Repairing airframes and structures
Overview
This standard identifies the competences you need to repair airframes and structures, in accordance with approved procedures. It covers both fixed wing and rotary winged aircraft. You will be required to select the appropriate tools and equipment to use, based on the repair operations required and to check that they are in a safe and serviceable condition. In carrying out the repair operations, you will be required to follow laid-down procedures and specific repair techniques, such as insertion repair, primary structure repair, secondary structure repair, tertiary structure repair and patch repair, in order to satisfy the repair scheme in the aircraft structural repair manual. The repair activities will also include making all necessary checks.
Your responsibilities will require you to comply with organisational policy and procedures for the repair activities undertaken and to report any problems with the repair activities that you cannot personally resolve, or that are outside your permitted authority, to the relevant people. You will be expected to work with a minimum of supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.
Your underpinning knowledge will provide a good understanding of your work and will provide an informed approach to applying the appropriate repair techniques and procedures. You will understand the airframe structure being repaired and will know about the components, repair techniques and fastening devices used during the repair operation, in adequate depth to provide a sound basis for carrying out the activities to the required specification.
You will understand the safety precautions required when carrying out the repair operations. You will be required to demonstrate safe working practices throughout and will understand the responsibility you owe to yourself and others in the workplace.
Performance criteria
You must be able to:
- work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
- follow the relevant specifications for the component to be repaired
- prepare the component for repair
- carry out the repairs within agreed timescale using approved materials and components and methods and procedures
- ensure that the repaired component meets the specified operating conditions
- produce accurate and complete records of all repair work carried out
- leave the work area and airframe in a safe and appropriate condition, free from foreign object debris on completion of the activities
Knowledge and Understanding
You need to know and understand:
- the specific safety precautions and procedures that you need to observe whilst carrying out the repairs (such as any specific legislation, regulations or codes of practice relating to the activities, equipment or materials)
- the importance of maintenance on and impact upon extended twin operations procedures (ETOpS) systems, legislation and local procedures
- the health and safety requirements of the work area in which you are carrying out the repair activities and the responsibility these requirements place on you
- the hazards associated with repairing airframes and systems and with the tools and equipment used and how to minimise them and reduce any risks
- the requirements and importance of understanding and applying human factors as defined by the regulatory requirements and the potential impact if these are not adhered to
- the protective equipment that you need to use for both personal protection (PPE) and protection of the aircraft
- the interpretation of drawings, standards, quality control procedures and specifications used for the repair (such as BS, ISO or BSEN schematics, symbols and terminology)
- how to carry out currency/issue checks on the repair scheme/specification you are working with
- how to identify the components to be used; component identification systems (such as codes and component orientation indicators)
- preparations to be undertaken on the airframe or structure, prior to repair
- the repair methods and procedures to be used and the importance of adhering to these procedures
- the various mechanical fasteners that will be used, and their method of installation (such as open and blind rivets, threaded fasteners, special securing devices)
- the importance of using the specified fasteners for the repair and why you must not use substitutes
- the application of sealants and adhesives within the repair activities and the precautions that must be taken when working with them
- the quality control procedures to be followed during the repair operations
- how to conduct any necessary checks to ensure the accuracy and quality of the repair
recognising defects (such as skin blemishes, poor skin lines, ineffective fasteners, foreign object damage)
the methods and equipment used to transport, handle and lift the structures into position and how to check that the equipment is within its current certification dates
- the tools and equipment used in the repair activities and their
calibration/care and control procedures - why tool/equipment control is critical and what to do if a tool or piece of equipment is unaccounted for on completion of the activities
- the problems that can occur with the repair operations and how these can be overcome
the recording documentation to be completed for the activities undertaken and where appropriate, the importance of marking and identifying specific pieces of work in relation to the documentation
the extent of your own responsibility and to whom you should report if you have problems that you cannot resolve
Scope/range
Scope Performance
Carry out all of the following activities during the repair:
- obtain and use the appropriate documentation (such as job instructions, aircraft assembly/repair drawings, planning and quality control documentation, aircraft procedures and specifications)
- adhere to procedures or systems in place for risk assessment, COSHH, personal protective equipment and other relevant safety regulations and procedures to realise a safe system of work
- provide and maintain a safe working environment for the repair activities
- obtain the correct tools and equipment for the activity, and check that they are in a safe, tested and usable condition and within current calibration date
- follow safe practice/approved repair techniques and procedures at all times
- ensure that correct part numbers are used, including (where appropriate) left or right handed parts
- return all tools and equipment to the correct location on completion of the repair activities
- dispose of waste materials in accordance with approved procedures
Repair one type of airframe or structure from:
- commercial aircraft
- light aircraft
- military aircraft
- helicopters
Undertake three of the following types of repair:
- insertion repair
- secondary structure repair
- patch repair
- primary structure repair
- tertiary structure repair
- other specific repair type
Repair airframes or structures, to include five the following methods and techniques:
- making holes in airframe
- profiling
- blending
- materials marking out
- deburring
- cutting
- securing and locking components
Use three of the following types of joining method during repairs:
- adhesives/sealants
- rivets
- special fasteners
- locking devices
- threaded fasteners
Ensure that repairs comply with one of the following:
- Civil Aviation Authority (CAA)/European Aviation Safety Agency (EASA)
- extended twin operations procedures (ETOpS) (where appropriate)
- Ministry of Defence (MoD)
- Military Aviation Authority (MAA)
- Aerospace Quality Management Standards (AS)
- customer standards and requirements
- Federal Aviation Authority (FAA)
- company standards and procedures
- BS, ISO or BSEN standards and procedures
- aircraft design/manufacturer's requirements
Complete the relevant paperwork, to include one from the following and pass it to the appropriate people:
- build records
- job cards
- log cards
- aircraft flight log
- aircraft log book
- other specific recording method
Scope Knowledge
Values
Behaviours
You will be able to apply the appropriate behaviours required in the workplace to meet the job profile and overall company objectives, such as:
- strong work ethic
- positive attitude
- team player
- dependability
- responsibility
- honesty
- integrity
- motivation
- commitment