7.14.

2 - COMPOSITE AND NON-METALLIC

COMPOSITE INSPECTION
-Composite structures require ongoing inspection intervals along with non-scheduled damage
inspection and testing.
-When a composite structure is damaged, it must first be thoroughly inspected to determine
the extent of the damage.
-Proper inspection and testing methods help determine the classification of damage.
-Some of the most common inspection and testing methods are visual inspections, tap testing,
and ultrasonic testing along with several other more advanced NDT methods.

VISUAL INSPECTION
-Visual inspection is the most used inspection method in aviation, on a daily basis.
-It is used to detect resin-rich areas, resin starvation, edge delamination, fiber breakage, cracks,
blistering, and other types of surface irregularities.
-A strong light and magnifying glass are useful tools for visual inspection, in extremely critical
cases a small microscope is helpful.
-However, using a flash light does not detect entrapped water.
-In addition, to properly inspect a composite using the backlight method, you must strip the
surface of all paint.
-This method is that not adequate as the core or internal damages are not visible.

TAP TEST (Acoustic test)

-It is used to detect damage in bonded parts, to detect delamination.
-The laminated part is tapped with a coin or small metallic object (ring, tap hammer).
-Undamaged laminated area produces a sharp pitch compared to dull sound if delaminated.
-However, changes in the thickness, reinforcements, fasteners, previous repairs gives a false
reading so it is not that of an accurate test.
-This kind of test does not indicate subsurface delamination, and should be limited to near
surface inspection.

ULTRASONIC INSPECTION
-The most common instrumental NDT method used.
-It is useful for detecting internal damage such as delamination, core crush and other subsurface
defects.
-Two methods:
1)Pulse echo
2)Transmission
1) Pulse echo
-Generates ultrasonic pulses, sends them through the part and receives the return echo. The
echo patters are displayed on an oscilloscope.
-An advantage of this method, is only one side is required for access.
-Disadvantage is, near-surface defects do not allow sound to pass through so defects under a
defect is not detected.
-This method works well on laminates because they do not reduce the magnitude of the sound
waves as much as a bonded core structure.
2)Transmission
-Uses two transducers.
-One transducer emits ultrasonic waves through the part and the other one receives them.
-It detects defects located at multiple levels throughout the structure.
-The ratio of the magnitude of sound vibration transmitted and received determines the
structures reliability.

RADIOGRAPHY
-It is used to detect differences in the thickness or physical density.
-Also, used to detect both surface and internal cracks.
-Also, detects entrapped water inside honeycomb core cells, and foreign objects in the
composite structure if the as density would differ.
-In addition to detecting the actual defect, it can also defect the extent and size of the damage.

THERMOGRAPHY
-It is used to locate flaws by temperature variations at the surface as heat is applied.
-Requires knowledge of thermal conductivity and a reference standard to compare.

DYE PENETRANT
-It is used to detect cracks and other defects in metallic surfaces, but should not be used on
composite structure as the dye maybe absorbed by the fiber and then would not adhere to the
new material, trying to remove the dye may cause more damage if used.

ACCOUSTIC EMISSION TESTING (Comparison test)

-Usually found in production facilities rather in maintenance.
-Good test sample must be available for comparison.
-It measures the sound of the structure and displays it on an oscilloscope.
-This type of testing detects entrapped water, cracks, delamination and other flaws.

PEEL TEST
-A peel test provides valuable insight into the failure process.
-The energy required for the pullout process is measured by the determination of the area
under the load-displacement curve.
-For strong adhesives, failure of the adhesive during the pullout phase of this test occurs by
cavitation and fibrillation (rapid contraction of fibers).
-Fibrillation of the adhesive is typically preceded by the formation of interfacial cavities. Two
factors contribute to cavitation:
1) Defects caused by surface roughness of the punch.
2) Large hydrostatic tension in the highly constrained adhesive layer.

SAFETY PRECAUTIONS WHEN HANDLING COMPOSITES

-The curing process releases solvents and volatiles, also chemicals are used in the cleaning and
preparation process. So safety equipment such as glasses, respirators, masks should be worn.
Refer to material safety data sheet for information.
-Chemicals may be transferred to mucous membranes so wash yourself before consuming.
-Vacuum downdraft tables, power tools with vacuum attachments, and portable vacuum
systems should be used when drilling and trimming, compressed air must not be used as it
combines with dust and can get through your lungs, and compressed air must not be used to
clean and it may penetrate to your cloth or skin.

MACHINING COMPOSITES
-The machining process consists of drilling, cutting, sanding and grinding of material.

CUTTING FABRICS
-Fiberglass or carbon/graphite
-It can be cut with conventional fabric scissors.
-Aramid fabric in its raw state is more difficult to cut.
-Scissors with special steel or ceramic blades and serrated edges are used to cut through
aramid.
-The advantage to ceramic scissors is that the serrated edges hold the fabric, while the blades
cut fabric without fraying the edges.
-Pre-impregnated materials can be cut with razor blade and utility knives using a template or
straight edge.

DRILLING COMPOSITES
-Delamination fracture breakout and separation are types of failures that may occur while
drilling composites.
-Delamination most often occurs as the drill pushes the last layer apart rather than drilling
through it.
-A fracture occurs when a crack forms along one of the layers usually due to the force of the
drill.
-To reduce the possibility of damage, the composite should be backed with wood block.
-A very sharp drill bit is required to prevent the delamination.
-If inaccessible, a wood backup is not possible. In this case a drill stop is useful.
-Do not use a cutting coolant when drilling holes into bonded honeycomb or form core
structures.
-Carbide drills work on all types of composites and have a longer life than standard steel bits.
-Diamond coated cutters perform well on fiberglass and carbon; however, they produce
excessive fuzzing around the cut on aramid components.
-The best drill bit to use on composites has an included angle of 135 degrees.
-While sanding, drilling or trimming composite structures very fine dust particles contaminate
the air therefore, respirators must be worm when performing these operations.

DRILLING ARAMID
-Using a conventional sheet-metal twist drill on aramid tends to produce fuzz around the holes.
-Special drills designed to machines aramid consist of brad point and C-shaped cutting edge to
cut the fiber without stretching and fraying the material.
-These drills last longer than conventional twist drills and produce a cleaner hole.
-Carbide drills were specifically designed for aramid composites, they also produce good holes
in fiberglass and carbon/graphite.

DRILLING FIBERGLASS OR CARBON/GRAPHITE

-Drilling fiberglass or carbon/graphite materials can be accomplished with most conventional
tools.
-However reduces the quality of the cutting edge, shortens the life of drill.
-Carbide or diamond-coated tools produce better results and longer tool life.
-A single cutting-edge dagger or spade bit is used when cutting the fiberglass and carbon
materials to reduce the tendency of fiber breakage.

SANDING
-Sanding is used to remove fabric one layer at a time during the repair process and to smooth
the outer surfaces of some composites.
-Aluminum oxide, for instance, should not be used when sanding carbon fibers as small particles
of aluminum may become lodged in the carbon fibers, which can cause galvanic corrosion.
-To prevent such corrosion, only Silicon Carbide or pure Carbide papers should be used.
-When sanding aramid, expect the material to fuzz and start to gloss when almost through the
layer.
-During the sanding process, it is important to look carefully for the gloss area, which indicates
that the next layer of laminate is near.
-Carbon/graphite material produces a very fine powder when sanded.
-It also usually easier to see the later of carbon than the aramid.
-Another way to tell if sanding through one layer has been completed is to look for the change
in weave orientation.
-A common problem is to sand too quickly or with too much pressure.

REMOVAL OF CORE MATERIAL

-To carry out a repair on a bonded composite component with a core material, it may be
necessary to remove the core material.
-For this purpose a router may be used.
-These can also be used to trim composite at high speeds.
-When routing Nomex honeycomb, carbon/graphite, or fiberglass laminated, a carbide blade
diamond-cut router bit works best.
-Aramid fiber, a herringbone router bit works best.

CUTTING TOOLS USED WITH COMPOSITE APPICATION

A) HOLE SAWS
-Hole saws tent to tear out the honeycomb core of aramid sandwich structure.
-Because of this, hole saws are not recommended on aramid laminated.
-For carbon/graphite cutting the holes saws may be fitted with a diamond-coated blade to
produce a cleaner cut

B) WATER-JET CUTTERS
-Water-jet cutters systems use a fine stream of water pumped at 30000 to 50000 psi through a
pinhole nozzle.
-Water-jet cutting does not produce dust or fumes, nor cause delamination or fuzzing of aramid
laminates. Water-jet cutting is used most often during the manufacturing process and is not
commonly used for repair applications.

C) BAND SAWS
-A band saw may be used to cut composites if the blade has at least 12 to 14 teeth per inch.
-Band saws produce some fuzzing when cutting aramid.

D) HYDRAULIC PRESS CUTTING

-During the manufacturing process, raw or pre-impregnated fabric can be cut using a large
hydraulic press.

E) LASER CUTTING
-Used in manufacturing composites.
-A laser uses a highly focused light beam to cut composite materials.
-Can be performed on both cured and uncured composite materials.

COMPOSITE REPAIR
-Depending on the manufacturer of the aircraft, classification of damage is usually placed in one
of three categories as,
A) Negligible damage
B) Repairable damage
C)Non-reparable damage
-Negligible damage maybe be corrected by a simple procedure with no flight restrictions.
-Repairable damage is damage to the skin, bond or core that cannot be repaired without placing
restriction on the aircraft or structure.
-If a particular damage cannot be repaired using such a structurally sound repair scheme that
damage is considered as a non-repairable damage.

TYPES OF REPAIRS
- There are four basic types of composite repair:
A) Bolted metal or cured composite patches
B) Bonded metal or cures composite patches
C) Resin injection
D) Laminating new repair piles to the damage.
-Bolted and bonded surface patches are not usually recommended due to the fact that these
types of patches do not restore the strength characteristics of the original structure. A bolted or
bonded patch that is attached to the surface also causes undesirable aerodynamic changes.

-Resin injection repairs are used to fills hole or voids. They are accomplished by injecting resin
into the hole of a damaged area using a need and syringe. This type of repair is usually done on
non-structural parts. The injected resin does not restore the original strength, and, in some
cases, expands the delamination.
-The most desirable type of permanent repair to composite structure is to laminate new repair
piles in the damaged area. This type of repair involves removing the damaged plies, and
laminating on new ones.

ASSESSMENT AND PREPARATION

-Proper damage assessment and repair preparation are a must.
-Steps such as the initial damage assessment and classification, materials preparation, surface
preparation, damage removal, cleaning, and water removal are essential to achieve airworthy
composite repair.

DAMAGE ASSESSMENT
-Before starting any repair, a complete and total assessment of the damage must be made.
-Visually examine the part to determine the type and extent of damage.
-Check the damaged area for water, oil, fuel, dirt or other foreign matter contamination.
-Check for delamination around the damaged area.
-Check for subsurface damage, if warranted, with other forms of advanced nondestructive
testing methods.
-Determine the repairable damage limits as found in the manufacturer’s repair manual.
-Determine the proper repair procedure, if approval, as outlined in the manufacturer’s repair
manual.
-Several of the more common types of composite damages include cosmetic defects, impact
damage, cracks and holes.

A) COSMETIC DEFECTS
-A cosmetic defect is a flaw on the surface of the skin that does not involve damage to the
structural reinforcing fibers.
-Improper handling is a main cause for chipping and scratching.
-Cosmetic defects do not usually affect the strength of the part.

B) IMPACT DAMAGE
-One of the most common causes of impact damage results from careless handling during
transportation or storage.
-Improper handling can cause nicking, chipping, cracking, or breaking away of pieces of edges or
corners.

C) CRACKS
-Cracks can occur in advanced composite structures, just as in metallic ones or advanced
methods like cracks may appear in the top paint or matrix layer or extended into the fiber
material and into the core, but appear to be located in the top surface only.
D) HOLE DAMAGE
-Hole damage may occur from impact, over torqued fasteners, or as a result of pulling through
of fasteners.
-Drilling an excess number of holes, holes drilled in the wrong locations or improperly sized
holes, can also be classified as hole damage.

MATERIAL PERPARATION
-Check the structural repair manual and determine the needed composite materials specific to
the area that was damaged on the aircraft

SURFACE PREPARATION
-Proper surface preparation is a key element to a good composite repair, It is one area that can
cause a repair to fail.
-Therefore, be sure to remove all surface contamination such as exhaust residue, hydraulic fluid
and other dirt by using a suitable soap and water solution followed by an approved solvent
-After cleaning the water surface, the paint must be removed from the damaged area in order
to allow adhesion.
-Do not use paint strippers.

CLEANING
-All repairs must be cleaned after sanding in order to remove all dust, dirt, oils and any other
sanding remnant.
-The strength of the bond is directly related to the condition of adhesion surface.
-A vacuum cleaner is routinely used to remove the dust from sanding.
-A solvent wash of MEK, acetone, butyl alcohol, or other approved cleaner removes dirt and
oils.
-Do not use compressed air to blow dust from the surface or it may cause delamination.
-Prior to the bonding process, some manufacturers may require a water break test to make sure
all oil and grease has been removed from the surface.
-The Water-break test is accomplished by flushing the repair with room temperature water.
-If the surface is properly cleaned, the water will run off the surface in a sheet.
-Before continuing with the bonding process, a heat lamp is commonly used to dry the surface
completely.

WATER REMOVAL
-Moisture trapped within a composite structure can be very dangerous.
-It may expand when heated, which would build up pressure and cause delamination.
-entrapped water that freezes will cause even more delamination as water expands as it freezes.
-Moisture can be detected using X-ray, laser holography, thermography and acoustic emission
testing.

FIBER ORIENTATION
-During the preparation phase of the any composite repair, orientation of the fibers must be
determined prior to beginning the repair.
-When repairing composite structures, the fiber orientation of the repair patch must be in the
same direction as the original to provide uniform and consistent stress diffusion throughout the
part.
-If the fiber orientation is not correctly applied, the strength is dramatically reduced increasing
the chance of failure.

IMPREGNATING RAW FABRIC

-Because pre-impregnated fabric may not be available for a repair, it is often necessary to
impregnate the fabric at the time of the repair.
-Once the shape of the bonding patches has been determined, the repair fabric is placed on a
clean work surface such as another sheet of plastic.
-Be sure to weight and mix the resigns according to the manufacturer’s requirements.
-The liquid resin is poured onto the fabric and worked in it using a squeegee.
-A resin-rich fabric is more susceptible to cracking, due to the lack of fiber support.
A resin-starved fabric does not provide the proper stiffness and strength needed to the repair.

APPLYING PRESSURE
-When performing a composite repair, pressure should be applied to the surface during the
curing operation.
-Applying pressure assists in the removal of the excess resin that is squeezed out.
-In addition, sustained pressure compacts the fiber layers together, removes trapped air and
maintains the contour of the repair relative to the original part.
-It also holds the repair securely to prevent shifting.

A) SHOT BAGS
-Shot bags are effective on large contoured surfaces that cannot be clamped.
-A disadvantage to this type of pressure application is that it cannot be used on the underside of
any part.

B) CLECOS
- Clecos are used in conjunction with pre-shaped Caul (pressure) plates to support the backside
of the repair.
-Not recommended due to the added problems of producing holes for the Clecos in the
structure.

C) SPRING CLAMPS
Spring clamps are used in conjunction with caul plates to distribute pressure evenly over the
repair area.
-Not recommended because they do not compensate for pressure changes when the resin
begins to glow.
-Spring clamps also increases the of compression damage

D) PEEL PLY
-Peel ply may be used to apply pressure in places that are inaccessible to vacuum bagging or
that have varied contours and shapes.
-It is used during the vacuum bagging process to facilitate the removal of the bleeder material
from the repair area.

E) VACUUM BAGGING
-Vacuum bagging works by using atmospheric pressure to provide even pressure over the
surface of the repair. Most effective method used.
-It is used on large surfaces and for most repair work.

METHODS OF CURING
-Some matrix systems can cure at room temperature while others require heat to achieve
maximum strength.
1) ROOM TEMERATURE CURE
-Some types of composite repairs may be occurred at room temperature (18-27’C) over a time
period of 8-24 hours depending on the type of resin used.
-It can be accelerated by applying low heat (60-71’C).
-Full cure strength is not usually achieved for five to seven days.
-Also used on non-structural or lightly loaded parts.

2) HEAT CURING
-The repair of parts that use these types of resins must also cure at high heat settings (120-
400’C) to restore the original strength.
-The amount of heat applied must be controlled by monitoring the surface temperature of the
repair.
-Over heating can cause severe damage.
-Heat curing can be accomplished using several different methods described below.

A) HEAT LAMP
-Heat lamps are not recommended due to the uncontrolled heating of the part.
-Heat lamps may localize the heat in one sport causing uneven curing.

B) HEAT GUN
-Heat guns must be controlled with a temperature monitor.
-Can produce heat up 400’C
-Excessive heat can evaporate resins, leaving dry areas in the part.

C) OVEN CURING
-Over curing offers controlled and uniform heating of all repair surfaces.
-Some ovens incorporate vacuum ports.
-Disadvantages to oven curing are that the part must be removed from the aircraft and must be
small enough to fit into the oven.
D) AUTOCLAVES
-Used in manufacturing of composites rather than repair.

E) Hot patch bonding.

-Hot patch bonding utilized a flexible silicon heating-blanket that incorporates a temperature
controlled.
-The preferred method of curing, due to the controlled even heating of the part.
-Most hot patch bonding machines also incorporate a vacuum pump to apply pressure during
the curing process.

-Repairs must also be allowed to cool at the proper rate, because they gain much of their
strength in the cooling process.
-A slow temperature rise and gradual cooling period is described.
-Two common methods of heat curing are the step cure method and ramp and soak method.

STEP CURING
-The temperature is brought up slowly to a specific temperature then held for a certain period,
then brought up and held again.
-This step-up process is continued until the cure temperature is reached.
-After the cure time has elapsed, the temperature is stepped down by slowly reducing
temperature in increments.
-A more sophisticated and accurate curing process may be accomplished using a programmable
controller.
-This controller may be programmed in a ramp and soak mode.
-The heating process is called ‘ramp’ time, once heated then hold at a particular temperature,
this specific hold time is called ‘ soak’ period.
-A ramp and soak profile depicts the entire heating and cooling cycle.

VACUUM-BAGGING PROCESS
-Vacuum bagging is one of the most common techniques used to apply pressure to a composite
repair.
-Once the composite repair is produced and the patches are in place, the repair area is covered
with a perforated parting film (peel ply), which allows any excess matrix to flow through to the
upper face and produces a smooth surface.
-Next, a bleeder material is placed over the repair to absorb the excess resin that is squeezed
out during the pressure application.
-Another parting film is then placed over the bleeder to keep it from sticking to the pressure
plate, which is placed over the last layer of parting film.
-A surface breather material is placed over the pressure plate to allow airflow up through the
vacuum valve.
-Bleeder and breather materials can be used of the same material and, in many cases, are used
interchangeable.
-If a thermocouple or temperature sensing device is used, it should be laid next to the repair
area and sealed with sealant tape.
-In addition, if a heat blanket is used to cur the part, a parting film should be installed to keep it
from sticking to the repair.
-Sealant tape is attached around the edges of the repair to produce an airtight seal.
-Vacuum-bagging film is laid over the repair and the edges sealed with sealant tape to produce
an airtight seal.
-An X is cut into the bagging film and slipped over the valve, making sure the hole is not too big.
-The area around the valve is then sealed using a rubber grommet.
-The valve is then attached to a vacuum hose, and a vacuum leak test performed.

MECHANICALLY FASTENED REPAIRS WITH PRE-CURED PATCHES

- The facilities and bagging equipment are not available to produce a proper composite repair so
a temporary repair made of a pre-cured patch inserted with blind fasteners may be used.
-However, this type of repair does not produce a structure with the same strength as the
original, and it may cause vibration because it is not a flush repair.
-These types of patches are usually stabilized using some type of mechanical bind fastener,
which is drilled through the patch and into the original part.
-The problem with using any type of rivet is that they have a tendency to crush the core and
produce delamination.
-Impact damage and delamination may occur due to the pressure of the rivet gun and bucking
bar and the expansion of the rivet.
-In addition, you must also make sure metallic fasteners will not react with the composite and
cause galvanic corrosion.

POTTED REPAIRS
-Potted repairs use a filler to complete the composite repair process.
-They provide an alternative to installing a core material plug but do not provide as much
strength as a core material.
-Filling a hole with a resin and filler mixture adds wright and decreases the flexibility of the part.

UNDERCUT POTTED REPAIR

-A composite structure that sustained puncture damage through one face sheet and the core
material may be repaired using a potted repair and surface patch.

LAMINATED STRUCTURE REPAIR

-Laminated structures are susceptible to several different types of damage such as surface
scratches, delamination, impact, and puncture damage.
-Each type of damage requires a different repair procedure.
-Following are several basic laminate composite repair procedures:

A) LAMINATE COSTMETIC REPAIR

-A cosmetic defect is a surface scratch that does not penetrate the first structural ply.
-This type of damage is classified as negligible damage.
-Superficial scratches, abrasion, or rain erosions can generally be repaired by applying one or
more coats of resin to the surface.

B) DELAMINATION REPAIR
-Delamination occurs when the laminate layers become separated or when the plies separate
from the core material.
-It can be cause by sonic vibration, entrapped moisture, and manufacturing defects.
-Delamination is sometimes referred to as un-bonding, or disbanding and, in some cases, can be
detected by shining a light over the part and looking at the damaged area at an angle.
-Delamination may look like a bubble or indentation on the surface of the part.
-Internal delamination is minor enough to repair using a potting compound.
-It can sometimes be repaired by simply injecting resin into the cavity that was caused by the
ply separation.
-If the delamination is severe enough it must be removed and repaired or replaced.

C) LAMINATE DAMAGE TO ONE SURFACE

-This part of repair calls for the removal and replacement of the damage laminate plies.
D) LAMINATE DAMAGE THROUGH THE PART
-The damage can be repaired by using a step cut that starts from one side of the part to the
other or from thicker laminated structures using a step cut that starts from both the sides
which, meets at the center of the structure.

SANDWICH STRUCTURE REPAIRS

-Sandwich structures are vulnerable to impact and puncture damage primarily because these
types of structures usually incorporate relatively thin face sheets.
-Because the face sheets of sandwich structures are relatively thin, delamination commonly
occur at the point where the face sheet bonds to the core material.
-Puncture damage may be repaired in several different ways depending on the size, extend, and
location of the damage.
-Two of the more common types of sandwich structure repair are described below:

A) PUNCTURE REPAIR
-Small punctures that penetrate one side and into the core material may be repaired using a
resin and filler mixture.
-Check the repair manual for damage limitations before proceeding with this type of repair.

B) HONEYCOMB CORE REPAIR

-As discussed previously, potted repairs may be made to areas of damage of up to one-inch
diameter.
-If the damaged area is larger than an inch or in a more critical area, a balsa wood or composite
honeycomb plug may be cut and bonded in place.
-If balsa is used, cut the plug so the grain is perpendicular to the skin.
-If honeycomb material is used, it should be the same density as the original core material.
-Aluminum alloy-faced honeycomb repairs of a simple puncture of an aluminum alloy-faced
honeycomb panel can be accomplished by covering with a doubler plate.
-The plate should be cut from a piece of aluminum the same or up to one and one-half times
the thickness of the original skin thickness.
-Additionally, the doubler should be tapered at a ratio of about 100:1

MAINTENANCE ENTRIES
-After performing any repair, a proper maintenance entry is required before the job is complete.
Several items specific to composite repair should be included in the description of work
performed such as the time, temperature and pressure used in the cure cycle.
-Type of fabric, core material, matrix, and adhesives used also must be metioned.

USAGE AND REPAIR

GENERAL
There are many uses for sealants on the aircraft, some of these usages are below:
1) Sealing the fuselage structure to make sure that the necessary internal pressure is kept.
2) Sealing the fuel tanks or for the repair of fuel tank sealing.
3) Sealing the external joints of the aircraft structure to make sure that water does not go into
the structure, and to make structure aerodynamically smooth.
4) Sealing riveted and bolted joints to make sure that liquids do not go into joints (corrosion
prevention)
5) Sealing sandwich structures to make sure that moisture does not go into the structure.
6) To prevent corrosion (galvanic action) between different metals.
7) To prevent corrosion between different materials, especially between CFRP and Al alloys.
8) To prevent fretting corrosion cause by fatigue stress or vibration between parts of the
structure.
9) To fill cavities.
10) To provide protection for the surfaces on housings, channels, tubes, electrical cables and
components and even already applied sealants.
11 ) To make sure that any leakage of aircraft fluids is kept in the particular area from which
drainage is easier.
12) Making and repairing bead seals.

REPAIR OF DAMAGED SEALANT

-The repair procedures are divided into:
1) Sealant bead repair
2) Fastener Sealing
3) Anchor Nut Sealing
4) Sealing gaps and cavities
5) Interfaying sealant
6) Making or repairing a bead

SAFETY PRECAUTION
- Sealants are made from chemicals which might release dangerous chemicals that can cause
damage to the eyes, the lungs and the skin.
-The sealant repair may have to be performed inside enclosed areas where the environment is
filled with flammable vapors.
-Use air circulation equipment, clean-air mask.
-If sealing material makes contact with the skin, or any other body part it must be removed
immediately and seek medical attention.
-Use a safetyman to monitor your work in an enclosed area placed outside the enclosed area.
-Do not smoke, or use open lamps in the vicinity.
-If illumination is required only approved flame proof lamps of 40W or less should be used.
-Before doing a repair near a moving part or an electrical circuit, perform steps required to
safety the system.
-Before performing any work with sealants, the structure, the extrusion gun, flame proof lamps,
and other tools, and the air circulation lines, and metals of the clean-air mask must be
grounded.

REPAIR PROCEDURES
-Area around the area of intended repair must be masked off to prevent any damage to the
undamaged sealant and undamaged structure.
-Non-metallic scrapers and a stiff brush may be used to remove the damaged sealant.
-Once the damaged sealant is removed the edges of the remaining sealant must be chamfered
to give a minimum taper.
-Make the faces of the tapers rough. This is done so as to provide a good overlap for the new
sealant to bond onto the remaining sealant.
-Clean the repair area with the cleaning agent approved for a job and use as little cleaning agent
as possible.
-Cleaned area must be dried immediately with a clean dry cloth.
-Do an inspection of the repair area to see if the protective finish of the surface is damaged.
-Prepare the correct sealant; put a layer of the sealant on the repair area. Use a spatula or
extrusion gun to do this.
-Make sure that there are no air bubbles under the sealant.
-Make sure that the sealant has made a good bond at the overlaps.
-Apply the correct protective layer over the sealant repair.

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