Prepared by : RJK Approved by : UH Original issue date : 18-11-2008 Document number : ARM-ZACE-002 Revision : 5 Revision date : 31-07-2015 Title : Herculight Patch Repair 1. Planning information A. Effectivity: This approved repair method will provide additional instructions and details for the repair of Herculight panel sheets on containers manufactured by Zodiac AirCargo Equipment. B. Reason: Due to the rough daily handling, the container panel sheets often show damages. To ease the maintenance process an approved repair method in addition to those as already given in the equivalent CMMs is required. C. Description: See section 3, Introduction D. Compliance: This approved repair method can be used for the repair of panel sheets of all different types of containers manufactured by Zodiac AirCargo Equipment. E. Note: Ensure that the panel sheet and patch are clean. 2. Material information A. Materials required: No special materials required B. Special tooling: No special tooling required
3. Introduction This repair instruction document is for use on all Herculight ULD s manufactured by Zodiac AirCargo Equipment. This is an additional document to the existing Zodiac ULD Manuals and will NOT disengage from the limits given in these documents. Damaged Herculight panels can be repaired by method of patching. Patches must be made of original Herculight material. If multiple damages in one panel are to be repaired, a single, larger patch that covers these multiple damages has to be used for repair if the distance between the holes is less than 76 mm (3 ) in order to allow the required minimum overlapping of the individual patches. To ensure a proper repair, the instructions as shown below have to be followed. The repair has to be performed by a repair shop certified. acc. to Part 145 or equivalent qualification level. In case of any questions / doubts pls. contact the OEM. Contacts: Reinier Kleis, Phone: +31-88-3743834 Mail: reinier.kleis@zodiacaerospace.com Ulf Hartmann, Phone: +31-88-3743920 Mail: ulf.hartmann@zodiacaerospace.com
4. Types of Damages Typically five (5) types of damages may occur: Type A: Straight cuts in the sheet with a max. length of 150 mm (6 ) (allowable damages, see CMM) Type B: Punctured sheets (holes) with a max. size of 150x150 mm (6 x6 ) (allowable damages, see CMM) Type C: Straight cuts in the sheet with a length of more than 150 mm (6 ) Type D: Punctured sheets (holes) with a size of more than 150x150 mm (6 x6 ) Type E: Damages at the outer edge reinforcement 5. Procedures Damages of Type A (within allowable damage limitation): These damages can be repaired by fixing a patch from INSIDE or OUTSIDE with a double sided tape (tape specification see page 8) covering the entire patch surface. Damages of Type B (within allowable damage limitation): These damages can be repaired by fixing a patch from INSIDE or OUTSIDE with a double sided tape (tape specification see page 8) around the outer edges. For cosmetic reasons or improved water tightness a second same sized patch may be also placed at the opposite side. NOTE: it is advised that repairs of Type A and Type B damages are performed using hotwelding process described for damages of Types C and Type D because this provides the highest quality bond between the patch and panel. The repair method making use of double sided tape is however allowed for Type A and Type B damages as a short term fix to restore container water tightness.
Damages of Type C (exceeding the allowable damage limitation) and patches covering more than one (1) damage: These damages can be repaired by hot-welding an adequately sized patch from INSIDE or OUTSIDE onto the sheet. Damages of Type D (exceeding the allowable damage limitation) and patches covering more than one (1) damage: These damages can be repaired by hot-welding an adequately sized patch from INSIDE or OUTSIDE onto the sheet. For cosmetic reasons or improved water tightness a second same sized patch may be also placed at the opposite side with self-adhesive tape. NOTE: To repair damages Types A/B/C/D the damaged sheet does not have to be removed from the container structure. Damages of Type E: These damages can be repaired by hot-welding a special patch that includes edge reinforcement, from OUTSIDE ONLY onto the sheet. NOTE: To repair damages Types E the damaged sheet may have to be be removed from the container structure. 6. Panel Preparation Damages Types A/B/C/D: Inspect the panel area to be repaired for any burrs or frayed edges. Trimming should be performed only for protrusions that extend beyond the plane of the panel. Trimming may be accomplished with scissors, utility knife, or other trimming tool. For straight cuts flattening the panel material may be sufficient.
Damages Type E: The damaged area of the edge reinforcement has to be removed. Please refer to 8.0 Patch Application for Damages Types E. 7. Patch Preparation Patches for damages Types A/B (self-adhesive tape): Patches for self-adhesive tape application may be manufactured from left-over Herculight panel material such as panels that are beyond economical repair, or may be made from new Herculight sheet specifically purchased for patch repair application (see material sizes and part numbers mentioned under Patches for damages Types C/D). Cut a piece of Herculight material dimensioned such that it will overlap the damaged area by minimum 38 mm (1,5 ) on all sides. Cutting may be accomplished with scissors, utility knife or other cutting tools. A patch may be cut any shape as long as the minimum of 38 mm (1,5 ) patch overlap around the damaged area is maintained. Prepare the patch for the application of double sided tape by thoroughly cleaning the surface of the patch with an industrial grade 2-propanol (isopropyl alcohol). Tape should be applied within 30 minutes after cleaning, if not the surfaces should be re-cleaned. Apply 38 mm (1,5 inch) wide 3M 9472LE double sided tape around the outer perimeter of the patch with pressure to the full area of the tape to create a proper bond. If ambient temperature is below 20ºC (70ºF), the patch should be heated with the use of a standard hair dryer before pressure is applied to create proper bonding. Additional tape may be applied in the center area of the patch (Damages Type A). Tape can be sourced from Zodiac or from a local 3M supplier: Description 3M Part Dimensions Zodiac Part number number Tape 3M 9472LE 1,5 x 180 yd 9-097-81
Patches for damages Types C/D (hot-welding): Patches for hot-welding application of any size may be manufactured from left-over Herculight panel material such as panels that are beyond economical repair or may be made from new Herculight sheet especially purchased for patch repair application. Dimension (mm) Dimension Zodiac Part number (inch) 508 x 508 20 x 20 4-087857 1016 x 1016 40 x 40 4-100337 1752,6 x 3048 69 x 120 4-102927 Cut a piece of Herculight material dimensioned such that it will overlap the damaged area by minimum 38 mm (1,5 ) on all sides. Cutting may be accomplished with scissors, utility knife or other cutting tools. A patch may be cut any shape as long as the minimum of 38 mm (1,5 ) patch overlap around the damaged area is maintained. Patches for damages Type E (hot-welding): Patches for the reinforcement edges are special patches and are available from Zodiac. For damages involving multiple holes, side patches are also needed. For these refer to 7.0 Patches for damages Types C/D (hot-welding). Repair patch (one hole) Repair patch (multiple hole) 3 x 4 inch 4-087858 8 x 55 inch 4-113012 4-087858 4-113012
8. Patch Application A patch could be applied from the INSIDE or OUTSIDE of the container. Prepare the damaged panel for the application of double sided tape or hot-welding by thoroughly cleaning the surface of the panel around the damaged area with an industrial grade 2-propanol (isopropyl alcohol). A patch should be applied within 30 minutes after cleaning, if not the surfaces should be re-cleaned. Damages Types A/B: A patch for type A/B type damages could be applied from the INSIDE or OUTSIDE of the container. If required it is allowed to fix a second patch at the opposite side as well. Before peeling the paper backing off the tape on the patch, test fit the patch over the damaged area to pre-locate, align the patch for installation, and check that a minimum overlap of the damaged area of 38 mm (1,5 ) is accomplished. Remove the backing paper from the patch and firmly press the patch over the damaged area. Align the patch and position it over the damaged area. Apply pressure to the full area of the tape to create a proper bond. If ambient temperature is below 20ºC (70ºF), the patch should be heated with the use of a standard hair dryer before pressure is applied to create proper bonding. Damages Types C/D: A patch for type C/D type damages could be applied from the INSIDE or OUTSIDE of the container. Prepare the patch for the application of hot-welding by thoroughly cleaning the surface of the patch with an industrial grade 2-propanol (isopropyl alcohol). The hot-welding process should be finished within 30 minutes after cleaning, if not the surfaces should be recleaned. Refer to 9.0 Hot Weld Instructions for the hot weld procedure. Damages Type E: A patch for type E type damages should always be applied ONLY from the OUTSIDE of the container. Refer to 9.0 Hot Weld Instructions for the hot weld procedure.
For damages involving only a single hole in the edge reinforcement, remove the panel to be repaired from the container (if needed). Trim the damaged area according fig 2, and then position the patch 4-087858 as shown in fig 5.
For damages involving multiple holes in the edge reinforcement, remove the panel to be repaired from the container (if needed). Trim the damaged area and patch 4-113012 as shown to ensure proper overlap. The split in the edge reinforcement requires additional patching. Cut a single-layer patch creating shown overlap.
9. Hot Weld Instructions The following tools are recommended for hot welding (alternative tools may be used): Image Description Zodiac P/N Leister Triac*, hot air hand tool for 120V application P0000039 Leister Triac*, hot air hand tool for 230V application * with digital temp display Leister wide slot nozzle 40 mm (Leister P/N 107.132) Leister one-arm pressure silicone roller 40 mm (Leister P/N 106.975) P0000040 P0000041 P0000042 Additionally a cutting or trimming tool such as scissors and a utility knife are needed. When operating the hot air tool, always follow the instructions as set forth in the manufacturer s manual. When welding Herculight material, the hot air tool should be set to 220ºC (428ºF). The ambient temperature is of influence and might require a different temperature setting. Wait until the tool has reached this temperature before initiating the welding process. When applying the correct temperature, the Herculight material will look transparent. Do not set the temperature too high as the Herculight material will start to look brown and eventually start looking burnt. The required temperature should be obtained locally by testing. Hot welding for damages type C/D Position the prepared patch on the prepared panel such that an overlap of 38 mm (1,5 ) is ensured from the edges of the hole or straight cut to be repaired. Position the nozzle of the hot air tool where the patch and the panel meet and keep in place until the polypropylene coating of the panel turns glossy, then fold the patch onto the panel to be repaired such that an overlap of 38 mm (1,5 ) is ensured.
Immediately after heating, apply pressure with the roller to fuse the corner of the patch to the panel. The patch is now tagged in position on the panel to be repaired. To weld the first edge of the patch to the panel, position the nozzle of the hot air tool between the patch and the panel. Slowly move the nozzle along the edge to be welded, immediately followed by applying pressure with the roller. To make sure enough heat is applied, verify that the patch does not detach from the panel after releasing pressure on the roller. If this is the case, repeat the procedure.
Repeat this process for two more sides of the patch. For the last side of the patch to be welded, it is not possible to insert the nozzle of the hot air tool between the patch and panel material. For this last edge, apply heat directly on top of the patch immediately followed by applying pressure with the roller. The patch is now welded unto the panel along its full perimeter. For damages close to (but not including) the panel edges, patch overlapping on the panel
edge reinforcements is allowed. Inspect the patch for areas of improper welding. If required, heat may be applied directly onto the patch and pressed with the roller to obtain proper welding in such areas. Hot welding for damages type E The procedure for welding the special patch for type E type damages is equal to the welding procedure as described for type C/D type damages. Due to the small area of the patch it is not possible to insert the nozzle of the hot air tool between the patch and the panel to be repaired. Therefore apply heat directly on top of the patch immediately followed by applying pressure with the roller. The area of the special patch 4-087858 to be welded to the panel being repaired is indicated in the below image. The areas of special patch 4-113012 and side patches to be welded to the panel being repaired is indicated in the below image. HATCHED AREAS TO BE WELDED