Apply plural component coatings. Learner resource. Supporting the LMF02. Light Manufacturing Furnishing Training Package

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1 Learner resource Supporting the LMF02 Light Manufacturing Furnishing Training Package

2 These materials were developed by Manufacturing Skills Australia. Manufacturing Skills Australia With the exception of any material protected by a trade mark and where otherwise noted, all material presented in this document is provided under a Creative Commons Attribution-No Derivative Works 3.0 Australia licence. Disclaimer This work is the result of consultations with Australian industry participants. It is a collaborative view and does not necessarily represent the view of Manufacturing Skills Australia or any specific body. For the sake of brevity it may omit factors which could be pertinent in particular cases. While care has been taken in the preparation of this material, Manufacturing Skills Australia and the original developer do not warrant that any licensing or registration requirements specified here are either complete or up-to-date for your State or Territory. Manufacturing Skills Australia and the original developer do not accept any liability for any damage or loss (including indirect and consequential loss) incurred by any person as a result of relying on the information contained in this material. Manufacturing Skills Australia, does not accept any liability to any person for the information or advice (or the use of such information or advice) which is provided in this material or incorporated into it by reference. The information is provided on the basis that all persons accessing this material undertake responsibility for assessing the relevance and accuracy of its content. No liability is accepted for any information or services which may appear in any other format. No responsibility is taken for any information or services which may appear on any linked websites. Published by: Manufacturing Skills Australia Release Date: 2008 For further information about this resource or any other work being undertaken by Manufacturing Skills Australia (MSA), please visit: Manufacturing Skills Australia Level 3, 104 Mount Street North Sydney NSW 2060 T: F: E: info@mskills.org.au W:

3 Contents About this resource... 1 How to use this resource... 1 How will I be assessed?... 2 What other resources are available?... 2 Introduction... 3 Quality assurance... 3 Preparing for work... 5 Health and safety... 5 Material safety data sheets... 7 Planning your work Surface preparation Tools and equipment Preparing for application of plural component coatings Checking surface preparation Preparing materials for coating Spray booth preparation Cleaning booth surfaces and floors Trialing applications Applying plural component coatings Applying the finishing materials Cleaning up Cleaning equipment Cleaning the work area Completing workplace records Activities Learning checklist Assessment checklist... 45

4 About this resource This resource has been developed to provide you with the underpinning knowledge required to assist you in applying plural component coatings. This resource also contains activities to test your underpinning knowledge, a learning checklist to monitor your experiences and an example assessment checklist. Industry trainers and Registered Training Organisations (RTOs) may use this resource as a learning and assessment tool. It is not compulsory and is provided as a support to the LMF02 Furnishing Training Package. Trainers and assessors should check they have the most current unit of competency by checking the National Training Information Service at or Manufacturing Skills Australia at How to use this resource This resource is divided into four main sections: underpinning knowledge and background information on applying plural component coatings activities to test your underpinning knowledge of applying plural component coatings a learning checklist which allows you to monitor your experiences in applying plural component coatings An example assessment checklist which will help you demonstrate competency. To complete this resource you should: read the information contained in the resource complete the activities as instructed have your answers checked by your trainer work with your trainer to practice applying plural component coatings read the assessment checklist complete an assessment. If you are having difficulties completing this resource because you do not have sufficient background knowledge or literacy skills, you should ask your trainer for assistance. Manufacturing Skills Australia 2008 Page 1

5 How will I be assessed? Your trainer and/or assessor will decide with you how and when you will be assessed. Your assessment should allow you to demonstrate all the skills and knowledge required to apply plural component coatings. This unit may be assessed in conjunction with other units of competency. Your trainer and/or assessor will tell you if you will be assessed this way. What other resources are available? To assist you complete this resource the following websites have been suggested for additional information. You should also research supplier information and manufacturers brochures. Websites Manufacturing Skills Australia 2008 Page 2

6 Introduction Plural component coatings are versatile materials that may be used as a complete finishing system. For example, two part sealer with two part top coat, or in conjunction with other finishing materials, for example, two part sealer with a lacquer-based top coat. Plural component coatings may be applied to solid timber, manufactured board and metal, however always check product specifications to make sure they are compatible. Plural component materials are more often known in the trade as 'two pot' coatings, one being the resin and the other the hardener. However, there are some products that consist of three parts, the resin, the hardener and another component, which depending upon the product, improves gloss or flow out. These components must be mixed together in precise proportions before use. Once mixed, a chemical reaction begins resulting in a hard film and once this reaction has started it cannot be reversed. This chemical reaction is also known as curing. This resource will look at: preparing for work preparing for application of plural component coatings applying plural component coatings cleaning up. Quality assurance Quality assurance is an important factor in planning your work. When effective quality principles are practiced by businesses they tend to generate benefits resulting in improved quality, which in turn leads to increased productivity, sales, and customer satisfaction. Quality assurance is a term used to describe the introduction, documentation and standardisation of quality systems and all the procedures that go with them to give us, and our customers, confidence that all our products or services will meet their requirements. Quality assurance is achieved by: providing a clear vision or idea of what quality is and how it can be achieved providing support and commitment to the process developing policy and procedures Manufacturing Skills Australia 2008 Page 3

7 providing empowerment for people to solve customer problems and produce quality providing support, encouragement, or coaching establishing customer information systems to find out whether customers are happy with the products creating self-managing work teams that are able to solve the customers' problems providing training establishing quality and productivity targets providing positive feedback, encouragement, support and information about achievement of targets. Manufacturing Skills Australia 2008 Page 4

8 Preparing for work The application of plural component materials requires careful preparation. As these materials are considered a health risk, care must be taken to ensure that all workers likely to come into contact with the product during and after application are protected. Furthermore, plural component polyurethane and polyester, dries much faster than solvent based coatings so the application needs to be carefully planned so that the work is ready for coating before the material begins to cure. If the coating 'sets' during application not only will it be wasted, but the spray equipment would be ruined. Consideration also needs to be given to the drying of the job once coated. As these materials take longer than solvent based coatings to dry, and are generally much more expensive, it is important to have an area away from the general work area for drying, otherwise these surfaces will be spoilt and require recoating. In this section we will look at: health and safety planning the work surface preparation tools and equipment. Health and safety Following health and safety procedures is very important to make sure you and your workmates are not injured at work. The application of most surface coatings is considered a health risk. However, there is an added risk with the use of two part polyurethane and polyester products as they contain free isocyanate. Polishers with a history of asthma or respiratory problems and those known to be sensitive to isocyanates should take particular precautions. If possible these people should not be engaged in any work involving these materials. Sensitisation is a condition in which breathing or skin conditions can return with increasing severity with any further exposure to the original sensitising agent, or similar substances even at very low exposures. If any reaction to these products is noted immediately stop using the material and seek medical advice. Symptoms include distress, dry throat and cough, severe headache, asthmatic breathing and chest tightening. Continued use may lead to permanent respiratory problems. Dusts from solid forms of isocyanates are also hazardous and should not be inhaled. Burning or breaking down polyurethane materials by heating may lead to the production of free isocyanates and a number of toxic gases such as carbon monoxide and hydrogen Manufacturing Skills Australia 2008 Page 5

9 cyanide. Isocyanates react slowly with water to produce carbon dioxide. While this is not in itself a hazardous reaction, dangerous pressures can develop inside closed containers if any isocyanate becomes contaminated with water. As isocyanate can only be smelled at concentrations considered to be harmful, it is dangerous to rely on odour to detect the presence of an isocyanate. Due to these added risks, careful consideration must be given to appropriate workflow for the application of these materials. Before mixing material make sure that appropriate personal protective equipment (PPE) is worn. Only sufficient material required for the item being coated should be mixed (bulk material should be kept in a properly constructed store) and this should be done in a well ventilated area such as a mixing booth or spray booth. Make sure that equipment is set up and operating to specifications prior to application and that all coating is applied in a properly constructed booth. Once coated, items should be placed in a drying room/area away from other workers so that they are not affected by fumes. Occupational health and safety legislation All states and territories have occupational health and safety (OHS) legislation that must be followed by all workplaces. This legislation covers: building codes material safety management systems hazardous substances and dangerous goods codes manual handling PPE. Workplaces also need to work within the boundaries of state and territory environmental legislation and health regulations. It is a good idea to find out what the regulations are for your local area. Manufacturing Skills Australia 2008 Page 6

10 Material safety data sheets Material safety data sheets (MSDS) are an important part in the correct handling, transporting, storage and application of hazardous goods and substances. The MSDS list all the relevant safety details that might affect: the user future processes the materials themselves other goods, substances and/or materials that the referenced materials are likely to come in contact with. MSDS satisfy Australian Standards on the responsibilities of the manufacturer and those who are likely to be associated with the substance at any stage of its life. An example of the headings and their content in a MSDS are given on the following pages. If you have difficulty understanding any of the information on the MSDS, the National Code of Practice for the Preparation of MSDS (NOHSC: 2011) provides a definition for each of the recommended information categories. This is available on the Australian Safety and Compensation Council website, Manufacturing Skills Australia 2008 Page 7