction.
Assessment type
Centre-devised practical assignment and short-answer questions
Learning outcome
The learner will:
1
Be able to interpret drawings, instructions, regulations and relevant codes of practice
Assessment criteria
The learner can:
1.1
1.2
1.3
1.4
1.5
1.6
use sources of information relevant to FRP manufacture
describe the function and physical properties of the materials used in FRP manufacture
state where to find the standards for testing FRP material specimens
use working drawings and specifications to extract the information to compile material
requirements
describe the requirements for a safe working environment
identify potential hazards when working with FRP
Range
(AC1.1) Sources of information relevant to FRP manufacture:
 codes of practice
 rules and regulations:
o Lloyd’s
o RCD
 customer/client specifications
 surveyor’s report
 manufacturers’ specifications
 safety data sheets
 scheme of work
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
79
 Boat Safety Scheme (BSS) (Inland Waterways Association)
 BS/EN standards applicable to the marine industry
 lines plans
 working drawings and designer’s specifications
 current drawing standards ISO 8888/2000
(AC1.2) Function and physical properties of the materials used in FRP manufacture:
material
function
physical properties
mould surface
create shape
strong and flexible
fabric
strength
changes state, dry
woven material, glass,
carbon, kevlar
resin
binds the fabric
2 part viscous liquid,
short pot life once
mixed, exothermic
reaction, solidifies
hardeners: slow, fast
tropical, standard,
ultra slow
mixes with resin and
cures
curing rates differ when
mixed with resin
core materials: foam,
plywood,
blockboard, balsa,
cork, honeycomb
strength, stiffness,
increases loadbearing
density, thickness and
porosity varies across
materials
filleting compounds:
colloidal silica, silica,
glass bubbles,
microfibres,
microballons
create radius to maintain
strength
mixed with resin to
create a paste
(AC1.3) Standards for testing FRP material specimens:
 BS/EN
 company practice
 manufacturers' data sheets
 Lloyd's rules
 RCD
 American standard
 technical data sheets
 safety data sheets
 design specification
(AC1.4) Working drawings and specifications:
 first and third angle orthographic projections
 oblique and isometric projections
 general layout and assembly drawings
 exploded and sectional views
 manufacturers’ drawings
 3D and digital drafts
(AC1.5) Requirements for safe working environments:
 provision of PPE
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
80
 fume cabinets
 washing facilities
 dust proof lighting
 dedicated dust and fume extraction (LEV systems)
 temperature control and humidity recording
 permitted short and long term exposure limits
 safe access and egress
 risk assessment
 RPE
 COSHH
 safe systems of work
 LOLER
 noise at work
 PAT
 grinding bay
 cutting room
 material room
 mixing room
 down draft table
(AC1.6) Potential hazards when working with FRP:
 curing agents:
o catalysts
o accelerators
o epoxy hardeners
 dust
 broken fibres
 solvents
 resin vapours
 exothermic reaction
 weight of finished components
 static cuts and burns
 health hazards
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
81
Learning outcome
The learner will:
2
Be able to plan and manufacture a mould and moulding
Assessment criteria
The learner can:
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
2.12
2.13
2.14
describe the methods of mould manufacture and maintenance and materials used
produce a simple plug to produce a mould
manufacture a basic mould
describe the need for stiffening and cradling to support moulds and hulls
identify different weave patterns used in cloth reinforcements
describe the resin ‘cure initiating’ or hardening systems used in FRP
describe the importance of correct mixing procedures for resins and additives
identify the tools, machinery, equipment and materials required for mould and lay up
operations
describe the methods used to check and monitor the resin/glass ratio
describe the methods of construction used in FRP manufacture
prepare the moulds prior to lay- up operations
explain the reasons for using templates for material preparations
list the components used in the vacuum bagging process
prepare operation sheets for simple constructions
Range
(AC2.1) Methods of mould manufacture:
 mould design considerations:
o draw off angles
o use of split moulds
o stiffening flanges and supports
o releasing methods (jacking points, compressed air points)
o stable material for mould construction
o male or female moulds
o splash mould
 mould or plug construction using:
o an existing hull to make the mould
o wood plug construction methods
o other appropriate former methods
o incorporation of inserts for fixing non skid surfaces
o skin fitting pads and recesses
o datum points for fixing internal fittings
(AC2.1) Maintenance:
 frequency of use
 production cycle
 storage
 environmental factors
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
82
(AC2.1)
(AC2.4)
(AC2.5)
(AC2.7)
 length of production
Materials:
 thermosetting plastics
 GRP
 FRP
 composite materials
 fibres used in composites such as:
o glass
o carbon
o aramid
o hemp
o woven cloths
o combination mats
o hybrid cloths
o pre-impregnated cloth (pre-pregs)
o bleed cloths
o peel ply
 resins
 pastes and liquid resins, ie:
o epoxies
o polyesters
o vinyl-esters
 ancillary materials including:
o organic peroxides (catalysts)
o accelerators
o colour pigments
o thixotropic agents
o fire retardants
o fillers
o adhesive film
o sheet and pre-shaped foam
o CNC cut kits (foam and reinforcements)
Need for stiffening and cradling:
 prevent distortion during and after manufacture
 withstand loads
 enable easy transportation
 enable tilting from side to side to gain access
 facilitate mould release
Weave pattern:
 chop strand mat
 continuous woven
 woven roving
 bi-axial
 uni-directional
 twill
 tissue
Mixing procedures:
 resin to reinforcement ratio
 percentage of pigment addition
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
83
 thixotropic agents
 fire retardants
 fillers
 weight
(AC2.8) Tools, machinery, equipment and materials:
 PPE
 RPE
 barrier creams
 release agents (wax or PVA)
 reinforcement fibre mat
 resin
 catalyst
 accelerator
 brushes
 various types of rollers consolidators
 cleaning solvents
 diamond tipped saws
 routers
 grinders
 vacuum pumps
 heat mats
 Stanley knife
 cutting shears
 mallet
 wedges
(AC2.9) Methods used to check and monitor resin/glass ratio:
 ash test
 test panel
 accurate recording of amounts used:
o weight
o percentage
o volume
o ratio
o saturation levels
(AC2.10) Methods of construction:
 contact moulding, wet lay ups
 resin transfer moulding
 use of pre-impregnated materials
 sandwich construction (use of foam, wood or honeycomb core)
 spiral winding
 vacuum bagging
 resin infusion
(AC2.11) Prepare the moulds:
 allow mould to acclimatise if brought in from outside in cold weather
 thoroughly clean
 make repairs if necessary
 surface rubbed down and polished to desired quality
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
84
 waxing and the application of release agents
(AC2.12) Reasons for using templates:
 cutting out reinforcement plies
 complex shapes
 checking profile shapes
 error proofing
 cost efficiency
 economies
 efficiency
 material efficiency
(AC2.13) Components used in the vacuum bagging process:
 porous release film
 absorption/bleeder cloth
 non-porous release cloth
 air breather
 sealing tape
 vacuum pump
 vacuum pressure gauge
 heat mats
 catch pot
 pipe work
 therma couple
Learning outcome
The learner will:
3
Be able to carry out operations correctly and in a safe manner
Assessment criteria
The learner can:
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
describe safe methods of transportation of jigs, moulds and components around the work
place
state the safety regulations and rules for safe use of lifting equipment
state the safety precautions to be observed when using FRP
prepare reinforcing materials prior to moulding
weigh and mix resins following stated specifications
carry out laminating operations
release FRP components from a mould and trim
use portable electrical equipment safely
Range
(AC3.1) Safe methods of transportation:
 casters on cradles
 trolleys
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
85
(AC3.2)
(AC3.3)
(AC3.5)
(AC3.6)
(AC3.7)
 trailers
 fork lift trucks
 manual handling
 overhead cranes
 pulley systems
Safety regulations and rules for safe use of lifting equipment:
 never exceed the safe working load (SWL)
 avoid shock loading
 never transport loads over persons
 types of sling and their safe use
 avoid twisting
 never bend around sharp corners
 importance of the angle between two slings (maximum 120o)
 all equipment should undergo periodical thorough examinations to LOLER and be
tagged
Safety precautions when using FRP materials:
 mixing of resin, catalysts and hardeners
 machining composites
 using of powered hand tools
 disposing of waste as hazardous waste
Weigh and mix resins:
 cleanliness
 weighing
 mixing
 pot life
 shelf life
 percentage
 volume
 ratio
 saturation levels
Laminating operations:
 flat panels
 curved panels
 hand lay up
 vacuum bagging
 resin infusion
 pre-impregnated
Safe use of portable electrical equipment:
 precautions against electric shock
 reduce the risk of electric shock by using low voltage supply
 regular testing of electrical equipment (PAT)
 identify safety regulations relating to electrically operated portable machine tools
including guarding, vacuum pump and trimming tools
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
86
Learning outcome
The learner will:
4
Know how to check the finished product with the specification
Assessment criteria
The learner can:
4.1
4.2
4.3
4.4
4.5
4.6
4.7
identify common manufacturing defects associated with FRP construction
describe the methods used for checking accuracy and quality components in FRP
construction
carry out visual inspection on a finished component
describe types of common damage that can occur to boat hulls and decks made of FRP
describe repair techniques available for defective FRP components
explain why it is important to protect completed modules, joinery and fittings and what
methods are used
describe how to reinstate the work area following completion
Range
(AC4.1) Common manufacturing defects:
 voids
 poor resin mix
 poor consolidation
 under saturation
 over saturation
 air bubbles
 distortion
 disbands
 star crazing
(AC4.2) Methods used for checking accuracy and quality:
 dimensional:
o measurement
o jigs
o profile
 shape:
o templates
o formers
 surface finish:
o visual inspection
 surface defects:
o visual inspection
o tap test
o use of thickness metres/gauges
o hardness test using a ‘Barcol’ test meter
o drawings and specification
(AC4.4) Common damage:
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
87
 impact
 osmosis
 scratches and gouges
 water ingress
 delamination
 disbond
 degradation
 cracks
 star crazing
(AC4.5) Repair techniques:
 gel coat repairs
 repairs made from inside component
 repairs made from outside component
 splash moulds
(AC4.6) Methods:
 covering with cloth or cardboard
 wrapping with bubble wrap
 coating
 storing in secure location until required
 correct labelling
(AC4.7) How to reinstate the work area:
 5s approach
 clear away all waste and discarded material
 return all tools and equipment to the stores or tool boxes/shadow board
 dismantle or return all jigs and templates to storage areas
 clean and sharpen all tools ready for the next job
 ensure the area is safe and free from dangers (risk assessment)
 ensure protection and labelling in place
 floors and access panels are replaced
Dummy Appendixes Chapter Title - please do not include in output
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
88
Appendix 1
Sources of general information
The following documents contain essential information for centres delivering City & Guilds
qualifications. They should be referred to in conjunction with this handbook. To download the
documents and to find other useful documents, go to the Centres and Training Providers homepage
on www.cityandguilds.com.
Centre Manual - Supporting Customer Excellence contains detailed information about the processes
which must be followed and requirements which must be met for a centre to achieve ‘approved
centre’ status, or to offer a particular qualification, as well as updates and good practice exemplars
for City & Guilds assessment and policy issues.
Specifically, the document includes sections on:
 The centre and qualification approval process
 Assessment, internal quality assurance and examination roles at the centre
 Registration and certification of candidates
 Non-compliance
 Complaints and appeals
 Equal opportunities
 Data protection
 Management systems
 Maintaining records
 Assessment
 Internal quality assurance
 External quality assurance.
Our Quality Assurance Requirements encompasses all of the relevant requirements of key
regulatory documents such as:


SQA Awarding Body Criteria (2007)
NVQ Code of Practice (2006)
and sets out the criteria that centres should adhere to pre and post centre and qualification
approval.
Access to Assessment & Qualifications provides full details of the arrangements that may be made
to facilitate access to assessments and qualifications for candidates who are eligible for
adjustments in assessment.
The centre homepage section of the City & Guilds website also contains useful information on
such things as:



Walled Garden: how to register and certificate candidates on line
Events: dates and information on the latest Centre events
Online assessment: how to register for e-assessments.
Centre Guide – Delivering International Qualifications contains detailed information about the
processes which must be followed and requirements which must be met for a centre to achieve
‘approved centre’ status, or to offer a particular qualification.
Specifically, the document includes sections on:
 The centre and qualification approval process and forms
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
89







Assessment, verification and examination roles at the centre
Registration and certification of candidates
Non-compliance
Complaints and appeals
Equal opportunities
Data protection
Frequently asked questions.
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
90
Appendix 2
Useful contacts
UK learners
General qualification information
International learners
General qualification information
Centres
Exam entries, Certificates,
Registrations/enrolment, Invoices, Missing
or late exam materials, Nominal roll reports,
Results
E: [email protected]
F: +44 (0)20 7294 2413
E: [email protected]
F: +44 (0)20 7294 2413
E: [email protected]
Single subject qualifications
Exam entries, Results, Certification, Missing
or late exam materials, Incorrect exam
papers, Forms request (BB, results entry),
Exam date and time change
F: +44 (0)20 7294 2413
F: +44 (0)20 7294 2404 (BB forms)
E: [email protected]
International awards
Results, Entries, Enrolments, Invoices,
Missing or late exam materials, Nominal roll
reports
F: +44 (0)20 7294 2413
E: [email protected]
Walled Garden
Re-issue of password or username,
Technical problems, Entries, Results, eassessment, Navigation, User/menu option,
Problems
Employer
Employer solutions, Mapping, Accreditation,
Development Skills, Consultancy
Publications
Logbooks, Centre documents, Forms, Free
literature
F: +44 (0)20 7294 2413
E: [email protected]
T: +44 (0)121 503 8993
E: [email protected]
F: +44 (0)20 7294 2413
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.
If you have a complaint, or any suggestions for improvement about any of the services that we
provide, email: [email protected]
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
91
About City & Guilds
As the UK’s leading vocational education organisation, City & Guilds is leading the talent revolution
by inspiring people to unlock their potential and develop their skills. We offer over 500 qualifications
across 28 industries through 8500 centres worldwide and award around two million certificates
every year. City & Guilds is recognised and respected by employers across the world as a sign of
quality and exceptional training.
City & Guilds Group
The City & Guilds Group is a leader in global skills development. Our purpose is to help people and
organisations to develop their skills for personal and economic growth. Made up of City & Guilds,
City & Guilds Kineo, The Oxford Group and ILM, we work with education providers, businesses and
governments in over 100 countries.
Copyright
The content of this document is, unless otherwise indicated, © The City and Guilds of London
Institute and may not be copied, reproduced or distributed without prior written consent. However,
approved City & Guilds centres and candidates studying for City & Guilds qualifications may
photocopy this document free of charge and/or include a PDF version of it on centre intranets on
the following conditions:


centre staff may copy the material only for the purpose of teaching candidates working towards
a City & Guilds qualification, or for internal administration purposes
candidates may copy the material only for their own use when working towards a City & Guilds
qualification
The Standard Copying Conditions (see the City & Guilds website) also apply.
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.
Published by City & Guilds, a registered charity established to promote education and training
City & Guilds
1 Giltspur Street
London EC1A 9DD
T +44 (0)844 543 0000
F +44 (0)20 7294 2413
www.cityandguilds.com
Level 2 Diploma in Boatbuilding (foundation) (2473-02)
92
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertisement