Level 3 Automotive BTEC

This subject is broken down into 57 topics in 14 modules:

  1. Health and Safety in the Automotive Work Environment 4 topics
  2. Automotive Foundation Engineering 5 topics
  3. Advanced Automotive Systems 4 topics
  4. Vehicle Chassis Systems 4 topics
  5. Automotive Engines and Engine Services 4 topics
  6. Vehicle Body Repair Principles 4 topics
  7. Advanced Automotive Body Repair 4 topics
  8. Vehicle Paint Refinishing 4 topics
  9. Vehicle Trim and Upholstery 4 topics
  10. Light Vehicle Transmission Systems 4 topics
  11. Vehicle Air Conditioning Systems 4 topics
  12. Vehicle Inspection and Testing 4 topics
  13. Hybrid and Electric Vehicle Technology 4 topics
  14. Motorcycle Engineering 4 topics
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  • 14
    modules
  • 57
    topics
  • 21,390
    words of revision content
  • 2+
    hours of audio lessons

This page was last modified on 28 September 2024.

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Automotive

Health and Safety in the Automotive Work Environment

Health and safety legislation

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Health and safety legislation

Health and Safety Legislation in the Automotive Industry

Understanding Legislation

  • The Health and Safety at Work Act 1974 (HSWA) is the primary piece of legislation covering occupational health and safety in the UK which also applies to the automotive industry.
  • It sets out the general duties which employers have towards employees and members of the public, and employees have to themselves and each other.
  • HSWA is enforced by The Health and Safety Executive (HSE) and local authorities.
  • HSE also provides guidance, advice, templates and tools for businesses to ensure they comply with the legislation.

Responsibilities of Employers

  • Employers are legally obliged to ensure the health, safety and welfare at work of all their employees.
  • They are responsible for providing a safe and secure working environment, safe systems of work, safe tools and machinery, and appropriate training and supervision.
  • Employers must carry out risk assessments to identify potential hazards and decide how to prevent harm.

Responsibilities of Employees

  • Employees have a duty to take care of their own health and safety and that of others who may be affected by their actions at work.
  • They must cooperate with employers and co-workers to help everyone meet their legal requirements.
  • Employees should not interfere with anything provided to safeguard their health and safety, follow provided instructions, and report any health and safety concerns to their employer.

Control of Substances Hazardous to Health (COSHH)

  • The COSHH Regulations 2002 require employers to control substances that are hazardous to workers' health.
  • In the automotive industry, this can include solvents and paints, petrol and diesel, adhesives, oils, brake fluids and battery acids.
  • Measures might include reducing the use of a hazardous substance, isolating workers from exposure, and providing protective workwear.

Personal Protective Equipment (PPE)

  • The Personal Protective Equipment at Work Regulations 1992 requires employers to provide appropriate protective clothing and equipment for their employees.
  • Examples in the automotive industry include steel-toe boots, gloves, overalls, eye protection, and head protection.

Workplace (Health, Safety and Welfare) Regulations 1992

  • These regulations ensure that workers have suitable welfare facilities including toilets, washing facilities, drinking water, and seating for breaks.
  • They also contain requirements for certain aspects such as general cleanliness, temperature, space, lighting and ventilation in the workplace.

Reporting of Injuries, Diseases and Dangerous Occurrences Regulations (RIDDOR)

  • RIDDOR 2013 requires employers, the self-employed and those in control of work premises to report certain serious workplace accidents, occupational diseases and near misses to HSE.
  • In the automotive industry, reportable injuries might include major injuries, like serious burns, mechanical contact injuries (being caught between rolling, moving or falling objects), and dangerous incidents like the collapse or failure of load-bearing parts.

Course material for Automotive, module Health and Safety in the Automotive Work Environment, topic Health and safety legislation

Automotive

Vehicle Paint Refinishing

Paint system components

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Paint system components

Fundamentals of Paint System Components

  • A Paint System typically consists of several coats: the primer, the basecoat and the clearcoat.
  • The Primer serves two main purposes: it helps the paint to adhere to the surface, and it provides a rust-inhibitor.
  • The Basecoat provides the colour. It can be a single layer or multiple layers for more complex colour schemes.
  • The Clearcoat seals and protects the basecoat, giving the finish its gloss and durability.

Primer

  • The primer is applied to a bare metal surface and provides crucial adhesion for the basecoat.
  • It often contains anti-corrosion chemicals to protect the metal from rust.
  • Primer can be Etch Primer or Epoxy Primer depending on its chemical composition.
  • Etch Primer uses phosphoric acid to etch into bare metal surfaces for better adhesion.
  • Epoxy Primer is a non-etching primer, meaning it simply provides a smooth surface for the paint to adhere to.

Basecoat

  • The basecoat is where the main colour of the car's finish is provided.
  • Basecoat can be a solid, metallic or pearlescent colour.
  • It's typically applied in multiple layers to develop complexity and depth of colour.
  • Modern basecoats are commonly water-based, echoing a larger industry shift towards more eco-friendly materials.

Clearcoat

  • The clearcoat or lacquer is the final coat and provides both aesthetic and functional benefits.
  • Its transparency allows the basecoat colour to shine through while adding a glossy finish.
  • It provides a hard protective layer which guards against weather damage, bird droppings, stone chips and UV light.
  • The gloss level of the clearcoat can be manipulated to give a matte, satin or high gloss finish.
  • Some clearcoats include UV inhibitors to reduce fading or yellowing caused by sunlight exposure.

Paint System Additives

  • Thinner or Reducer is added to the paint to bring it to the right viscosity for application.
  • Hardener or Catalyst is added to the clearcoat to speed up the drying process.
  • A Flex Agent can be added to make the paint flexible and less likely to crack when used on a flexible surface.
  • Fisheye Eliminator can be added to prevent the formation of small craters or "fisheyes" in the finish.

Remember, the quality and longevity of the paint finish relies heavily on correctly applying each component in the correct order. Each layer of the paint system plays a vital role in the overall result.

Course material for Automotive, module Vehicle Paint Refinishing, topic Paint system components

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