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Elements and Performance Criteria

1. Prepare to undertake repair or modification
   • Modification or the repair scheme is identified in accordance with structural repair manual and/or approved data
   • Specialist advice is obtained in establishing an approved repair scheme where a standard repair scheme cannot be identified or where damage is beyond specified limits
   • All materials and equipment required are organised
   • Structure is supported and prepared in accordance with the applicable maintenance manual to ensure personnel safety and freedom from damage
   • Jigs, fixtures or bracing are used, as required, to maintain shape and/or alignment
2. Repair/modify aircraft structure
   • Structural repairs/modifications are performed, in accordance with approved repair scheme or modification drawings and instructions, ensuring that aircraft standard practices are used and process requirements are carried out while observing all relevant work health and safety (WHS) requirements, including the use of material safety data sheets (MSDS) and items of personal protective equipment (PPE)
   • Work area is cleaned of all waste material or contaminants
   • Required mensuration/alignment checks are completed and components are adjusted, where necessary, to operate within prescribed specifications
   • Repaired components or assemblies are tagged, sealed and packaged or cradled in accordance with specified procedures, where required
   • Required maintenance documentation is completed and processed in accordance with standard enterprise procedures

Range Statement

This field allows for different work environments and conditions that may affect performance. Essential operating conditions that may be present (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) are included.
Repair tasks include:	Removing and installing structural hardware and fastening devices Repairing by replacement major load-carrying structural members, such as skins, longerons, spars, frames and bulkheads
Assembly stress defects include:	Oil canning Buckling Contour misalignment
Procedures and requirements include:	Industry standard procedures specified by manufacturers, regulatory authorities or the enterprise

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Performance Evidence

Evidence required to demonstrate competency in this unit must be relevant to and satisfy all of the requirements of the elements and performance criteria under the specified conditions of assessment, and must include:

applying relevant WHS regulations and practices, including the use of MSDS and PPE

using approved maintenance documentation and aircraft publications relating to aircraft structure

identifying aircraft structural assembly fasteners by interpretation of markings, numbering systems, size, shape and colour

correctly interpreting and/or producing repair scheme/modification drawings, including third angle projection, isometric, sectional formats and hand sketches

using appropriate hand tools and machines to remove and assemble aircraft structural components, parts, sections and skin, including riveting equipment, drilling equipment, aligning tools and material fasteners (grip pins)

applying correct removal, installation and repair techniques for:

a range of rivets (blind and solid) using hand, squeeze and pneumatic situations

a range of close tolerance fasteners (standard and oversize – hillocks and taper locks), including hole preparation

threaded devices, including internal and external thread cutting, Helicoil inserts and damaged stud replacement

hardware assembled by close tolerance fits using heat, cooling and force methods, including bearings, bushes and inserts

correctly supporting the aircraft structure by jacking, trestling and/or jigging methods

performing mensuration checks after structure reassembly.

It is essential that the procedures take into account all aircraft and personal safety precautions relating to aircraft structure.

Evidence of transferability of skills and knowledge related to the major repair and modification of aircraft structure is essential. This may be demonstrated through application across a number of aircraft systems or aircraft types. Ability to interpret repair/modification procedures and specifications and apply them in practice is critical. The application of the procedures should also clearly indicate knowledge of structural flight loads and aerodynamic requirements.

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Knowledge Evidence

Evidence required to demonstrate competency in this unit must be relevant to and satisfy all of the requirements of the elements and performance criteria and include knowledge of:

aircraft construction principles and structural component attachment methods for primary structure:

fuselage

wings and attachment fittings

horizontal and vertical stabilisers and attachment fittings

pylons and attachment fittings

flight control surfaces

engine mounts and nacelles and attachment fittings

undercarriage attachments

procedures for replacement of primary structure components, such as:

fuselage frames and longerons

wing spars or spar caps

wing-to-fuselage attachment fittings

tailplane attachment fittings

undercarriage attachment fittings

aircraft mensuration checks – when required and methodology

repair of integral fuel tanks and sealing of faying surfaces, including specific WHS and PPE requirements

surface finishes and methods of restoration

how to obtain MSDS

relevant maintenance and structural repair manuals and modification data

relevant regulatory requirements and standard procedures.

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