Skyflex. aircraft sealant. Airbus A320 Aircraft Family Installation Guide
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1 Airbus A320 Aircraft Family Installation Guide
2 Summary Operators of Airbus A320 family of aircraft have experienced problems with structural corrosion appearing under the floors requiring maintenance sooner than anticipated. The operators developed a new sealing method that includes GORE SKYFLEX Aircraft Sealant to reduce this corrosion. This will reduce maintenance costs, reduce maintenance time, increase aircraft availability and increase profitability for the operators. Gore SKYFLEX Aircraft Sealant GORE SKYFLEX Aircraft Sealant offers the lightest weight, non-curing, non-hazardous form-in-place sealant technique. This product can be installed and maintained more efficiently than all other sealant methods. This revolutionary material provides excellent protection against corrosion, water ingress, and other environmental influences including fuels and oils. GORE SKYFLEX Sealant remains flexible and compliant over many panel installation cycles, retaining all of the designed benefits and features that are crucial to ensure the integrity of every application today. GORE SKYFLEX Sealant is available in many forms, including ribbed sealant tape, flat sealant tape, sheet, die cut gaskets, and environmental and fuel resistant forms. For more information or assistance in choosing the sealant right for your application contact Gore. Benefits Reduce maintenance costs Non Hazardous/no hazardous waste disposal Resistant to corrosion Multiple panel removal/installation cycles possible Lightweight Protection against water ingress and other environmental influences No sealant cure time Easy to install Conforms to surface irregularities Temperature range: -240 C to +260 C wet areas of the aircraft. The enhancements include the following materials: GSC Clip nut tape GSC Edge protection tape GSC Sealant tape GSC Galley mount washers GSC Lav tub washers Panel Preparation In order to convert from polysulfide sealant to GORE SKYFLEX Sealant all old sealant and dirt must be cleaned from the aircraft structure and panel surfaces. A non-metallic scraper should be used to remove the old sealant. Polysulfide sealant may be left in gaps or irregularities to provide a level sealing surface. Panels should be cleaned with an approved solvent prior to installation of GORE SKYFLEX Aircraft Sealant. If priming, painting, or surface treatment are required, that work should be completed before sealant installation. Any gaps or irregularities not filled with polysulfide sealant should be filled with GORE SKYFLEX Sealant compensation tape, part number GSC (formerly GUA ). Installation Guide This Installation Guide describes the installation of GORE SKYFLEX Aircraft Sealant as an enhancement to the corrosion prevention in the wet areas of Airbus A320 family of aircraft. Only Gore supplied enhancements are included in this document; other enhancements are covered by the appropriate manufacturer. This document applies to the floorboards and structures in 2
3 Airbus A320 Aircraft Family Installation Guide Clip Nut Tape Clip nut tape is used on the structure to protect the finish (primer, paint, etc.) in the area where clip nuts are applied. To use, simply remove clip nut tape from the backer and apply over the hole in the structure as shown. Clip nut tape contains two kiss cuts to easily allow the fastener to fit through the sealant. Center the kiss cut on the hole. Clip nut tape is not reusable, as the adhesive is designed with low tack for easy removal. The tape is supplied on a roll. To install edge protection tape, remove the release liner and apply the tape so that approximately 1/3 of the tape width is on the top of the board. Fold the remaining tape around the edge and adhere to the bottom panel. Once the tape is installed, the clip nut may be installed in accordance with the Aircraft Maintenance Manual (AMM) or engineering order. Sealant System The illustration shows the sealant system and its components. Edge Protection Tape Before applying sealant, floorboards must be cleaned as previously stated. Any old sealant or existing non-gore sealant must be removed and new GORE Edge Protection Tape applied. GORE Edge Protection Tape is applied on the edges of the floorboard to protect the edges from damage and isolate the conductive and abrasive fibers from the structure to prevent chaffing of paint and primer Fastener Edge tape Floorboard Floorboard sealant Gap sealant Cord goes under sealant Clip nut Clip nut tape Floor beam The edge protection tape should be applied wherever the floorboard contacts the structure, in order to keep all contact areas the same height. 3
4 Sealant Installation Once the floorboard is cleaned and new edge protection tape installed, this board is ready for installation of GORE SKYFLEX Sealant. GORE SKYFLEX Sealant should be applied around perimeter of the floorboard and wherever the floorboard touches the floor supporting structure. This will ensure all contact areas of the board are the same height. stretches and smooths the material so that a single layer of continuous sealant is inside the corner. Only a small amount of material remains to be blended into the corner. The edge of the panel has a single continuous ribbon of sealant around the perimeter. For best sealing and compensation of variations between the floorboards and the floor structure, the technique used is a continuous cornering method with the large bulb overhanging the edge of the floor panel. A detail of the edge of the floorboard shows the large bulb overhang. About 3mm of tape (the same width as the large bulb) should overhang the edge of the board to permit panels to seal against each other and the structure. This also allows liquid sealant to be poured into gap. A finished corner should look like this. Note that the sealant is not overlapped and that corner is flat and smooth. This method insures maximum sealing of the floorboard. To install the sealant tape begin near a fastener hole on the straight edge of the board. Start by peeling back a few centimeters of the release paper and apply the sealant with the large bulb to the outside and overhanging the edge of the floorboard. Continue to install tape around the perimeter of the board using the same technique for the corners until the starting point is reached. Once the starting point is reached, trim the length of the sealant to allow a 3 to 5mm overlap. Remove the release paper and press the tape onto the starting point. Cornering Method and Smoothing At the corner, swing tape around the corner with the large bulb in position and allow the inside to rise up (do not allow adhesive to touch). Once the outside edge of the tape is in place, stretch and smooth the inside edge flush. To smooth the inside of the corner, the technician carefully 4
5 Airbus A320 Aircraft Family Installation Guide Sealing Floorboard Interior Once the sealant has been installed on the perimeter of the board, a layer of sealant tape must be applied to any area of the board that contacts the aircraft structure. This ensures all contact areas are the same height and prevents bowing or popping of the board when load is applied, as well as isolates the carbon fibers of the board from any exposed metal on the structure. The perimeter of this floorboard has GORE SKYFLEX Sealant applied. The edge protection tape has been applied to the interior of the floorboard where it contacts the structure. SKYFLEX Sealant has yet to be applied on top of the edge protection tape. When all the sealant has been applied to the panel, it is ready for the fastener holes to be punched out. The sealant is very strong and flat tipped fasteners will have a difficult time penetrating the sealant unless pre-punched by a sharp object such as a scribe or awl. By rubbing the tape in place, the pressure sensitive adhesive is activated and fastener holes can be located by the color change. The technician uses an awl to punch the fastener hole. The installation procedure of panels sealed with GORE SKYFLEX Sealant is the same as the existing procedure (refer to AMM). Floor structure must be clean and any corrosion or coating repairs including corrosion prevention compounds (CPC), primer, and paint must be applied and cured before floorboard installation. If the overhanging material causes interference during installation, manually compress the material to allow the board to be installed. Here the sealant is being applied to the contact areas inside the perimeter. This ensures all contact areas will be the same height. The overlap with the perimeter tape should be approximately 1 to 2mm. When the width of the contact area is wider than one piece of sealant tape, use two pieces of sealant side-by-side. Install the tapes with the large bulbs facing out and overlap the tapes by 1 to 2 mm. If the tape protrudes above the level of the floorboard after floorboard installation, use a thin non metallic scraper to push the sealant far enough below the top of the board to allow liquid sealant to be poured into the gap. 5
6 Shown are installed panels from the avionics bay. Note that sealant is installed anywhere the floor structure contacts the floorboards. Galley Hard Mounts Galley hard mounts seal the mount to non-textile flooring (NTF) junction. The mount uses a sealant kit containing three washers and a mount seal. The washers go on the top and bottom of the bushing and under the fastener head. The mount seal goes between the galley stud and the NTF. The current sealing option uses an o-ring that quickly hardens and creates a leak path for liquids. This leak path exposes dissimilar metals and the carbon floorboard to liquids creating a battery and corrosion. Lav Mount Washer Kit The drawing shows the placement of the washers with adhesive on each side of the spacers. Washers without adhesive are used under the fastener head. Care should be taken during lavatory installation not to disturb the washer placement. 6
7 Airbus A320 Aircraft Family Installation Guide
8 Worldwide Sales and Support Contact Information China: Beijing China: Shanghai China: Shenzhen Germany International Japan Korea North America Singapore Taiwan United Kingdom GORE, SKYFLEX, and designs are trademarks of W. L. Gore & Associates, Inc W. L. Gore & Associates, Inc. W. L. Gore & Associates, Inc. 402 Vieve s Way Elkton, MD (800) 445-GORE (4673)
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