1 Table of contents 164

2025-05-02_BR_V5

Version 5 is valid from 2nd May, 2025 Version 4 is valid until 1st October, 2025

1. List of Abbreviations		4
2. Terms and Definitions		4
3. Change Log		5
4. Scope		6
5. General Requirements for the GWO Blade Repair		6
5.1 Target Group		6
5.2 Aims and Objectives		6
5.3 Validity Period		7
5.4 Course Codes		7
5.5 Participant Prerequisites for the Blade Repair Module		7
6. General Resources Required to Deliver Blade Repair Module		7
6.1 Instructors		7
6.2 Practical Training Facilities		8
6.3 Training Equipment		9
7. Using this Standard to Develop Training		9
8. Administration and Certification of Module		9
8.1 Participant Performance Assessment		9
9. Module – Blade Repair		12
9.1 Aims and Objectives of the Blade Repair Module		12
9.2 Duration		13
9.3 Blade Repair Module Participant Ratio		13
9.4 Blade Repair Module Timetable		13
9.5 Detailed Description of the Blade Repair Module		19
Lesson 1 - Introduction to the training		19
ELEMENT 1.1 - Safety instructions and emergency procedures		19
ELEMENT 1.2 - Facilities		20
ELEMENT 1.3 - Introduction		20
ELEMENT 1.4 - Scope and main learning objectives		21
ELEMENT 1.5 - Ongoing assessments (participant assessment form)		21
ELEMENT 1.6 - Motivation		22
ELEMENT 1.7 - Human factors		22
Lesson 2 - Safety data sheets		24
ELEMENT 2.1 - Safety Data Sheets		24
ELEMENT 2.2 - Safety data sheet location		25
ELEMENT 2.3 - Safety instructions		25
ELEMENT 2.4 - Hazard labels and symbols		26
ELEMENT 2.5 - Personal protective equipment		27
Lesson 3 - Work instruction		27
ELEMENT 3.1 - work instruction (WI)		28
ELEMENT 3.2 - Locate work instruction		28
Lesson 4 - Risk assessment		29
ELEMENT 4.1 - Risk assessments		29
ELEMENT 4.2 - Updated risk assessment		30
Lesson 5 - Secure an area		30
ELEMENT 5.1 - Locate procedures		31
ELEMENT 5.2 - Securing the area		31
Lesson 6 - Contamination		32
ELEMENT 6.1 - Characteristics		32
ELEMENT 6.2 - Work instructions as mitigation		33
ELEMENT 6.3 - Avoiding contamination		33
Lesson 7 - Waste segregation		35
ELEMENT 7.1 - Why segregate waste?		35
ELEMENT 7.2 - Correct waste segregation		35
ELEMENT 7.3 - Waste segregation information		36
Lesson 8 - Ergonomics		36
ELEMENT 8.1 - Classroom		37
ELEMENT 8.2 - Workshop		37
ELEMENT 8.3 - Bladework		37
Lesson 9 - Lock out tag out (LOTO)		38
ELEMENT 9.1 - Lock out tag out		39
Lesson 10 - Personal protective equipment		39
ELEMENT 10.1 - Purpose		40
ELEMENT 10.2 - Application		40
ELEMENT 10.3 - Limitations		41
ELEMENT 10.4 - Task specific		41
ELEMENT 10.5 - Disposal		42
Lesson 11 - Masks and filters		43
ELEMENT 11.1 - Purpose		43
ELEMENT 11.2 - Filter categories		43
ELEMENT 11.3 - Categories and lifetime		44
ELEMENT 11.4 - Masks		45
ELEMENT 11.5 - Apply filters		46
Lesson 12 - Chemical safety		46
ELEMENT 12.1 - Purpose		46
ELEMENT 12.2 - Transfer procedures		47
ELEMENT 12.3 - Information about chemicals		48
ELEMENT 12.4 - Equipment check		48
ELEMENT 12.5 - Prevention and mitigation		49
Lesson 13 - Composites and blade construction		50
ELEMENT 13.1 - Aerodynamics		50
ELEMENT 13.2 - Blade construction		51
ELEMENT 13.3 - Sandwich panel		53
ELEMENT 13.4 - Blade enhancements		53
ELEMENT 13.5 - Faults, implications and mitigations		54
Lesson 14 - Materials		55
ELEMENT 14.1 - Reinforcement materials		56
ELEMENT 14.2 - Matrix materials		57
ELEMENT 14.3 - Adhesives		57
ELEMENT 14.4 - Surface coatings		58
ELEMENT 14.5 - Chemical handling and application		59
ELEMENT 14.6 - Curing		60
Lesson 15 - Tools and equipment		61
ELEMENT 15.1 - Mechanical, electrical and Pneumatic principles		61
ELEMENT 15.2 - Utilisation of tools and materials		62
ELEMENT 15.3 - Calibration		64
ELEMENT 15.4 - Lamination tools		64
ELEMENT 15.5 - Heating blankets		65
ELEMENT 15.6 - Checking electrical tools and equipment		65
ELEMENT 15.7 - Vibrating tools		67
ELEMENT 15.8 - Electrical safety devices		68
ELEMENT 15.9 - Documentation types		69
Lesson 16 - Phase test		70
ELEMENT 16.2 - Phase test		70
Lesson 17 - Lamination skills		70
ELEMENT 17.1 - Fibre orientation		71
ELEMENT 17.2 - Kinked or bent fibres		71
ELEMENT 17.3 - Overlaps		72
ELEMENT 17.4 - Dry fibres and air voids		73
ELEMENT 17.5 - Mixing ratio		74
ELEMENT 17.6 - Calculation of matrix material		75
ELEMENT 17.7 - Curing at elevated temperatures		76
ELEMENT 17.8 - Ascertaining correct curing		77
ELEMENT 17.9 - Ambient temperature and humidity		78
ELEMENT 17.10 - Recording ambient temperature and humidity		79
Lesson 18 - Basic lamination		80
ELEMENT 18.1 - Minimise risks associated with Composite fibre work		80
ELEMENT 18.2 - Fibreglass mats		81
ELEMENT 18.3 - Fibre orientation and moulding theory		81
Lesson 19 - Sandwich panel		83
ELEMENT 19.1 - Minimise risks associated with composite fibre work		84
ELEMENT 19.2 - Sandwich construction		85
ELEMENT 19.3 - Curing of fibre reinforced composite laminate		86
ELEMENT 19.4 - Producing a composite sandwich panel		88
ELEMENT 19.5 - Trailing edge section		90
Lesson 20 - Painting		91
ELEMENT 20.1 - Completion of blade		91
Lesson 21 - Blade inspection		93
ELEMENT 21.1 - Typical failures		93
ELEMENT 21.2 - Reactions to damage categories		94
ELEMENT 21.3 - Focused and scaled photographs		95
ELEMENT 21.4 - Tap test		96
ELEMENT 21.5 - Lighting		97
ELEMENT 21.6 - Inspection tools and methods		97
ELEMENT 21.7 - Types of damage		98
Lesson 22 - Inspection lightning protection system		99
ELEMENT 22.1 - Surface components		100
ELEMENT 22.2 - Visual and conductivity inspection		100
ELEMENT 22.3 - Measure resistance		101
Lesson 23 - Sanding skills		102
ELEMENT 23.1 - Sanding		102
Lesson 24 - Grinding skills		104
ELEMENT 24.1 - Grinding		105
Lesson 25 - Surface repairs		106
ELEMENT 25.1 - Minimise risks associated with composite fibre work		107
ELEMENT 25.2 - Filler adhesion		107
ELEMENT 25.3 - Reproduce surface profile		108
ELEMENT 25.4 - Paint adhesion		109
ELEMENT 25.5 - Layer thickness		109
ELEMENT 25.6 - Apply paint with a roller		110
ELEMENT 25.7 - Layer thickness with wet film		110
ELEMENT 25.8 - Record ambient temperature and humidity		111
ELEMENT 25.9 - Inspection and documentation		112
Lesson 26 - Laminate repairs		112
ELEMENT 26.1 - Minimise risks associated with composite fibre work		113
ELEMENT 26.2 - Safe removal of damaged material		113
ELEMENT 26.3 - Identifying fibre direction		114
ELEMENT 26.4 - Reinforcement overlaps and matrix adhesion		115
ELEMENT 26.5 - Mixing		116
ELEMENT 26.6 - Repair layers		117
ELEMENT 26.7 - Wetting out fibres using appropriate tools		118
ELEMENT 26.8 - Wetting out fibres with matrix material		118
ELEMENT 26.9 - Vacuum consolidation		119
ELEMENT 26.10 - Curing the repair using heating blankets		120
ELEMENT 26.11 - Verifying the curing		121
ELEMENT 26.12 - Recording the ambient temperature and humidity		122
Lesson 27 - Filling and shaping		123
ELEMENT 27.1 - Filler		123
Lesson 28 - Trailing edge repairs		124
ELEMENT 28.1 - Minimise risks associated with composite fibre work		124
ELEMENT 28.2 - Repair task		125
ELEMENT 28.3 - Crack repairs		125
ELEMENT 28.4 - Recreating blade profile		127
ELEMENT 28.5 - Record ambient temperature and humidity		128
Lesson 29 - Leading edge repairs		128
ELEMENT 29.1 - Minimise risks associated with composite fibre work		128
ELEMENT 29.2 - Repair task		129
ELEMENT 29.3 - Leading edge repair		129
ELEMENT 29.4 - Relocate leading edge		130
Lesson 30 - Sandwich panel repair		131
ELEMENT 30.1 - Minimise risks associated with composite fibre work		132
ELEMENT 30.2 - Repair task		132
ELEMENT 30.3 - Repair inner and outer laminate		133
ELEMENT 30.4 - Replacement core		134
ELEMENT 30.5 - Inspection and documentation		135
Lesson 31 - Bond line repairs		135
ELEMENT 31.1 - Debonding		136
ELEMENT 31.2 - Injection of adhesive		136
ELEMENT 31.3 - Injecting material in the trailing edge		138
Lesson 32 - Summary and final test		139
ELEMENT 32.2 - Summary		139
ELEMENT 32.3 - Final test		139
Lesson 33 - Training review		139
ELEMENT 33.1 - Training review		140
ELEMENT 33.2 - Feedback session		140
Annex 1 - Equipment list		142
Annex 2 - Practical exercise (example)		146
Annex 3 - Work instruction (example)		150
Annex 4 - Photocard		158
Annex 5 - Version History		159

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