SAQA All qualifications and part qualifications registered on the National Qualifications Framework are public property. Thus the only payment that can be made for them is for service and reproduction. It is illegal to sell this material for profit. If the material is reproduced or quoted, the South African Qualifications Authority (SAQA) should be acknowledged as the source.
SOUTH AFRICAN QUALIFICATIONS AUTHORITY 
REGISTERED UNIT STANDARD: 

Fabricate specialised polymer composite parts and complex assemblies 
SAQA US ID UNIT STANDARD TITLE
110283  Fabricate specialised polymer composite parts and complex assemblies 
ORIGINATOR
SGB Plastics Manufacturing 
PRIMARY OR DELEGATED QUALITY ASSURANCE FUNCTIONARY
-  
FIELD SUBFIELD
Field 06 - Manufacturing, Engineering and Technology Manufacturing and Assembly 
ABET BAND UNIT STANDARD TYPE PRE-2009 NQF LEVEL NQF LEVEL CREDITS
Undefined  Regular  Level 4  NQF Level 04  28 
REGISTRATION STATUS REGISTRATION START DATE REGISTRATION END DATE SAQA DECISION NUMBER
Reregistered  2018-07-01  2023-06-30  SAQA 06120/18 
LAST DATE FOR ENROLMENT LAST DATE FOR ACHIEVEMENT
2024-06-30   2027-06-30  

In all of the tables in this document, both the pre-2009 NQF Level and the NQF Level is shown. In the text (purpose statements, qualification rules, etc), any references to NQF Levels are to the pre-2009 levels unless specifically stated otherwise.  

This unit standard does not replace any other unit standard and is not replaced by any other unit standard. 

PURPOSE OF THE UNIT STANDARD 
The skills, values and knowledge reflected in this unit standard are required by people in the field of polymer composite fabrication. The fabrication of composites requires the combination of two or more different materials to form a product. What makes composites unique is that a composite material is formed at the same time as the structure itself is being fabricated. This means that the person who is making the structure is creating the properties of the resultant composite material, and so the manufacturing processes that are used have an unusually critical part to play in determining the performance of the resultant structure. Composites are not like metals, where a sheet might be made in one factory and shaped into a car roof in another. With composites it all happens at once. The products are often subjected to considerable or sometimes extreme stress when in operation and the manufacturing process needs to be consistent and accurate.

Qualifying learners are able to:
  • Fabricate specialised composite parts
  • Fabricate complex polymer composite assemblies
  • Co-ordinate fabrication activities to fabricate specialised fabrications or complex assemblies
  • Set up and maintain fabrication equipment

    Specialised parts and complex assemblies are products which:
  • Are special purpose by nature, ie limited quantities, one-offs
  • Are intended for extreme conditions
  • Are safety critical
  • Use specialised fabrication techniques
  • Require specialised resins and reinforcements or combinations
  • Require several components to be accurately aligned and joined
  • Will be used as tooling or as moulds for complex parts
  • Have bio-medical applications, eg prosthetics
  • Are generally cured at elevated temperatures

    Fabrication also includes repairs or modifications to specialised parts.

    The following examples are intended to illustrate the kind of part but not to act as a limitation: ships, complex boat hulls, structural aircraft parts and control surfaces, pressurised vessels, chemical processing plant, parts intended for motor sport, civil engineering structures.

    The learning outcomes in this unit standard contribute to the exit level outcomes required for the National Certificate in Polymer Composite Fabrication (NQF Level 4) and related qualifications. 

  • LEARNING ASSUMED TO BE IN PLACE AND RECOGNITION OF PRIOR LEARNING 
    This unit standard has been designed as part of a progression. It is one of a series of unit standards for activities below, at and above this level. The credits assigned to it are based on the assumption that I am learning what is needed for this unit standard as part of my learning for a range of related unit standards. If I have experience in these related activities but do not have credits for them, I can obtain credits by being assessed through a process that recognises prior learning. If I do not have such experience of related activities, then my learning time will be increased. I can choose to be assessed and obtain credits against those other unit standards as I make progress towards the outcomes of this unit standard. 

    UNIT STANDARD RANGE 
    The scope and level of this unit standard is determined by the ranges as indicated under the specific outcomes.
    Fabrication includes repair, manufacture of moulds or tooling
    Resin and reinforcement also includes pre-impregnated materials, core materials, fillers. 

    Specific Outcomes and Assessment Criteria: 

    SPECIFIC OUTCOME 1 
    Verify materials specified against the drawing or works instruction. 
    OUTCOME NOTES 
    Verify materials specified against the drawing or works instruction, verify information related resin and reinforcements, plan the fabrication process, generate relevant documentation and brief team members. 
    OUTCOME RANGE 
    Resins: polyester, vinyl ester, epoxy, furane, urethane, acrylic
    Additives: accelerators, catalysts, hardeners, fillers, pigments, release agents, flame retardant
    Reinforcements: glass, carbon, aramid, uni/multiaxial, pre-pregs, core materials. 

    ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    Refer to consolidated Assessment Criteria in Specific Outcome 9. 

    SPECIFIC OUTCOME 2 
    Draw, check and prepare materials for the fabrication process. 
    OUTCOME RANGE 
    Prepare material includes formulating and mixing resins, additives, catalysts, hardeners, accelerators and initiators; measuring, laying out and cutting of reinforcements; thawing, pre-heating and preparation of pre-impregnated 

    ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    Refer to consolidated Assessment Criteria in Specific Outcome 9. 

    SPECIFIC OUTCOME 3 
    Prepare moulds and tooling, apply release agents and surface finish materials. 
    OUTCOME NOTES 
    Prepare moulds and tooling, apply release agents and surface finish materials, lay up and consolidate the matrix. 
    OUTCOME RANGE 
    Lay up includes filled resin systems
    Processes include: Spray coatings and lay-ups, vacuum infusion, bagging, resin transfer moulding (RTM), autoclaves. 

    ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    Refer to consolidated Assessment Criteria in Specific Outcome 9. 

    SPECIFIC OUTCOME 4 
    Establish set-up conditions, set up, operate, shut down and maintain processing machinery. 
    OUTCOME RANGE 
    Machinery includes autoclaves, vacuum machinery, resin pumps, spray equipment. 

    ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    Refer to consolidated Assessment Criteria in Specific Outcome 9. 

    SPECIFIC OUTCOME 5 
    Prepare joints, align and bond parts and sections. 

    ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    Refer to consolidated Assessment Criteria in Specific Outcome 9. 

    SPECIFIC OUTCOME 6 
    Demould and post-treat products. 
    OUTCOME RANGE 
    Post-treat includes trimming, finishing edges, polishing surface, balancing. 

    ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    Refer to consolidated Assessment Criteria in Specific Outcome 9. 

    SPECIFIC OUTCOME 7 
    Identify and rectify fabrication faults and complete records. 

    ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    Refer to consolidated Assessment Criteria in Specific Outcome 9. 

    SPECIFIC OUTCOME 8 
    Verify conformance, test and hand over the final product. 

    ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    Refer to consolidated Assessment Criteria in Specific Outcome 9. 

    SPECIFIC OUTCOME 9 
    Interact with work group members and clients. 

    ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    The assessment criteria have been formulated in this way to provide guidance to assessors:
  • For the purposes of integrated assessment.
  • To achieve a balance between performing tasks and understanding.
  • To focus on the achievement of the purpose of the unit standard.

    Results achieved
  • Finished product meets specification.
  • Records are completed.
  • Instructions are understood and carried out.

    Indicators
  • Analytical and methodical approach to planning, fabrication and problem solving is demonstrated.
    > Each step has been verified.
    > Materials, equipment and resources are used efficiently.
  • Equipment is set up, operated and shut down according to equipment specifications and work instructions.
  • Equipment, tools and tooling, materials and safety equipment are cared for and used responsibly and according to work instructions.
  • Healthy group dynamics is maintained.
    > Tone of instructions (respect, two-way communication).
    > Group participation in achieving objectives.
  • All aspects of the fabrication process are dealt with consistently and conform to specification.

    Understanding confirmed
  • Demonstrate understanding by discussing questions related to all as pects of the fabrication process planning, fabrication, workgroup relationships and quality issues.
  • Link theoretical concepts to the design and the product specifications. 


  • UNIT STANDARD ACCREDITATION AND MODERATION OPTIONS 
    My assessment will be governed by the policies and guidelines of the MERSETA Education and Training Quality Assuror which has jurisdiction over this field of learning. My assessor will (at the very least) be accredited and have a technical qualification in this learning area.

    I can be assessed in the language of my choice although if I have to report incidents or conditions to someone else, I will be assessed on my ability to report in the language commonly used in my working environment.

    I will be assessed in the workplace but I can submit documents, projects, test results and assignments that were not produced in the workplace.

    I can be assessed against this unit standard to obtain credits or as part of an integrated assessment for a qualification. 

    UNIT STANDARD ESSENTIAL EMBEDDED KNOWLEDGE 
    1. Names & functions of:
  • Materials
  • Symbols, abbreviations, conventions
  • Measuring equipment, scales and rulers
  • Specialised materials
  • Product components and design features

    2. Purpose of:
  • Various types of polymeric materials, fillers, reinforcements and core materials
  • Materials handling and preparation processes and procedures
  • End-product

    3. Attributes, properties characteristics
  • Properties of materials
  • Specialised materials

    4. Sensory cues
  • Smell and feel of properly and improperly formulated mixed and cured material

    5. Processes, event
  • Preparation, laying up, consolidating the matrix
  • Monitoring the cure
  • Product finishing, assembly and fittings
  • Machine set up variables - temperature and pressure schedules, mixing ratios, application rates

    6. Causes and effects, implications:
  • Implications of poor planning
  • Implications of particular environmental conditions
  • Implications of poor fabrication practices
  • Effects of materials on processing equipment, health and the environment
  • Causes and remedies of problems related to materials and the fabrication process.

    7. Procedures and techniques:
  • Ratios and measuring and mixing of materials
  • Laying out and cutting of materials,
  • Calculations of angles and orientation of fibres
  • Fabrication of specialised materials, complex geometries
  • Reporting of problems
  • Recording of data

    8. Theory: rules, principles, laws:
  • Forces, pressure, rheology, temperature (exothermic reactions, activation energy) change of state, wetting, capillary action
  • Structure of polymers; polymerisation and cross-linking reactions: influence of catalysts, accelerators, monomers, inhibitors, diluents, contaminants, temperature and humidity
  • Scientific concepts related to pressure, temperature, density, ratios, strength, modulus
  • Performance of polymers, reinforcements and composites

    9. Relationships, systems:
  • Relationship between humidity and temperature and processing times and characteristics. 

  • UNIT STANDARD DEVELOPMENTAL OUTCOME 
    N/A 

    UNIT STANDARD LINKAGES 
    N/A 


    Critical Cross-field Outcomes (CCFO): 

    UNIT STANDARD CCFO IDENTIFYING 
    Identify and solve problems
  • Anticipate and prevent problems 

  • UNIT STANDARD CCFO WORKING 
    Work effectively with others
  • Lead a workgroup
  • Enforce manufacturing standards with workgroup (discipline, codes) 

  • UNIT STANDARD CCFO ORGANISING 
    Organise and manage myself and my activities
  • Manage resources and maintain efficiency
  • Plan and sequence work in workgroup 

  • UNIT STANDARD CCFO COLLECTING 
    Collect, analyse, organise and critically evaluate information
  • Collate, verify and apply information form various sources, eg codes of practice, engineering drawings, quality procedure manuals, material and equipment manuals. 

  • UNIT STANDARD CCFO COMMUNICATING 
    Communicate effectively
  • Ensure understanding of instructions
  • Compile and make oral and written reports. 

  • UNIT STANDARD CCFO SCIENCE 
    Use science and technology effectively and critically
  • Evaluate the impact of the environment on the process and make adjustments accordingly. 

  • UNIT STANDARD CCFO DEMONSTRATING 
    Demonstrate an understanding of the world as a set of related systems
  • Understand and apply processes and relationships of:
  • Fabrication and end use
  • Workgroup
  • Customer 

  • UNIT STANDARD ASSESSOR CRITERIA 
    N/A 

    REREGISTRATION HISTORY 
    As per the SAQA Board decision/s at that time, this unit standard was Reregistered in 2012; 2015. 

    UNIT STANDARD NOTES 
    N/A 

    QUALIFICATIONS UTILISING THIS UNIT STANDARD: 
      ID QUALIFICATION TITLE PRE-2009 NQF LEVEL NQF LEVEL STATUS END DATE PRIMARY OR DELEGATED QA FUNCTIONARY
    Core  36153   National Certificate: Polymer Composite Fabrication  Level 4  Level TBA: Pre-2009 was L4  Reregistered  2023-06-30  MERSETA 
    Elective  50560   Further Education and Training Certificate: Small Craft Construction  Level 4  NQF Level 04  Passed the End Date -
    Status was "Registered" 
    2009-08-31  Was MERSETA until Last Date for Achievement 


    PROVIDERS CURRENTLY ACCREDITED TO OFFER THIS UNIT STANDARD: 
    This information shows the current accreditations (i.e. those not past their accreditation end dates), and is the most complete record available to SAQA as of today. Some Primary or Delegated Quality Assurance Functionaries have a lag in their recording systems for provider accreditation, in turn leading to a lag in notifying SAQA of all the providers that they have accredited to offer qualifications and unit standards, as well as any extensions to accreditation end dates. The relevant Primary or Delegated Quality Assurance Functionary should be notified if a record appears to be missing from here.
     
    1. Plastics Federation of South Africa (MAITLAND) (TP) 
    2. Plastics Federation of South Africa (MIDRAND) (TP) 
    3. Plastics Federation of South Africa (WESTMEAD) (TP) 



    All qualifications and part qualifications registered on the National Qualifications Framework are public property. Thus the only payment that can be made for them is for service and reproduction. It is illegal to sell this material for profit. If the material is reproduced or quoted, the South African Qualifications Authority (SAQA) should be acknowledged as the source.