Collision Structural Repair
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Course Introduction

 

Core Standards of the Course

Strand 1
Students will participate in personal and leadership development activities through SkillsUSA or another appropriate career and technical student organization.

Standard 1
Student will use communication skills to effectively communicate with others.

1. Understand when it is appropriate to listen and to speak.
   
2. Understand and follow verbal and written instructions for classroom and laboratory activities.
   

Standard 2
Student will effectively use teamwork to respectfully work with others.

1. Identify and understand different roles in working with a team.
   

Standard 3
Student will use critical thinking and problem-solving skills.

1. Analyze the cause of the problem.
   
2. Develop a solution to address the problem.
   
3. Implement the plan.
   
4. Evaluate the effectiveness of the plan.
   

Standard 4
Student will be dependable, reliable, steady, trustworthy, and consistent in performance and behavior.

1. Set and meet goals on attendance and punctuality.
   
2. Prioritize, plan, and manage work to complete assignments and projects on time.
   

Standard 5
Student will be accountable for results.

1. Use an achievement chart for activities and behaviors in class that encourages a personal evaluation of classroom performance.
   
2. File a regular written report on progress toward completion of assignments and projects.
   

Standard 6
Be familiar with the legal requirements and expectations of the course.

1. Be familiar with the course disclosure statement and all requirements for successful completion of the course.
   
2. Demonstrate workplace ethics, e.g. fair, honest, disciplined.
   

Strand 2
Students will participate in work-place readiness activities.

Standard 1
Student will demonstrate employability skills.

1. Use a career search network to find career choices.
   
2. Write a resume including a list of demonstrated skills.
   
3. Write a letter of application.
   
4. Complete a job application.
   
5. Participate in an actual or simulated job interview.
   

Standard 2
Student will participate in a work-based learning experience outside the classroom.

1. Student will plan and implement a work-based learning experience aligned with their career goal.
   

Strand 3
Students will understand and demonstrate safety and environmental practices.

Standard 1
Select and use proper personal safety equipment; take necessary precautions with hazardous operations and materials in accordance with federal, state, and local regulations.

Standard 2
Locate OEM procedures to identify material and composition of the vehicle being repaired (mild steel, high strength steel, ultra-high strength steel, aluminum, etc.).

Standard 3
Locate procedures and precautions that may apply to the vehicle being repaired.

Standard 4
Identify vehicle system precautions and/or inspections to include but not limited to supplemental restraint system (SRS), advanced driver assistance systems (ADAS), hybrid/electric/alternative fuel vehicles, locations and recommended procedures before inspecting or replacing components.

Standard 5
Perform vehicle clean-up; complete quality control using a checklist on operations performed.

Standard 6
Understand safety practices related to general shop, personal protection, vehicle lifts, and hand and power equipment.

Standard 7
Understand and identify different fasteners and their applications and repair procedures.

Standard 8
Understand how to select and properly use hand and select power tools.

Performance Skill
Understand and demonstrate safety and environmental practices.

1. Select and use proper personal safety equipment; take necessary precautions with hazardous operations and materials in accordance with federal, state, and local regulations.
   
2. Locate OEM procedures to identify material and composition of the vehicle being repaired (mild steel, high strength steel, ultra-high strength steel, aluminum, etc.).
   
3. Locate procedures and precautions that may apply to the vehicle being repaired.
   
4. Identify vehicle system precautions and/or inspections to include but not limited to supplemental restraint system (SRS), advanced driver assistance systems (ADAS), hybrid/electric/alternative fuel vehicles, locations and recommended procedures before inspecting or replacing components.
   
5. Perform vehicle clean-up; complete quality control using a checklist on operations performed.
   
6. Understand safety practices related to general shop, personal protection, vehicle lifts, and hand and power equipment.
   
7. Understand and identify different fasteners and their applications and repair procedures.
   
8. Understand how to select and properly use hand and select power tools.
   

Strand 4
Students will understand and demonstrate frame inspection and repair.

Standard 1
Measure and diagnose structural damage using a metric tape measure and a tram gauge.

Standard 2
Properly install vehicle on to a frame bench/rack.

Standard 3
Analyze, straighten and align mash (collapse) damage.

Standard 4
Analyze, straighten and align sag damage.

Standard 5
Analyze, straighten and align side sway damage.

Standard 6
Analyze, straighten and align twist damage.

Standard 7
Analyze, straighten and align diamond frame damage.

Standard 8
Remove and replace damaged structural components.

Standard 9
Remove and replace protective coatings; restore corrosion protection to repaired or replaced frame areas and anchoring locations.

Standard 10
Analyze and identify misaligned or damaged steering, suspension, and powertrain mounting points and components.

Standard 11
Align or replace misaligned or damaged steering, suspension, and powertrain mounting points and components.

Standard 12
Identify heat limitations and monitoring procedures for structural components.

Standard 13
Demonstrate an understanding of structural foam applications.

Standard 14
Measure and diagnose structural damage using a three-dimensional measuring system (mechanical, electronic, laser), etc.

Standard 15
Determine the extent of the direct and indirect damage and the direction of impact; document the methods and sequence of repair.

Standard 16
Analyze and identify crush/collapse zones.

Performance Skill
Understand and demonstrate frame inspection and repair.

1. Measure and diagnose structural damage using a metric tape measure and a tram gauge.
   
2. Properly install vehicle on to a frame bench/rack.
   
3. Analyze, straighten and align mash (collapse) damage.
   
4. Analyze, straighten and align sag damage.
   
5. Analyze, straighten and align side sway damage.
   
6. Analyze, straighten and align twist damage.
   
7. Analyze, straighten and align diamond frame damage.
   
8. Remove and replace damaged structural components.
   
9. Remove and replace protective coatings; restore corrosion protection to repaired or replaced frame areas and anchoring locations.
   
10. Analyze and identify misaligned or damaged steering, suspension, and powertrain mounting points and components.
    
11. Align or replace misaligned or damaged steering, suspension, and powertrain mounting points and components.
    
12. Identify heat limitations and monitoring procedures for structural components.
    
13. Demonstrate an understanding of structural foam applications.
    
14. Measure and diagnose structural damage using a three-dimensional measuring system (mechanical, electronic, laser), etc.
    
15. Determine the extent of the direct and indirect damage and the direction of impact; document the methods and sequence of repair.
    
16. Analyze and identify crush/collapse zones.
    

Strand 5
Students will understand and demonstrate unibody and unitized structure inspection, measurement, and repair.

Standard 1
Analyze and identify misaligned or damaged steering, suspension, and powertrain mounting points that can cause vibration, steering, and chassis alignment problems.

Standard 2
Align or replace misaligned or damaged steering, suspension, and powertrain mounting points that can cause vibration, steering and chassis alignment problems.

Standard 3
Measure and diagnose unibody damage using a metric tape measure and tram gauge.

Standard 4
Measure and diagnose unibody vehicles using a dedicated (fixture) measuring system.

Standard 5
Diagnose and measure unibody vehicles using a three-dimensional measuring system (mechanical, electronic, and laser, etc.).

Standard 6
Determine the extent of the direct and indirect damage and the direction of impact; plan and document the methods and sequence of repair.

Standard 7
Attach anchoring devices to vehicle; remove or reposition components as necessary.

Standard 8
Straighten and align roof rails/headers and roof panels.

Standard 9
Straighten and align rocker panels and pillars.

Standard 10
Straighten and align vehicle openings, and floor pans.

Standard 11
Straighten and align quarter panels, wheelhouse assemblies, and rear body sections (including rails and suspension/powertrain mounting points).

Standard 12
Straighten and align front-end sections (aprons, strut towers, upper and lower rails, steering, and suspension/power train mounting points, etc.).

Standard 13
Determine structural repair component or replacement recommendations.

Standard 14
Identify proper cold stress relief methods.

Standard 15
Determine sectioning procedures of a steel body structure.

Standard 16
Remove and replace damaged structural components.

Standard 17
Determine the extent of damage to aluminum structural components; repair, weld, or replace.

Standard 18
Analyze and identify crush/collapse zones.

Performance Skill
Understand and demonstrate unibody inspection, measurement, and repair.

1. Analyze and identify misaligned or damaged steering, suspension, and powertrain mounting points that can cause vibration, steering, and chassis alignment problems.
   
2. Align or replace misaligned or damaged steering, suspension, and powertrain mounting points that can cause vibration, steering and chassis alignment problems.
   
3. Measure and diagnose unibody damage using a metric tape measure and tram gauge.
   
4. Measure and diagnose unibody vehicles using a dedicated (fixture) measuring system.
   
5. Diagnose and measure unibody vehicles using a three-dimensional measuring system (mechanical, electronic, and laser, etc.).
   
6. Determine the extent of the direct and indirect damage and the direction of impact; plan and document the methods and sequence of repair.
   
7. Attach anchoring devices to vehicle; remove or reposition components as necessary.
   
8. Straighten and align roof rails/headers and roof panels.
   
9. Straighten and align rocker panels and pillars.
   
10. Straighten and align vehicle openings, and floor pans.
    
11. Straighten and align quarter panels, wheelhouse assemblies, and rear body sections (including rails and suspension/powertrain mounting points).
    
12. Straighten and align vehicle openings, floor pans, and rocker panels.
    
13. Determine structural repair component or replacement recommendations.
    
14. Identify proper cold stress relief methods.
    
15. Determine sectioning procedures of a steel body structure.
    
16. Remove and replace damaged structural components.
    
17. Determine the extent of damage to aluminum structural components; repair, weld, or replace.
    
18. Analyze and identify crush/collapse zones.
    

Strand 6
Students will understand and demonstrate fixed glass removal, reinstallation, or replacement.

Standard 1
Identify considerations for removal, handling, one time use parts, and installation of advanced glass systems (comfort and safety features).

Standard 2
Remove and reinstall or replace modular glass using recommended materials.

Standard 3
Check for water leaks, dust leaks, and wind noise.

Standard 4
Identify considerations for pre-scan, post-scan, and recalibration procedures.

Performance Skill
Understand and demonstrate fixed glass removal, reinstallation, or replacement.

1. Identify considerations for removal, handling, one time use parts, and installation of advanced glass systems (comfort and safety features).
   
2. Remove and reinstall or replace modular glass using recommended materials.
   
3. Check for water leaks, dust leaks, and wind noise.
   
4. Identify considerations for pre-scan, post-scan, and recalibration procedures.
   

Strand 7
Students will understand and demonstrate metal welding, cutting, and joining.

Standard 1
Identify the considerations for cutting, removing, and welding various types of steel, aluminum, and other metals.

Standard 2
Determine the correct GMAW welder type, electrode/wire type, diameter, and gas to be used in a specific welding situation.

Standard 3
Set up, attach work clamp (ground), and adjust the GMAW welder to “tune” for proper electrode stickout, voltage, polarity, flow rate, and wire-feed speed required for the substrate being welded.

Standard 4
Store, handle, and install high-pressure gas cylinders; test for leaks.

Standard 5
Determine the proper angle of the gun to the joint and direction of gun travel for the type of weld being made.

Standard 6
Protect adjacent panels, glass, vehicle interior, etc. from welding and cutting operations.

Standard 7
Identify hazards; foam coatings and flammable materials prior to welding/cutting procedures.

Standard 8
Protect computers and other electronics/wires prior to welding procedures.

Standard 9
Clean and prepare the metal to be welded, assure good metal fit-up, apply weld-through primer if necessary, clamp or tack as required.

Standard 10
Determine the joint type (butt weld with backing, lap, etc.) for weld being made.

Standard 11
Determine the type of weld (continuous, stitch weld, plug, etc.) for each specific welding operation.

Standard 12
Perform the following welds: plug, butt weld with and without backing, and fillet etc., in the flat, horizontal, vertical, and overhead positions.

Standard 13
Perform visual evaluation and destructive test on each weld type.

Standard 14
Identify the causes of various welding defects; make necessary adjustments.

Standard 15
Identify cause of contact tip burn-back and failure of wire to feed; make necessary adjustments.

Standard 16
Identify cutting process for different substrates and locations; perform cutting operation.

Standard 17
Identify different methods of attaching structural components (squeeze type resistance spot welding (STRSW), riveting, structural adhesive, MIG bronze, rivet bonding, weld bonding, etc.).

Performance Skill
Understand and demonstrate metal welding and cutting.

1. Identify the considerations for cutting, removing, and welding various types of steel, aluminum, and other metals.
   
2. Determine the correct GMAW welder type, electrode/wire type, diameter, and gas to be used in a specific welding situation.
   
3. Set up, attach work clamp (ground), and adjust the GMAW welder to “tune” for proper electrode stickout, voltage, polarity, flow rate, and wire-feed speed required for the substrate being welded.
   
4. Store, handle, and install high-pressure gas cylinders; test for leaks.
   
5. Determine the proper angle of the gun to the joint and direction of gun travel for the type of weld being made.
   
6. Protect adjacent panels, glass, vehicle interior, etc. from welding and cutting operations.
   
7. Identify hazards; foam coatings and flammable materials prior to welding/cutting procedures.
   
8. Protect computers and other electronics/wires prior to welding procedures.
   
9. Clean and prepare the metal to be welded, assure good metal fit-up, apply weld-through primer if necessary, clamp or tack as required.
   
10. Determine the joint type (butt weld with backing, lap, etc.) for weld being made.
    
11. Determine the type of weld (continuous, stitch weld, plug, etc.) for each specific welding operation.
    
12. Perform the following welds: plug, butt weld with and without backing, and fillet etc., in the flat, horizontal, vertical, and overhead positions.
    
13. Perform visual evaluation and destructive test on each weld type.
    
14. Identify the causes of various welding defects; make necessary adjustments.
    
15. Identify cause of contact tip burn-back and failure of wire to feed; make necessary adjustments.
    
16. Identify cutting process for different substrates and locations; perform cutting operation.
    
17. Identify different methods of attaching structural components (squeeze type resistance spot welding (STRSW), riveting, structural adhesive, MIG bronze, rivet bonding, weld bonding, etc.).
    

Strand 8
Students will understand and perform damage analysis.

Standard 1
Position the vehicle for inspection under proper lighting; take photos to identify the vehicle and document damage.

Standard 2
Identify components to be removed to gain access to damaged areas.

Standard 3
Analyze damage to determine appropriate methods for overall repairs.

Standard 4
Determine the direction, point(s) of impact, and extent of direct, indirect, and inertia damage.

Standard 5
Gather details of the incident/accident necessary to determine the full extent of vehicle damage.

Standard 6
Identify and record pre-existing damage.

Standard 7
Identify and record prior repairs.

Standard 8
Perform visual inspection of structural components.

Standard 9
Identify structural damage using measuring tools and equipment.

Standard 10
Perform visual inspection of non-structural components and members.

Standard 11
Determine parts, components, material type(s) and procedures necessary for a proper repair.

Standard 12
Identify type and condition of finish; determine refinish labor operations as required.

Standard 13
Identify suspension, electrical, and mechanical component physical damage.

Standard 14
Identify safety systems physical damage.

Standard 15
Identify interior component damage.

Standard 16
Identify add-on accessories and modifications.

Standard 17
Identify single (one time) use components.

Standard 18
Identify and document illuminated dash malfunction indicator lamp(s) (MIL).

Standard 19
Perform a pre-repair inspection of the vehicle with the customer. Record fit and finish concerns (color mismatch, factory gaps, unrelated prior damage and prior repairs).

Performance Skill
Understand and perform damage analysis.

1. Position the vehicle for inspection under proper lighting; take photos to identify the vehicle and document damage.
   
2. Prepare vehicle for inspection by providing access to damaged areas.
   
3. Analyze damage to determine appropriate methods for overall repairs.
   
4. Determine the direction, point(s) of impact, and extent of direct, indirect, and inertia damage.
   
5. Gather details of the incident/accident necessary to determine the full extent of vehicle damage.
   
6. Identify and record pre-existing damage.
   
7. Identify and record prior repairs.
   
8. Perform visual inspection of structural components and members.
   
9. Identify structural damage using measuring tools and equipment.
   
10. Perform visual inspection of non-structural components and members.
    
11. Determine parts, components, material type(s) and procedures necessary for a proper repair.
    
12. Identify type and condition of finish; determine refinish labor operations as required.
    
13. Identify suspension, electrical, and mechanical component physical damage.
    
14. Identify safety systems physical damage.
    
15. Identify interior component damage.
    
16. Identify add-on accessories and modifications.
    
17. Identify single (one time) use components.
    
18. Identify and document illuminated dash malfunction indicator lamp(s) (MIL).
    
19. Perform a pre-repair inspection of the vehicle with the customer. Record fit and finish concerns (color mismatch, factory gaps, unrelated prior damage and prior repairs).
    

Strand 9
Students will understand and perform estimating.

Standard 1
Determine and record customer/vehicle owner information.

Standard 2
Identify and record vehicle identification number (VIN) information, including nation of origin, make, model, restraint system, body type, production date, engine type, and assembly plant.

Standard 3
Identify and record vehicle mileage and options, including trim level, paint code, transmission, accessories, and modifications.

Standard 4
Identify safety systems; determine precautions, inspections and replacement items as required.

Standard 5
Apply appropriate estimating and parts nomenclature (terminology).

Standard 6
Determine and apply appropriate estimating sequence.

Standard 7
Utilize estimating procedure pages.

Standard 8
Apply estimating guide footnotes, headnotes, and line notes as needed.

Standard 9
Identify operations requiring labor value judgment.

Standard 10
Select appropriate labor value for each operation (structural, non-structural, mechanical, and refinish).

Standard 11
Select and price OEM parts, optional OEM parts, aftermarket parts, recycleable/used parts, remanufactured, rebuilt, and reconditioned parts; verify availability, compatibility, and condition.

Standard 12
Determine necessary sublet operations.

Standard 13
Determine included and non-included operations and miscellaneous items.

Standard 14
Recognize and apply overlap deductions.

Standard 15
Determine additional material and charges.

Standard 16
Determine refinishing material and charges.

Standard 17
Apply math skills to establish charges and totals.

Standard 18
Identify differences between computer generated and manually written estimates.

Standard 19
Identify procedures to restore corrosion protection; establish labor values, and material charges.

Standard 20
Recognize the cost effectiveness of the repair and determine the approximate vehicle retail, and repair value.

Standard 21
Recognize the differences in estimating platforms when using different information provider systems.

Standard 22
Interpret computer-assisted and manually written estimates; verify the information is current.

Standard 23
Determine telematic/connectivity of the vehicle and place vehicle in service mode.

Standard 24
Identify vehicle safety recalls using the vehicle identification number (VIN).

Standard 25
Review damage report and analyze damage to determine appropriate methods for overall repair; communicate with team members to verify accuracy and resolve discrepancies.

Performance Skill
Understand and perform estimating.

1. Determine and record customer/vehicle owner information.
   
2. Identify and record vehicle identification number (VIN) information, including nation of origin, make, model, restraint system, body type, production date, engine type, and assembly plant.
   
3. Identify and record vehicle mileage and options, including trim level, paint code, transmission, accessories, and modifications.
   
4. Identify safety systems; determine precautions, inspections and replacement items as required.
   
5. Apply appropriate estimating and parts nomenclature (terminology).
   
6. Determine and apply appropriate estimating sequence.
   
7. Utilize estimating guide procedure pages.
   
8. Apply estimating guide footnotes, headnotes, and line notes as needed.
   
9. Identify operations requiring labor value judgment.
   
10. Select appropriate labor value for each operation (structural, non-structural, mechanical, and refinish).
    
11. Select and price OEM parts, optional OEM parts, aftermarket parts, recycleable/used parts, remanufactured, rebuilt, and reconditioned parts; verify availability, compatibility, and condition.
    
12. Determine necessary sublet operations.
    
13. Determine included and non-included operations and miscellaneous items.
    
14. Recognize and apply overlap deductions.
    
15. Determine additional material and charges.
    
16. Determine refinishing material and charges.
    
17. Apply math skills to establish charges and totals.
    
18. Identify differences between computer generated and manually written estimates.
    
19. Identify procedures to restore corrosion protection; establish labor values, and material charges.
    
20. Recognize the cost effectiveness of the repair and determine the approximate vehicle retail, and repair value.
    
21. Recognize the differences in estimating platforms when using different information provider systems.
    
22. Verify accuracy of estimate compared to the actual repair and replacement operations.
    
23. Determine telematic/connectivity of the vehicle and place vehicle in service mode.
    
24. Identify vehicle safety recalls using the vehicle identification number (VIN).
    
25. Review damage report and analyze damage to determine appropriate methods for overall repair; communicate with team members to verify accuracy and resolve discrepancies.
    

Strand 10
Students will understand and perform customer relations and sales skills.

Standard 1
Introduce yourself, acknowledge and greet customer/client/visitor; offer assistance.

Standard 2
Listen to client; collect information and identify client’s concerns, needs and expectations.

Standard 3
Establish cooperative attitude with customer/client.

Standard 4
Deal with dissatisfied customer/client, seek resolution.

Standard 5
Identify customer/client preferred communication method; follow up to keep customer/client informed about parts and the repair process.

Standard 6
Recognize basic claims handling procedures; explain to customer/client.

Standard 7
Project positive attitude and professional appearance.

Standard 8
Provide and review warranty information.

Standard 9
Provide and review technical and consumer protection information.

Standard 10
Estimate and explain duration of out-of-service time.

Standard 11
Demonstrate negotiation skills to obtain a mutual agreement.

Standard 12
Interpret and explain estimate to customer/client.

Performance Skill
Understand and perform customer relations and sales skills.

1. Introduce yourself, acknowledge and greet customer/client/visitor; offer assistance.
   
2. Listen to client; collect information and identify client’s concerns, needs and expectations.
   
3. Establish cooperative attitude with customer/client.
   
4. Deal with dissatisfied customer/client, seek resolution.
   
5. Identify customer/client preferred communication method; follow up to keep customer/client informed about parts and the repair process.
   
6. Recognize basic claims handling procedures; explain to customer/client.
   
7. Project positive attitude and professional appearance.
   
8. Provide and review warranty information.
   
9. Provide and review technical and consumer protection information.
   
10. Estimate and explain duration of out-of-service time.
    
11. Demonstrate negotiation skills to obtain a mutual agreement.
    
12. Interpret and explain estimate to customer/client.
    

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