SRM-51-70-10 Repair Design Guideline

Customer : ENV Manual : SRM
Type : A320 Selected effectivity : ALL

Rev. Date : Feb 01, 2021
51-70-10 REPAIR DESIGN GUIDELINE
1. General
A. Purpose of the Repair Design Guideline
Each repair on an aircraft structure has to be capable of sustaining the original justified design loads for
static, fatigue and damage tolerance requirements. Only the static requirements will be considered in this
chapter.
A static or stress analysis is performed to make sure that the structure can withstand the applied ultimate
loads without failure and without permanent deformation at limit load.
There are two main approaches in demonstrating the static strength capability of the repair design. The
approach taken depends on how much is known concerning the existing loading in the repaired part.
(1). All details of the applied loading are known:
In this case, a detailed stress analysis of the part to be repaired results in an optimized repair design.
This is generally the approach taken by the manufacturer.
(2). No details of the applied loading are known:
In this case the REVERSE ENGINEERING METHOD may be employed to evaluate the repair static
strength capability.
B. Scope and Limitations
This topic presents some guidelines which may be used when designing repairs for extruded/formed
sections. These guidelines are based on the reverse engineering method.
As explained in Paragraph 1.D (Principle), these guidelines are based on the restoration of the static
strength of the repaired part.
The resulting repair will therefore comply with the static strength requirements. These guidelines, when
used together with the other standard SRM principles and guidelines (fastener hole and drill data, fastener
pitch and edge distance data, sealing, etc.) may be used repairs to secondary structure without referring
back to AIRBUS.
These guidelines may also be used when designing repairs, which are to be submitted to AIRBUS for
approval, however it should be noted that the assumption taken when designing a repair based on the
reverse engineering method are often conservative and may result in over-designed repairs.
The proposed method addresses only the static performance of the repair since no fatigue and damage
tolerance assessment is required for repair solutions referring to this part. Nevertheless these repair
solutions ensure minimum acceptable fatigue and damage tolerance performances.
List of Symbols
This list shows which symbols has been incorporated into the repair design guideline. It also shows the
measurement unit of the used symbol and its description.
SYMBOL UNIT DESCRIPTION

Ai mm ² Cross Sectional Area of the Element
ai mm External Breadth of the Element
bi mm Calculate Element Breadth (Refer to Paragraph 2.D.(1))
Ec MPa Young`s Modulus (Compressive)
Fbru Mpa Allowable Ultimate Bearing Stress. Examples use e/d = 2.0
Fst,i N Element Crippling Load (Refer to Paragraph 2.D.(3))
Fst,p N Profile Crippling Load (Refer to Paragraph 2.D.(4))
Fsu MPa Allowable Ultimate Stress in Pure Shear
Ftu MPa Allowable Tensile Stress
Fty MPa Yield Strength at 0,2% Strain
Ki - Dimensionless Crippling Factor (Refer to Paragraph 1.D.(2).(d).2)
L mm Profile Length
r mm Radius
Print Date: February 01, 2021 Page 1 of 110

© AIRBUS S.A.S. ALL RIGHTS RESERVED. CONFIDENTIAL AND PROPRIETARY DOCUMENT.
SYMBOL UNIT DESCRIPTION

si mm Element Thickness
xi - Dimensionless Intermediate Factor (Refer to Paragraph 2.D.(2))
yi - Dimensionless Crippling Stress of Element (Refer to Paragraph 2.D.(2))
µ - Poisson`s Ratio
kr MPa Critical Elastic Crippling Stress
st,i MPa Element Crippling Stress (Refer to Paragraph 2.D.(2))
- Slenderness Ratio
Table 001
C. Factor Definitions
(1). Safety Factor
The relation of the maximum allowable load without failure and without permanent deformation and
the designed applied load is expressed in a value known as the safety factor. In aircraft design the
factor of safety is 1.5.
- Ultimate Load = 1.5 * Limit Load
(2). Reserve Factor
The degree to which a structure can withstand the ultimate load is expressed in a value known as the
reserve factor (R.F.). The reserve factor must be greater or equal to 1.0.
- Reserve Factor (R.F.) = Allowable Load / Applied Load
- R.F. 1.00
(3). Margin of Safety
An other expression of the reserve factor is margin of safety (MS).
- Margin of Safety = Reserve Factor - 1
- M.S. 0
D. Principle
(1). Repair Material and Dimensions
In order to restore the original structure capability, a basic principle when reinforcing or splicing a part
is to use the same material as the original. The thickness of the repair part should ensure that the
cross-sectional area of the repair restores the original cross sectional area. Generally use one gauge
thicker than the original.
(2). Analysis
A static analysis for a repair requires normally the following checks:
- Tension check
- Shear check
- Compression check
- Check to ensure that the fasteners are able to transfer the applied loading.
For the reverse engineering approach the structures engineer must calculate the allowable load
in the pre-damaged state and then compare that to the post-repair allowable load. The allowable
load in the pre-damaged state can only be calculated if a stress in the repaired area is assumed.
This assumed stress is related to the material of the repaired part, i.e. assume a stress equal to the
ultimate tensile stress, the lower of Ftu or 1.5 * Fty of the material for the tension check and to the
component geometry for the compression check.
The reverse engineering method uses the 'A' basis values from the tables given in Chapter 51-70-
11. For extrusions the values in the L material direction are used as the material direction is known.
For items made from sheet the values in the Lt material direction are taken except if the value in the L
direction is lower than the Lt value.
To calculate the allowable load in the pre-damaged state the section to be considered is:
- for profiles: The original net section of the part.This section is the original profile section minus
the area(s) corresponding to the original fastener holes. Additional repair fastener holes not

considered. The repair fastener holes are not taken into account as we need to calculate the
maximum potential strength of the original part in order to design the repair with this capability. If
you take into account the repair fastener holes then the potential tensile strength of the original part
will be underestimated.
- for plates and webs: The repair net section of the part.This section is the one of the considered (cut
out width) minus the area corresponding to the original and the additional repair fastener holes.
For plates and web repairs the section to be taken corresponds to the width of the cutout (length
of cutout * web thickness) minus the area of additional repair fastener holes (diameter of hole *
original web thickness * number of fasteners in the cutout length).
(a) Tension and Shear Check
For the tension and shear check, material allowable tables have been developed which include
the main material properties for most common alloy (Refer to Chapter 51-70-11 - Material
Allowable Values). For calculation refer to Paragraphs 2.A and 2.B.
(b) Compression Check
For the compression check, refer to the method detailed in Chapter 51-70-14 Allowable Buckling
Loads for Standard Sections. This method can be used to determine pre and post allowable
loading. For calculation refer to Paragraph 2.D.
(c) Fastener Check
For the fastener check, the pre-damage tension and compression loads should be compared and
the maximum used as the applied fastener load. Tables of allowable values (Refer to Chapter
51-70-13- Fasteners - Strength of Mechanically Joints) can be used to determine the allowable
fastener load. For calculation refer to Paragraphs 2.A.(3), 2.B.(3) and 2.C.(4). The reserve factor
must again be greater or equal to 1.
(d) Allowable Compressive Load
1 General
The reverse engineering method can be used to calculate the compressive crippling load
of short metal profiles of a general shape. The calculation is based on an empirical method
following sufficient tests on various shapes and materials.
The calculation method assumes that the profile can be idealized using flat rectangular
plates of constant thickness. The crippling load of the profile is the sum of the crippling load
of all rectangular elements.
The method is valid for crippling failure of profiles only. Other forms on instability, e.g.
buckling or torsional instability may appear at lower compressive loading.
For longer profiles (slenderness ratio one edge free a/s 12; no edge free a/s 25) section
buckling failure should be investigated.
For calculating the allowable buckling load refer to Paragraph 2.D. For data of allowable
local buckling load for standardized formed sections and profiles refer to Chapter 51-70-14 -
Allowable Local Buckling Load.
2 Crippling Factor - K
The crippling factor Ki is depending on the ratio L/a and element edge support. For a static
justification the values to be used are:
- Ki = 0.41 for an element with one edge free
- Ki = 3.6 for an element with no edge free and where a1 - s1 > 0.2 * a2 If this condition is
not fulfilled then Ki = 0.41
(For dimensions, refer to Paragraph 2.D.(1))
2. Calculation
A. Calculation under Tensile Load
(1). Maximum Tensile Load
Ptmax Maximum Tensile Load

Ptmax = A * (Ftu or 1,5 * Fty, or whichever A Cross Sectional Area

is less) [N] Fty Ultimate Tensile Stress
Table 002
(2). Reserve Factor
PtmaxRep PtmaxRep Maximum Tensile Load of Repaired Part

R.F. = -------------- [ ] R.F. Reserve Factor 1.0
PtmaxOri PtmaxOri Maximum Tensile Load of Origin Part
Table 003
(3). Determination of Fastener Number
PtmaxOri PtmaxOri Maximum Tensile Load of Origin Part

NoRow -------------- [ ] NoRow Number of Fastener Rows
FultimRiv FultimRiv Ultimate Handling Force of one Row of Rivets
Table 004
B. Calculation under Shear Load

(1). Maximum Shear Load
PSmax Maximum Shear Load

Psmax = A * Fsu [N] A Net Section Area
Fsu Ultimate Shear Stress
Table 005
(2). Reserve Factor
PsmaxRep PSmaxRep Maximum Shear Load of Repaired Part

R.F. = -------------- [ ] R.F. Reserve Factor 1.0
PsmaxOri PSmaxOri Maximum Shear Load of Origin Part
Table 006
PsmaxOri PtmaxOri Maximum Shear Load of Origin Part

NoRow -------------- [ ] NoRow Number of Fastener Rows
Table 007
C. Determination of Shear or Bearing Critical for Sections in Double Shear
(1). Calculation of Double Shear Fastener Allowable (Fds)
Fds Fastener Allowable in Double Shear

Fds = 2 * c * Fss [N]

c For c determination refer to Chapter 51-70-13 - Fasten-

ers - Strength of Mechanically Joints - Paragraph 1.F.(1).
Fss Fastener Allowable in Single Shear from tables in
Chapter 51-70-13
Table 008
(2). Determination of Max Fastener Allowable Load Based on Bearing Stress Allowable
Pallow Allowable Load

Pallow = s * d * FBru [N] s Thickness of Concerned Material
d Diameter of the Hole
FBru Ultimate Bearing Stress from Chapter 51-70-11
Table 009
(3). Determination of Bearing Stress Based on Fastener in Double Shear
Fbru max Max Bearing Stress from Fastener in Double

Fds Shear
Fbru max = ----------- [MPa] Fds Fastener Allowable in Double Shear
s*d s Thickness of Origin Part
d Diameter of the Hole
Table 010
NOTE: Is Fbru max Fbru ? - The limitation is given by the lowest value which is then used to de-
termine the allowable fastener load to be used.
PsmaxOri PSmaxOri Maximum Shear Load of Origin Part

NoRow = -------------- [ ] NoRow Number of Fastener Rows
Table 011
D. Calculation under Crippling Load
(1). Calculated Element Breadth bn
The calculated breadth of element 1, bi=Ai/si

FORMED PROFILES EXTRUDED PROFILES
s s
r r
s
s
a a
a a
ELEMENT
s
s
a
a
r r r
s
s
a a a a
s s r
b a 0.2
ONE EDGE FREE
2 4 s s s
1 r s r
b a s b a 1 0.2
2 2 2 s s
s s r
b a 2 0.2
2 2 s s s
NO EDGE FREE
r r s r
b a s b a s 1 0.2 b a s 2 0.2
2 s s 2 s s s
NS6 51 70 10 0 AAM0 01 0
Figure 001 (sheet 1) / 51-70-10

** ON A/C [+]

(2). Calculating Element Crippling Stress

x INTERMEDIATE FACTOR
b ELEMENT BREADTH
b F
x F YIELD STRENGTH AT 0.2 STRAIN
s K E
K CRIPPLING FACTOR
E YOUNG S MODULUS
y 1.4 0.628 x WHEN x 1.095
0.78
y WHEN 1.095 x 1.633
NS6 51 70 10 0 ACM0 01 0
0.69
y WHEN x 1.633
x
y F MPa ELEMENT CRIPPLING STRESS
Figure 002 (sheet 1) / 51-70-10

** ON A/C [+]

(3). Calculating Element Crippling Load
Fst,i = bi * si * st,i [N] Fst,i Element Crippling Load

bi Calculated Element Breadth
si Element Thickness
st,i Element Crippling Stress
Table 012
(4). Calculating Profile Crippling Load
Fst,p Profile Crippling Load

Fst,p = Fst,i [N]
Fst,i Element Crippling Load
Table 013
3. Example 1 - Riveted Flange Cutout

SECTION
2 4
A-A
1
2 3
A 4
1 MIN
ORIGINAL PART
NS6 51 70 10 0 AEM0 01 0
A
AREA A: 2 x 3 FASTENERS 1
Figure 003 (sheet 1) / 51-70-10 Repair of the Damaged Area

** ON A/C [+]

A. Material
ITEM NOMENCLATURE QTY MATERIAL/REMARKS

1 Joining section AR To be determined per following reverse engin-
eering method.
2 Section insert AR Use the same section and material as the origin-
al section or equivalent material as per Chapter
51-31-11.
3 Rivet countersink 1005 AR As per existing rivet type and diameter. Number
of rivet row and alternative type are determined
per following reverse engineering method.
4 Rivet, universal HD AR Number of row, rivet and alternative type and
diameter are determined per following reverse
engineering method.
- Structure paint AR Material No.16-005 (Refer to the Consumable
Materials List (CML))
- Pretreatment for painting AR Material No. 13-002 (Refer to the CML)
- Sealant AR Material No. 09-001 (Refer to the CML)
- Cleaning agent AR Material No. 11-003 (Refer to the CML)
- Structure paint AR Material No. 16-001 or 16-006 (Refer to the
CML)
- Structure paint AR Material No. 16-002 (Refer to the CML)
(1). Notes
NOTE:
- All parts and fasteners have to be installed with PR 1436G (Material No. 09-013) wet assembly.
- Break sharp edges.
- All dimensions are in millimeters.
- All parts to be adjusted on A/C.
NOTE: Except specified, respect the following SRM rules:
- Fastener hole and drill data (Refer to Chapter 51-44-00).

- Fastener oversize and alternative (Refer to Chapter 51-43-00).
- Fastener pitch and edge distance data (Refer to Chapter 51-47-00).
- Paint coating (Refer to Chapter 51-23-00).
- Sealing processes (Refer to Chapter 51-24-00).
- Countersinking (Refer to Chapter 51-46-00).
- Torque value (Refer to Chapter 51-49-00).
NOTE: The bend radius of repair part must be made so that the outside radius of the inner nesting
part is greater than the inside radius of the adjacent part.
- Original Part:
Clad Sheet metal 2024-T42 thickness 1.6 mm
Table 014
- Doubler:

Table 015
(2). Material Data
Documentation SRM (Refer to Chapter 51-70-11, Table 3)

Allowable Loads [MPa] Original Part Doubler
Ftu 390 410
Fty 230 235
Mini (Ftu or 1.5*Fty) 345 352.5
Fcy 235 250
Fsu 220 230
Fbru 560 560
Ec 66900 70300
Table 016 - Material Data
NOTE: 'A' basis values used in the Lt material direction as the sections are made from sheet material.
(3). Fastener and Rivets

(a) Determination of allowable fastener load
Rivet Csk 1005 DIA 4 MS20426AD in sheet metal 2024-T42 - t = 1.6 mm
Table 017
Quantity = 1 each per row of fasteners
From Chapter 51-70-13 Table 007.
Fultimate = 2330 N
The calculation is done in the original part and covers the doubler.
Rivet universal DIA 4
Table 018
NOTE: The upper flange fasteners ensure stability between the original part and the doubler re-
pair with cutout, by consistency with lower flange definition, that is to say the same num-
ber of fasteners (with same dia) and the same materials, but rivets universal instead of
rivet countersink.
(5). Calculation under tensile load

CUTOUT ORIGINAL PART DOUBLER REPAIR
20 15 18.4
4 1.6 4 1.8
NS6 51 70 10 0 AGM0 00 0
20 18.4
Figure 004 (sheet 1) / 51-70-10 Sketch of the Sections

** ON A/C [+]

Cutout Original Part Doubler Repair

Section = length * thickness [ mm² ]
Section = (15 - 4)mm * 1.6 mm Section = (18.4 - 4)mm * 1.8 mm
Section = 17.6 mm ² Section = 25.92 mm ²
Ptens max = Section * Ftu mini [ N ]
Ptens max = 17.6 mm² * 345 MPa Ptens max = 25.92 mm² * 352.5 MPa
Ptens max = 6072 N Ptens max = 9136.8 N
Table 019
(a) Check of reserve factor
Ptens max doubler

Reserve Factor = ------------------- 1
Ptens max orig
Table 020
9136.8 N
Reserve Factor = ------------------- = 1.50
6072 N
Table 021
(b) Determination of fasteners number
One row of rivets includes :
1Rivet single shear - Fultimate single 1 * 2330 N

shear:
Total load One row of rivet can handle : Ful- 2330 N

timate:
Ptens max orig

Number of Fasteners -------------------
Fultimate
Table 022
6072 N
Number of Fasteners ------------ = 2.61
2330 N
Table 023
It is necessary to install 3 rows of fasteners.
(6). Calculation for crippling verification
The original flange is restored by the doubler flange with increased thickness, equal or lower width,
same shape and equal or better material characteristics. The repair is covered by the original part for
crippling and buckling.
4. Example 2 - Extrusion Cutout

SECTION
A-A
1
2
A
ORIGINAL PART
NS6 51 70 10 0 AJM0 00 0
A
1
AREA A: 2 x 3 FASTENERS

** ON A/C [+]

A. Material

1 Joining section AR As per existing section but of next thicker gauge.
Material substitution factor as per Chapter 51-
70-12 may be used to determined other accept-
able repair part. To be determined per following
reverse engineering method.
2 Hi-Lok AR As per existing fastener. Number of fastener row
and alternative type are determined per follow-
ing reverse engineering method.
3 Hi-Lok AR Number of row, fastener and alternative type
and diameter are determined per following re-
verse engineering method.
CML)
(1). Notes
NOTE:

- Original Part:
Extrusion 7075-T6511 thickness 2 mm
Table 024
- Doubler:
Extrusion 7075-T6511 thickness 2.5 mm

Table 025
(2). Material Data

Ftu 520 540
Fty 470 490
Mini (Ftu or 1.5*Fty) 520 540
Fcy 470 490
Fsu 280 290
Fbru 940 940
Ec 73800 73800
NOTE: 'A' basis values used in the L material direction as the profiles are extrusions.

1 Replace existing fasteners with Hi-Lok type fasteners.
NOTE: The upper flange fasteners ensure stability between the original part and the doubler
repair with cutout, by consistency with the lower flange definition, that is to say the
same number of fasteners (with same dia) and the same materials, but rivets univer-
sal instead of rivet countersink.

Hi-Lok DAN5 protruding 4.8 dia in extrusion 7075-T6511 - t = 2 mm
Table 027
Fultimate = 8620 N

20 2 22 4.8
2.5
NS6 51 70 10 0 ALM0 00 0

** ON A/C [+]


Section = 20 mm * 2 mm Section = (22 - 4.8)mm * 2.5 mm
Section = 40 mm ² Section = 43 mm ²
Ptens max = 40 mm² * 520 MPa Ptens max = 43 mm² * 540 MPa
Ptens max = 20800 N Ptens max = 23220 N
Table 028
Ptens max doubler

Reserve Factor = ------------------- 1
Ptens max orig
Table 029
23220 N
Reserve Factor = ------------------- = 1.12
20800 N
Table 030
1Rivet single shear - Fultimate single shear: 1 * 8620 N
Total load One row of rivet can handle : Fultimate: 8620 N
Ptens max orig

Fultimate
Table 031
20800 N
8620 N
Table 032
It is necessary to install 3 rows of fasteners
5. Example 3 - Complete Extrusion Cutout

SECTION
A-A
1
4
2 A
ORIGINAL PART
FASTENERS ROW
NS6 51 70 10 0 ANM0 01 0
1 2
A
3
AREA A: 2 x 4 ROWS OF FASTENERS

** ON A/C [+]

A. Material

51-31-00.
engineering method.
CML)
(1). Notes
NOTE:

- Original Part:
Extrusion 7075-T6511 thickness 2 mm
Table 033
- Doubler:

Table 034
(2). Material Data

Ftu 520 540
Fty 470 490
Fcy 470 490
Fsu 280 290
Fbru 940 940
Ec 73800 73800
NOTE: 'A' basis values used in the L material direction as the profiles are extrusions.

Original fasteners, rivets Csk 1005 4.8 dia, become Hi-Lok Csk 1005
DAN 6 dia 4.8 for repair fasteners in extrusion 7075-T6511 - t = 2.0 mm
Table 036
From Chapter 51-70-13 Table .
Fultimate = 7850 N
Rivet universal 4 dia MS20470DD in extrusion 7075-T6511 - t = 2 mm
Table 037
Fultimate = 3660 N


R 2 R 2.2
25 25 4
4.8 2 4.8 2.2
NS6 51 70 10 0 AQM0 00 0
CH. 2 x 2
25 25

** ON A/C [+]


Section = (25 + 23 - 4.8)mm * 2mm Section = (25 + 22.8 - 4.8 - 4)mm * 2.2 mm
Ptens max = 86.4 mm² * 520 MPa Ptens max = 85.8 mm² * 540 MPa
Table 038
Ptens max doubler

Reserve Factor = ------------------- 1
Ptens max orig
Table 039
46332 N
Reserve Factor = ------------------- = 1.03
44928 N
Table 040

shear:

shear:

timate:
Ptens max orig

Fultimate
Table 041
44928 N
11510 N
Table 042


6. Example 4 - Profile Cutout

1 MIN
SECTION
B-B
B 3
ORIGINAL PART
NS6 51 70 10 0 ASM0 01 0
AREA A: 2 x 4 FASTENERS 2

** ON A/C [+]

A. Material

CML)
(1). Notes
NOTE:

- Original Part:
Table 043
- Doubler:

Table 044
(2). Material Data

Ftu 400 410
Fty 260 235
Mini (Ftu or 1.5*Fty) 390 352.5
Fcy 290 250
Fsu 230 230
Fbru 750 560
Ec 66900 70300
NOTE: 'A' basis values used in the Lt material direction as the profiles are made from sheet.

Replace existing fasteners with Hi-Lok type fasteners
Table 046
Rivet universal 4.8 dia MS20470DD in clad sheet metal 2024-T42 - t = 1.8 mm
Table 047
Fultimate = 5020 N
The calculation is done on the doubler and covers the original part.

8 10
22 22
4.8
NS6 51 70 10 0 AUM0 00 0
1.4 1.8

** ON A/C [+]


Section = (8 mm + 20.6 mm) * 1.4 mm Section = (10 + 20.2 - 4.8) mm * 1.8 mm
Ptens max = 15615.6 N Ptens max = 16116.3 N
Table 048
Ptens max doubler

Reserve Factor = ------------------- 1
Ptens max orig
Table 049
16116.3 N
Reserve Factor = ------------------- = 1.03
15615.6 N
Table 050

shear:

timate:
Ptens max orig

Fultimate
Table 051
15615.6 N
5020 N
Table 052
It is necessary to install 4 rows of Fasteners.
(a) Determination of profile element 1
The crippling has to be checked because:
- The doubler upper flange (area 1) has greater width than the original (10 mm > 8 mm).

- The material characteristics of the doubler are lower than the original part.
For the crippling/buckling capacity of the doubler use areas 1 and 2 (Refer to Chapter 51-70-14).

8 10
AREA 1 AREA 1
UPPER FLANGE UPPER FLANGE
1.4 28 1.8 30
NS6 51 70 10 0 AWM0 01 0
AREA 2 AREA 2

** ON A/C [+]

(b) Determination of allowable element crippling load
Cutout Original Part area 1 one free edge Doubler Repair area 1 one free edge
Material: 2024-T3 clad Material: 2024-T42 clad
Thickness: 1.4 mm Thickness: 1.8 mm
a1 = 8 mm a1 = 10 mm
Fst,1 = 2964 N Refer to Chapter 51-70-14 Table Fst,1 = 4144 N Refer to Chapter 51-70-14 Table
114 115
Table 053
(c) Determination of profile element 2

AREA 2 NO AREA 2 NO
FREE EDGE FREE EDGE
EDGE NO FREE
EDGE NO FREE
28 x 1.4 30 x 1.8
NS6 51 70 10 0 AYM0 00 0
EDGE NO FREE EDGE NO FREE

** ON A/C [+]

Original part Doubler repair

a1 = 8 mm a1 = 10 mm
a2 = 28 mm a2 = 30 mm
s = 1.4 mm s = 1.8 mm
Table 054
If a1 - s 0.2 * a2 then Kn = 3.6 else Kn = 0.41

8 mm - 1.4 mm 0.2 * 28 mm 10 mm - 1.8 mm 0.2 * 30 mm
6.6 > 5.6 X Kn = 3.6 8.2 > 6 X Kn = 3.6
K2 = 3.6 K2 = 3.6
Table 055

a1 = 28 mm a1 = 30 mm
Fst,2 = interpolation necessary Fst,2 = 13119 N Refer to Chapter 51-70-14 Ta-
ble 115
Table 056
(d) Interpolation of allowable element crippling load

ax = 25 mm --> Fst,x = 9732 N ( Chapter 51-70-
14 Table 114)
(next lower value of length an)
ay = 30 mm --> Fst,y = 11079 N ( Chapter 51-
70-14 Table 114)
(next higher value of length an)
(Fst,y - Fst,x) * (an - ax)
Fst,n = Fst,x + ------------------------------- [N]
ay - ax
(11079-9732) * (28-25)
Fst,n = 9732 + ------------------------
(30 - 25)
Fst,n = 10540 N
Table 057
(e) Determination of element crippling load Fst,p

8 10
AREA 1 AREA 1
1.4 28 1.8 30
NS6 51 70 10 0 BAM0 01 0
AREA 2 AREA 2
22 20

** ON A/C [+]

Fst,p = Fst,i = Fst,1 + Fst,2 + Fst,3 + ....... [N]

area 1 + area 2 area 1 + area 2
Fst,p = 2964 N + 10540 N Fst,p = 4144 N + 13119 N
Fst,p = 13504 N Fst,p = 17263 N
Table 058
(f) Check of reserve factor
Fst,p doubler
Reserve Factor = ------------------- 1
Fst,p orig
Table 059
17263 N
Reserve Factor = ------------------- = 1.28
13504 N
Table 060
7. Example 5 - Profile Cutout

1 MIN
SECTION
A-A
2 A 4
ORIGINAL PART 1
NS6 51 70 10 0 BCM0 01 0
FASTENERS ROW
A
AREA A: 2 x 4 FASTENERS 3 2

** ON A/C [+]

A. Material

CML)
- Structure paint AR Material No.16-002 (Refer to the CML)
(1). Notes
NOTE:

- Original Part:
Clad sheet metal 2024-T3 thickness 1.4 mm
Table 061
- Doubler:

Table 062
(2). Material Data

Ftu 400 410
Fty 260 235
Mini (Ftu or 1.5 * Fty) 390 352.5
Fcy 290 250
Fsu 230 230
Fbru 750 560
Ec 66900 70300
NOTE: 'A' basis values used in the Lt material direction as the profiles are made from sheet.

Hi-Lok Csk 1005 DAN 6 dia 4.8 in clad sheet metal 2024-T3 - t = 1.4 mm
Table 064
Fultimate = 4490 N
Rivet universal 4 dia MS20470DD in clad sheet

metal 2024-T3 - t = 1.4 mm
Table 065
Fultimate = 3660 N

8 10
28 30 4
4.8 4.8
NS6 51 70 10 0 BEM0 00 0
1.4 1.8
22 20

** ON A/C [+]


Section = (8 + 22 + 25.2 - 4.8)mm * 1.4 mm Section = (10 + 20 + 26.4 - 4 - 4.8) mm * 1.8 mm
Table 066
Ptens max doubler

Reserve Factor = ------------------- 1
Ptens max orig
Table 067
30202.2 N
Reserve Factor = ------------------- = 1.10
27518.4 N
Table 068
1Hi-Lok single shear - Fultimate single 1 * 4490 N

shear:

shear:

timate:

Ptens max orig

Fultimate
Table 069
27518.2 N
8150 N
Table 070
It is necessary to install 4 rows of fasteners:

- 4 Hi-Lok and 4 rivets.

(a) Verification of allowable slenderness ratio x

AREA 1 ONE AREA 1 ONE

EDGE FREE EDGE FREE
8 x 1.4 10 x 1.8
EDGE FREE EDGE NO FREE EDGE FREE EDGE NO FREE
AREA 2 NO AREA 2 NO
EDGE FREE EDGE FREE
EDGE NO FREE
EDGE NO FREE
28 x 1.4 30 x 1.8

NS6 51 70 10 0 BGM0 01 0

** ON A/C [+]

ORIGINAL REPAIR DOUBLER

Area 1: One free edge Area 1: One free edge
a1/s1 12 a1/s1 12
8/1.4 = 5.71 12 10/1.8 = 5.55 12
Table 071
ORIGINAL REPAIR DOUBLER

Area 2: No free edge Area 2: No free edge
a2/s2 25 a2/s2 25
28/1.4 = 25 25 30/1.8 = 16.66 25
Table 072
(b) Calculation of profile element ...... (n)
(c) Determination of profile element 1

AREA 1 ONE AREA 1 ONE

EDGE FREE EDGE FREE
8 x 1.4 10 x 1.8
EDGE FREE EDGE NO FREE EDGE FREE EDGE NO FREE
NS6 51 70 10 0 BJM0 00 0

** ON A/C [+]

(7). Determination of allowable element crippling load

a1 = 8 mm a1 = 10 mm
Fst,1 = 2964 N Fst,1 = 4144 N
Table 073
(a) Determination of profile element 2

AREA 2 NO AREA 2 NO
EDGE FREE EDGE FREE
EDGE NO FREE
EDGE NO FREE
28 x 1.4 30 x 1.8
FS6 51 70 10 0 BLM0 00 0

** ON A/C [+]

(8). Determination of crippling factor Kn

a Case - one edge free
a Case - no edge free
If an-1 - s 0.2 * an then Kn = 3.6 else Kn = 0.41

8 mm - 1.4 mm 0.2 * 28 mm 10 mm - 1.8 mm 0.2 * 30 mm
6.6 mm > X5.6 mm X Kn = 3.6 8.2 mm > 6 mm X Kn = 3.6
K2 = 3.6 K2 = 3.6
Table 074

a2 = 28 mm a2 = 30 mm
Fst,2 = Interpolation necessary Fst,2 = 13119 N
Table 075
(9). Interpolation of allowable element crippling load

ax = 25 mm --> Fst,x = 9732 N
(next lower value of length an)
ay = 30 mm --> Fst,y = 11079 N
(next higher value of length an)
(Fst,y - Fst,x) * (an - ax)
Fst,n = Fst,x + ------------------------------- [N]
ay - ax
(11079-9732) * (28-25)
Fst,2 = 9732 + ------------------------
(30 - 25)
Fst,2 = 10540 N
Table 076
(a) Determination of element crippling load Fst,p

8 10
AREA 1 AREA 1
1.4 28 1.8 30
NS6 51 70 10 0 BNM0 01 0
AREA 2 AREA 2

** ON A/C [+]

Fst,p = Fst,i = Fst,1 + Fst,2 + ....... [N]

Fst,p = 2964 N + 10540 N Fst,p = 4144 N + 13119 N
Fst,p = 13504 N Fst,p = 17263 N
Table 077
(b) Check of reserve factor
Fst,p max doubler

Reserve Factor = ------------------- 1
Fst,p max orig
Table 078
17263 N
Reserve Factor = ------------------- = 1.28
13504 N
Table 079
8. Example 6 - Typical T-Profile Cutout

SECTION 1
A-A 2
1 MINI
1 1
A 4
2
NS6 51 70 10 0 BQM0 01 0
AREA A: 2 x 5 FASTENERS FASTENERS ROW

** ON A/C [+]

A. Material

51-31-00.
3 Rivet, universal HD AR As per existing fastener. Number of fastener row
engineering method.
CML)
(1). Notes
NOTE:

- Original Part:
Extrusion 7075-T73511 50 mm * 25 mm thickness 2 mm
Table 080
- Doubler:

Extrusion 7075-T6511 50 mm * 25 mm thickness 2 mm
Table 081
(2). Material Data
Documentation SRM (Refer to Chapter 51-70-11, Tables 6 & 7)

Ftu 450 520
Fty 400 470
Mini (Ftu or 1.5 * Fty) 450 520
Fcy 400 470
Fsu 240 280
Fbru 810 940
Ec 73800 73800
NOTE: 'A' basis values have been used in the L material direction as the parts are made from extru-
sions.

For original attached flange (single shear) and free flange (double shear).
Rivet universal 4 dia MS20470DD in extrusion 7075-T73511 - t = 2 mm
Table 083
Fultimate = 3660 N
The calculation is done for the original part and covers the doubler.
(4). Calculation of double shear fastener in free flange
Fultimate double = 2 * c * Fultimate
Table 084
NOTE: For c determination refer to Chapter 51-70-13 Paragraph 1.F.
t/D = 2/4 = 0.5 > 0.33 therefore c = 1

t = thickness 2 mm, D = hole diameter 4 mm
Fult double shear = 2 * 1 * 3360 N = 7320 N
Table 085
Fult double shear = 7320 N

Table 086
(5). Verification of bearing
Fultimate shear
Fbru max = -------------------
thickness * dia
Table 087
NOTE: Check if Fbru max Fbru allow.
7320 N
Fbru max = ------------------- = 915 MPa
2.0 mm * 4.0 mm
Table 088
Fbru max = 915 MPa Fbru allow = 810 MPa
Table 089
NOTE: Fbru max > Fbru allow so use Fbru allow to determine the allowable load based on bearing.
The limitation is given by bearing in the original part and covers the doubler.
(6). Allowable load based on Allowable bearing
Fultimate = Fbru allow * thickness * dia
Table 090
Fultimate = 810 MPa * 2.0 mm * 4.0 mm
Table 091
Fultimate = 6480 N
Table 092

4
25 25
4 4 2 4 2
x2
NS6 51 70 10 0 BSM0 00 0
CH. 2 x 2
50 25

** ON A/C [+]


Section = (50 + 23 - 2 * 4) mm * 2 mm Section = 2 * (25 + 23 - 2 * 4) mm * 2.2 mm
Ptens max = 130 mm² * 450 MPa Ptens max = 160 mm² * 520 MPa
Table 093
Ptens max doubler

Reserve Factor = ------------------- 1
Ptens max orig
Table 094
83200 N
Reserve Factor = ------------------- = 1.42
58500 N
Table 095
+

shear:
Total load One row of rivet can handle : Fultimate: 13800 N

Ptens max orig

Fultimate
Table 096
58500 N
13800 N
Table 097

9. Example 7 - Typical C-Type Beam upper flange Cutout

SECTION
6 7 1
B-B
GAP 1
2 3
2
CUTOUT HEIGHT: H H 4
CUTOUT WIDTH
X 64 FOR EXAMPLE
B
PITCH 16
3
X 3 PITCHES
H
B
H
1
NS6 51 70 10 0 BUM0 01 0
1 ORIGINAL DESIGN FOR THR REPAIR FLANGE WAS 6mm.

THIS HAD TO BE INCREASED TO 7mm FOLLOWING THE CRIPPLING CALCULATION.
AREA A: 2 x 7 FASTENERS FOR TENSILE STRENGTH
AREA B: 7 FASTENERS FOR SHEAR STRENGTH

** ON A/C [+]

A. Material

eering method.
2 Joining Section AR To be determined per following reverse engin-
eering method.
engineering method.
CML)
(1). Notes
NOTE:

- Original Part:
Sheet metal 2024-T42 clad thickness 1.4 mm
Table 098
- Doubler:
Sheet metal 2024-T42 clad thickness 1.6 mm
Table 099
(2). Material Data


Ftu 390 390
Fty 230 230
Mini (Ftu or 1.5 * Fty) 345 345
Fcy 235 235
Fsu 220 220
Fbru 560 560
Ec 66900 66900
NOTE: 'A' basis values used in the Lt material direction as the parts are made from sheet.

Rivet universal 4 dia MS20470DD in clad sheet metal 2024-T42 - t = 1.4 mm
Table 101
Fultimate = 3270 N

6 6
R 4
20 R 4 23.8 4
1.4 4 1.6
NS6 51 70 10 0 BWM0 00 0
20 20

** ON A/C [+]


Section = (20 + 18.6 + 4.6) mm * 1.4 mm Section = (20 + 22.2 + 4.4 - 2 * 4) mm * 1.6 mm
Table 102
Ptens max doubler

Reserve Factor = ------------------- 1
Ptens max orig
Table 103
21307.2 N
Reserve Factor = ------------------- = 1.02
20865.6 N
Table 104

timate:
Ptens max orig

Fultimate
Table 105
20865.6 N
3270 N
Table 106
It is necessary to install 7 rows of fasteners (see area A).
(5). Calculation under shear load
Cutout Width = 64 mm

1.4 7 4 1.6
NS6 51 70 10 0 BYM0 00 0
64 112 7 pitches

** ON A/C [+]


Section = 64 mm * 1.4 mm Section = (112 - 7 * 4) mm * 1.6 mm
= Section * Fsu [ N ]
Pshear max = 89.6 mm² * 220 MPa Pshear max = 134.4 mm² * 220 MPa
Pshear max = 19712 N Pshear max = 29568 N
Table 107
Pshear max doubler

Reserve Factor = ------------------- 1
Pshear max orig
Table 108
29568 N
Reserve Factor = ------------------- = 1.5
19712 N
Table 109

shear:

timate:
Pshear max orig

Fultimate
Table 110
19712 N
3270 N
Table 111
It is necessary to install 7 rows of fasteners (see Area B).
(6). Calculation for Crippling Verification (Refer to Figure 027)

ORIGINAL PART DOUBLER REPAIR

AREA 1: ONE EDGE FREE AREA 1: ONE EDGE FREE
EDGE 1: EDGE 1:
s 1.4 s 1.6
20 23.8
EDGE NO FREE a 6 EDGE NO FREE a 6 7
6 6
s 1.4 r 4 EDGE FREE s 1.6 r 4 EDGE FREE

AREA 2: NO EDGE FREE AREA 2: NO EDGE FREE
EDGE 2: EDGE 2:
NS6 51 70 10 0 CAM0 01 0
a 20 s 1.4 a 23.8 s 1.6
AREA 1 AREA 2 AREA 1 AREA 2

F F F F F F F F
F 1722 6321 F 2363 8726

11089
RF 1.38
F 8043 N 8043 F 11089 N
Figure 025 (sheet 1) / 51-70-10 Calculation for Crippling Verification

** ON A/C [+]

(7). Comparison Buckling/Crippling Allowable Load

20 23.8
6 7
s 1.4 r 4 EDGE FREE s 1.6 r 4 EDGE FREE
AREA 1: ONE EDGE FREE AREA 2: NO EDGE FREE AREA 1: ONE EDGE FREE AREA 2: NO EDGE FREE
s 1.4 s 1.6
a 20 s 1.4 a 23.8 s 1.6
NS6 51 70 10 0 CCM0 00 0
a 6 a 7
a a a a
12 25 12 25
s s s s
6 20 7 23.8
4.28 12 14.28 25 4.37 12 14.87 25
1.4 1.4 1.6 1.6
Figure 026 (sheet 1) / 51-70-10 Comparison Buckling/Crippling Allowable Load

** ON A/C [+]

(8). Calculation For Crippling Verification

20
EDGE NO FREE
EDGE NO FREE ORIGINAL PART
6
s 1.4 r 4 LIKE x 1.095

EDGE FREE
AREA 1: ONE EDGE FREE - CRIPPLING FACTOR, K - CALCULATED ELEMENT BREADTH, B - ELEMENT CRIPPLING STRESS THEN y 1.4 0.628x - ELEMENT CRIPPLING LOAD AREA 1 + AREA 2
s 1.4 K 0.41 1 r b R y 1.4 0.628x F b s s

b a s
R F 235 MPa 2 2 x y 1.4 0.628 x 0.28 4.3 x 1.4 x 286
s K E F
a 6 E E 66900 MPa 1 4 y 1.22 F 1722 N
b 6 1.4
2 2 4.3 235
x s y R
b 4.3 1.4 0.41 66900 s 1.22 x 235
x 0.28 s 286
LIKE x 1.095
AREA 2: NO EDGE FREE - CRIPPLING FACTOR, K - CALCULATED ELEMENT BREADTH, B - ELEMENT CRIPPLING STRESS THEN y 1.4 0.628x - ELEMENT CRIPPLING LOAD - PROFILE CRIPPLING LOAD
a s 0.2a r b R y 1.4 0.628x F b s s F F F F
b a s
a 20 s 1.4 6 1.4 0.2 20 CHECK OF AREA 1 OF 2 x
s K E y 1.4 0.628 x 0.37 F 16.6 x 1.4 x 272 F 1722 + 6321
SUPPORTING FUNCTION
4.6 4 K 3.6 4 y 1.16 F 6321 N F 8043 N
b 20 1.4
2 16.6 235
R 235 MPa x s y R
b 16.6 1.4 3.6 66900 s 1.16 x 235
E 66900 MPa
x 0.37 s 272
11089
RF 1.38
23.8 8043
EDGE NO FREE
EDGE NO FREE DOUBLER REPAIR
s 1.6 r 4
EDGE FREE LIKE x 1.095
AREA 1: ONE EDGE FREE - CRIPPLING FACTOR, K - CALCULATED ELEMENT BREADTH, B - ELEMENT CRIPPLING STRESS THEN y 1.4 0.628x - ELEMENT CRIPPLING LOAD AREA 1 + AREA 2
s 1.6 K 0.41 1 r b R y 1.4 0.628x F b s s

b a s
R F 235 MPa 2 2 x y 1.4 0.628 x 0.30 5.2 x 1.6 x 284
s K E F
a 6 7 E E 66900 MPa 1 4 y 1.21 F 2363 N
b 7 1.6
2 2 5.2 235
a 7mm DUE TO y R
x
HYPOTHESIS AREA 2 b 5.2 1.6 0.41 66900 1.21 x 235
x 0.30 284 MPa
AREA 2: NO EDGE FREE - CRIPPLING FACTOR, K FLANGE IS ADEQUATE - ELEMENT CRIPPLING STRESS LIKE x 1.095 - ELEMENT CRIPPLING LOAD - PROFILE CRIPPLING LOAD
a s 0.2a r THEN y 1.4 0.628x F b s s F F F F
b a s b R
a 23.8 s 1.6 6 1.6 0.2 23.8 2 x 20.2 x 1.6 x 270
s K E y 1.4 0.628x F F 2363 + 8726
NS6 51 70 10 0 DAM0 01 0
4.4 4.76 NOT ACCEPTABLE. 4

b 23.8 1.6 y 1.4 0.628 x 0.39 F 8726 N F 11089 N
FLANGE TO BE IMPROVED.
2 20.2 235
HYPOTHESIS NEW FLANGE 7mm. x y 1.15
CHECK OF AREA 1 b 20.2 1.6 3.6 66900
THIS HYPOTHESIS INCREASE THE PARAGRAPH OF SUPPORTING s y R
B, C AND E (NOT CONSIDERED).
x 0.39 s 1.15 x 235
a s 0.2a
s 270 MPa
7 1.6 0.2 23.8
5.4 4.76 K 3.6
Figure 027 (sheet 1) / 51-70-10 Calculation For Crippling Verification

** ON A/C [+]

(9). Crippling Buckling


6 6 7
AREA 1 AREA 1
R 4 R 4
20 1.4 23.8 1.6
AREA 2 AREA 2
CHECK OF AREA 1 OF SUPPORTING FUNCTION CHECK OF AREA 1 OF SUPPORTING FUNCTION

b 6 SEE AREA 1 b 6 SEE AREA 1
b s 0.2 a b s 0.2 a
6 1.4 0.2 20 6 1.6 0.2 23.8
4.6 4 4.4 4.76 NOT ACCEPTABLE. FLANGE TO BE IMPROVED.
HYPOTHESIS NEW FLANGE 7mm.
b 7 SEE AREA 1
b s 0.2 a
7 1.6 0.2 23.8
5.4 4.76
AREA 1: ONE EDGE FREE AREA 1: ONE EDGE FREE

6 x 1.4 7 x 1.6
EDGE NO FREE EDGE FREE EDGE FREE EDGE NO FREE
FOR 2024T42 CLAD THICKNESS s 1.4 a 6: FOR 2024T42 CLAD THICKNESS s 1.6 a 7:
FROM 51-70-14 TABLE 153 FROM 51-70-14 TABLE 153
a 8mm CRIPPLING 2360 N a 8mm CRIPPLING 2739 N
a 10mm CRIPPLING 2882 N a 10mm CRIPPLING 3398 N
a 6mm CRIPPLING 1838 N BY EXTRAPOLATION a 7mm CRIPPLING 2409.5 N BY INTERPOLATION
EXTRAPOLATION 2360 2882 2360 1838 N EXTRAPOLATION 2739 3398 2739 2 2409.5 N
AREA 2: EDGE NO FREE EDGE NO FREE AREA 2: EDGE NO FREE EDGE NO FREE
20 x 1.4 23.8 x 1.6

FOR 2024T42 CLAD THICKNESS s 1.4 a 20 : FOR 2024T42 CLAD THICKNESS s 1.6 a 23.8 :
FROM 51-70-14 TABLE 153 FROM 51-70-14 TABLE 153
NS6 51 70 10 0 DCM0 01 0
CRIPPLING 6376 N a 20mm CRIPPLING 7393 N

a 25mm CRIPPLING 9154 N
AREA 1 + AREA 2
a 23.8mm CRIPPLING 8731 N BY INTERPOLATION
1838 6376 8214 N
INTERPOLATION 7393 9154 7393 x 3.8 5 8731 N
AREA 1 + AREA 2
11140.5
RF 1.36 2409.5 8731 11140.5 N
8214
Figure 028 (sheet 1) / 51-70-10 Crippling Buckling

** ON A/C [+]

10. Example 8 - Typical Formed Section Cutout

SECTION FASTENERS ROW

B-B
3
3
1
2
1
B
NS6 51 70 10 0 CEM0 01 0
B
4

** ON A/C [+]

A. Material

eering method.
eering method.
51-31-00.
engineering method.
CML)
(1). Notes
NOTE:

- Original Part:
Bent section 2024-T42 clad 50 mm * 25 mm thickness 1.6 mm
Table 112
- Doubler:

Table 113
(2). Material Data

Ftu 390 390
Fty 230 230
Fcy 235 235
Fsu 220 220
Fbru 560 560
Ec 66900 66900
NOTE: 'A' basis values used in Lt material direction as parts made from sheet.

Rivet universal DIA 4 MS20470DD in clad sheet metal 2024-T42 - t = 1.6 mm
Table 115
Fultimate = 3660 N
Table 116
Fultimate = 3660 N

4 1.6
50 4 44
4 1.6 40.8 4
4
NS6 51 70 10 0 CGM0 00 0
4
26.8
25
21.8 1.6

** ON A/C [+]


Section = (50 + 2 * 23.4 - 4) mm * 1.6 mm Section = [(44 + 25.2 - 3 * 4) mm + (40.8 + 20.2 -
3 * 4) mm] * 1.6 mm
Table 117
Ptens max doubler

Reserve Factor = ------------------- 1
Ptens max orig
Table 118
58616 N
Reserve Factor = ------------------- = 1.14
51233 N
Table 119
+

shear:

shear:

timate:
Ptens max orig

Fultimate
Table 120
51233 N
14640 N

Table 121
11. Example 9 - Typical Formed Section Cutout

SECTION
A-A 3
3 ORIGINAL PART
2
A 5
1
NS6 51 70 10 0 CJM0 01 0
FASTENERS ROW
A
1
4

** ON A/C [+]

A. Material

eering method.
eering method.
51-31-00.
engineering method.
engineering method.
CML)
(1). Notes
NOTE:

- Original Part:
Bent section 2024-T42 clad 50 mm * 25 mm thickness 1.6 mm

Table 122
- Doubler:
Table 123
(2). Material Data

Ftu 390 390
Fty 230 230
Fcy 235 235
Fsu 220 220
Fbru 560 560
Ec 66900 66900
NOTE: 'A' basis values used in the Lt material direction as the parts are made from sheet.

(a) Determination of allowable fastener for original attached
Table 125
Fultimate = 3660 N
(a) Determination of allowable fastener load for web (double shear)
Table 126
Fultimate = 3660 N
(5). Calculation of double shear fastener in web

Fultimate double shear = 2 * c * Fultimate
Table 127
NOTE: For c determination refer to Chapter 51-70-13, Paragraph 1.F.

t/D = 1.6/4 = 0.4 >0.33 therefore c = 1.
t = thickness 1.6 mm, D = hole diameter 4.0 mm.
Fult double shear = 2 * 1 * 3360 N = 7320 N
Table 128
Table 129
(6). Verification of bearing
Fultimate shear
Fbru max = -------------------
thickness * dia
Table 130
7320 N
Fbru max = ------------------- = 1144 MPa
1.6 mm * 4.0 mm
Table 131
Table 132
The limitation is given by bearing limitation in original part and covers the doubler.
(7). Allowable load based on Allowable bearing
Table 133
Table 134
Fultimate = 3584 N
Table 135


(a) Determination of allowable fastener load in free flange
Table 136
Fultimate = 3660 N
The calculation is done in original part and covers the doubler.


4 1.6
4
44 4
50
4 1.6 4 38.4
NS6 51 70 10 0 CLM0 00 0
4 4
26.8
25
23.4 1.6

** ON A/C [+]


Section = (50 + 23.4 + 23.4 -4) mm * 1.6 mm Section = ((44 + 25.2 - (3 * 4)) * 1.6) mm * ((38.4 *
21.8 - (3 * 4)) * 1.6) mm
Table 137
Ptens max doubler

Reserve Factor = ------------------- 1
Ptens max orig
Table 138
58167 N
Reserve Factor = ------------------- = 1.13
51225 N
Table 139

in web
1Rivet single shear - Fultimate single shear: in at- 1 * 3660 N

tached flange
1Rivet single shear - Fultimate single shear: in 1 * 3660 N

free flange

timate:
Ptens max orig

Fultimate
Table 140
51233 N


14488 N
Table 141
(10).Calculation for crippling verification
Refer to method given in example 7, Paragraph 9.
12. Example 10 - I-Type Beam upper flange Cutout

A
3 2
4 5
FASTENERS ROW
SECTION
2 A-A
CUTOUT HEIGHT LIMITATION FOR THIS TYPE

1 1
OF REPAIR FIGURE: H H 4
NS6 51 70 10 0 CNM0 01 0
AREA A: 2 x 3 ROWS OF FASTENERS FOR TENSILE STRENGTH
AREA B: 4 FASTENERS FOR SHEAR STRENGTH

** ON A/C [+]

A. Material

eering method.
51-31-00 .
3 Hi Lok AR Number of row, fastener and alternative type
CML)
(1). Notes
NOTE:

- Original Part:
Table 142
- Doubler:

Bent section 2024-T42 thickness 1.6 mm
Table 143
(2). Material Data
Documentation SRM (Refer to Chapter 51-70-11, Tables 3 & 7)

Ftu 490 390
Fty 420 230
Fcy 420 235
Fsu 260 220
Fbru 905 560
Ec 73800 66900
NOTE: 'A' basis values have been used in the material direction for the extrusion and in the Lt materi-
al direction for the formed section.

(a) Calculation for Csk Hi-Lok in free flange (single shear)
Hi-Lok Csk 1005 4.8 dia HL11V-6 (DAN 6) in clad sheet metal 2024-T42 - t = 1.6 mm
Table 145
From Chapter 51-70-13 Table .
Fultimate = 4220 N
The calculation is done in the doubler and covers the original part.
(a) Calculation for protruding head Hi-Lok fasteners in web (double shear)
Hi-Lok protruding DAN5 4.8 dia HL10V-6 in clad sheet metal 2024-T42 - t = 1.6 mm
Table 146
Fultimate = 4520 N
The calculation is done in the doubler and covers the original part.
(5). Calculation of double shear fastener

Fultimate double shear = 2 * Fultimate
Table 147
NOTE: Refer to Chapter 51-70-13, Paragraph 1.F.
Fult double shear =2 * 4520 N = 9040 N
Table 148
Table 149
(6). Allowable load based on allowable bearing
Original part
Fultimate shear
Fbru max = -------------------
thickness * dia
Table 150
9040 N
Fbru max = ------------------- = 1177 MPa
1.6 mm * 4.8 mm
Table 151
Table 152
(7). Allowable load
Table 153
Table 154
Fultimate = 6950 N
Table 155
(8). Allowable load based on allowable bearing
Repair Doubler

Fultimate shear
Fbru max = -------------------
thickness * dia
Table 156
9040 N
Fbru max = ------------------- = 588 MPa
2 * 1.6 mm * 4.8 mm
Table 157
Table 158
(9). Allowable load
Table 159
Fultimate = 560 MPa * 2 * 1.6 mm * 4.8 mm
Table 160
Fultimate = 8601 N
Table 161
The limitation is given by bearing in the original part and covers the doubler.
(10).Calculation under tensile load

25
50 1.6
4.8
22
R 2.5
R 3
x2
100 40
NS6 51 70 10 0 CQM0 00 0
4.8
1.6
1.6

** ON A/C [+]


Section = (50 mm + 20.4 mm) * 1.6 mm Section = ((40 + 23.4 - (2 * 4.8)) * 1.6) mm * 2 mm
Section = 112.6 mm ² Section = 172 mm ²
Ptens max = 112.6 mm² * 490 MPa Ptens max = 172 mm² * 345 MPa
Table 162
Ptens max doubler

Reserve Factor = ------------------- 1
Ptens max orig
Table 163
59340 N
Reserve Factor = ------------------- = 1.07
55174 N
Table 164
One row of rivets includes:
2Rivet double shear in web - Fastener strength limited by bear- 2 * 6950 N

ing in original part

free flange

free flange

timate:
Ptens max orig

Fultimate
Table 165
55174 N


22340 N
Table 166
(11).Calculation under shear load
Cutout Width = 60 mm

2
1.6 4 4.8 1.6
NS6 51 70 10 0 CSM0 00 0
60 80 4 pitches

** ON A/C [+]


Section = 60 mm * 1.6 mm Section = ((80 - (4 * 4.8)) * 1.6)mm * 2
Pshear max = Section * Fsu [ N ]
Pshear max = 96 mm² * 260 MPa Pshear max = 194 mm² * 220 MPa
Table 167
Pshear max doubler

Reserve Factor = ------------------- 1
Pshear max orig
Table 168
42680 N
Reserve Factor = ------------------- = 1.7
24960 N
Table 169
One row of rivets include:
1Rivet double shear - Fultimate single shear: (limited by bearing in ori- 1 * 6950 N
ginal part)

timate:
Pshear max orig

Fultimate
Table 170
24960 N
6950 N
Table 171
It is necessary to install 4 fasteners in area B.
(12).Calculation for crippling verification
13. Example 11 - Web Repair (Limited Cutout Height)

2 DETAIL OF STRESS
CUTOUT
CUTOUT HEIGHT: H H 3
FASTENERS ROW
H
H
A
LIMITED
CUTOUT HEIGHT
P
P
R UNLIMITED
CUTOUT WIDTH
FASTENERS ROW
1 SECTION
A-A
NS6 51 70 10 0 CUM0 01 0
CUTOUT
EXAMPLE 48x48
AREA A: TENSILE AND SHEAR LOAD
AREA B: SHEAR LOAD

** ON A/C [+]

A. Material

1 Doubler AR As per existing web material but of next thick-
er gauge. Material substitution factor as per
Chapter 51-70-12 may be used to determined
other acceptable gauge.
engineering method.
- Structure paint AR Material No.16-001 or 16-006 (Refer to the
CML)
(1). Notes
NOTE:

- Original Part:
Sheet metal 2024-T42 - thickness 1.4 mm
Table 172
- Doubler:
Table 173
(2). Material Data


Ftu 395 395
Fty 235 235
Mini (Ftu or 1.5*Fty) 352.5 352.5
Fcy 235 235
Fsu 230 230
Fbru 560 560
Ec 73700 73700
NOTE: 'A' basis values used in the Lt material direction except for Fcy where the L material direction
has been used due to the lower value.

Rivet universal DIA 4 MS20470DD in sheet metal 2024-T42 - t = 1.4 mm
Table 175
Fultimate = 3270 N in original part
Fultimate = 3660 N in doubler repair
The fastener capacity is taken as the minimum value = 3270 N for the original part.
(4). Calculation of Area A

48 48
D D D 1.4 D D D 1.6
NS6 51 70 10 0 DEM0 00 0
4xD 4xD

** ON A/C [+]


Section = (48 - (3 * 4)) * 1.4 mm Section = (48 - (3 * 4)) * 1.6 mm
Ptens max = 50.4 mm² * 352.5 MPa Ptens max = 57.6 mm² * 352.5 MPa
Table 176
(a) Check of Tensile reserve factor
Ptens max doubler

Reserve Factor = ------------------- 1
Ptens max orig
Table 177
20304 N
Reserve Factor = ------------------- = 1.14
17766 N
Table 178
(b) Check of Shear reserve factor
Pshear max doubler

Reserve Factor = ------------------- 1
Pshear max orig
Table 179
13248 N
Reserve Factor = ------------------- = 1.14
11592 N
Table 180
NOTE: For the same material characteristics for the repair doubler and the original web the RF's
can be determined directly by the ratio of the thickness' i.e. R.F. = 1.6/1.4 = 1.14.
(c) Combination Tensile and Shear Check

The maximum (principle) stress is limited to Ftu.
The calculation in tensile covers any combined stress in tensile and shear.
(d) Compression Check
The original section is restored by the doubler section with increased thickness and equal or
better material characteristics (Fcy and Ec).
(5). Calculation of Area B
The calculation of area A (tensile + shear) covers area B (shear only)

(6). Determination of Fastener Number in Area A

Evaluation of max fastener load:
- The tensile load has been calculated in Paragraph 13.A.(4):
Ptens max orig = 17766 N
- The shear load has been calculated in Paragraph 13.A.(4):
Pshear max orig = 11592 N
The max resultant load by fasteners row (conservative) is:
R = #P²tens max orig + P²shear max orig)0.5
R = #17766² + 11592² N)0.5
R = 21214 N
Capacity of 1 row of 3 fasteners:

3 * 3270 = 9810 N
21214 N
Number of Fastener rows -------------- = 2.16
9810 N
Table 181
It is necessary to install 3 rows (9 fasteners).
(7). Determination of Fastener Number in Area B
3 * 3270 = 9810 N
11592 N
Number of Fastener rows ----------- = 1.18
9810 N
Table 182
14. Example 11 - Plate Repair (Unlimited Cutout Size)

DETAIL OF STRESS
CUTOUT
FASTENERS ROW
R P
UNLIMITED
A P CUTOUT WIDTH
P
P
R UNLIMITED
CUTOUT WIDTH
FASTENERS ROW
A
SECTION
1
A-A
NS6 51 70 10 0 CWM0 01 0
CUTOUT
EXAMPLE 48x48
AREA A: TENSILE AND SHEAR LOAD
AREA B: TENSILE AND SHEAR LOAD

** ON A/C [+]

A. Material

1 Doubler AR As per existing web material but of next thick-
er gauge. Material substitution factor as per
Chapter 51-70-12 may be used to determined
other acceptable gauge.
engineering method.
- Pretreatment for painting AR Material No. 13–002 (Refer to the CML)
CML)
(1). Notes
NOTE:

- Original Part:
Table 183
- Doubler:
Table 184
(2). Material Data

Ftu 395 395
Fty 235 235


Mini (Ftu or 1.5*Fty) 352.5 352.5
Fcy 235 235
Fsu 230 230
Fbru 560 560
Ec 73700 73700
NOTE: 'A' basis values used in the Lt material direction except for Fcy where the L material direction
has been used due to the lower value.

Rivet universal DIA 4 MS20470DD in sheet metal 2024-T42 - t = 1.4 mm
Table 186
Fultimate = 3270 N in original part
Fultimate = 3660 N in doubler repair
The fastener capacity is taken as the minimum value = 3270 N for the original part.
(4). Calculation of Area A

48 48
D D D 1.4 D D D 1.6
NS6 51 70 10 0 DGM0 00 0
4xD 4xD

** ON A/C [+]


Section = (48 - (3 * 4)) * 1.4 mm Section = (48 - (3 * 4)) * 1.6 mm
Ptens max = 50.4 mm² * 352.5 MPa Ptens max = 57.6 mm² * 352.5 MPa
Table 187
(a) Check of Tensile reserve factor
Ptens max doubler

Reserve Factor = ------------------- 1
Ptens max orig
Table 188
20304 N
Reserve Factor = ------------------- = 1.14
17766 N
Table 189
(b) Check of Shear reserve factor
Pshear max doubler

Reserve Factor = ------------------- 1
Pshear max orig
Table 190
13248 N
Reserve Factor = ------------------- = 1.14
11592 N
Table 191
NOTE: For the same material characteristics for the repair doubler and the original web the RF's
can be determined directly by the ratio of the thickness' i.e. R.F. = 1.6/1.4 = 1.14.
(c) Combination Tensile and Shear Check

The maximum (principle) stress is limited to Ftu.
The calculation in tensile covers any combined stress in tensile and shear.
(d) Compression Check
The original section is restored by the doubler section with increased thickness and equal or
better material characteristics (Fcy and Ec).
(5). Calculation of Area B
The calculation of area A (tensile + shear) covers area B (shear only)

(6). Determination of Fastener Number in Area A or B

- The tensile load has been calculated in Paragraph 13.A.(4):
Ptens max orig = 17766 N
The max resultant load by fasteners row (conservative) is:
R = #P²tens max orig + P²shear max orig)0.5
R = #17766² + 11592²)0.5 N
R = 21214 N

3 * 3270 = 9810 N
21214 N
Number of Fastener rows ---------- = 2.16
9810 N
Table 192
End of document


SRM-51-70-10 Repair Design Guideline

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SRM-51-70-10 Repair Design Guideline

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Customer : ENV Manual : SRM

Type : A320 Selected effectivity : ALL

51-70-10 REPAIR DESIGN GUIDELINE

SYMBOL UNIT DESCRIPTION

Print Date: February 01, 2021 Page 1 of 110

SYMBOL UNIT DESCRIPTION

Print Date: February 01, 2021 Page 2 of 110

Ptmax Maximum Tensile Load

Print Date: February 01, 2021 Page 3 of 110

Ptmax = A * (Ftu or 1,5 * Fty, or whichever A Cross Sectional Area

PtmaxRep PtmaxRep Maximum Tensile Load of Repaired Part

(3). Determination of Fastener Number

PtmaxOri PtmaxOri Maximum Tensile Load of Origin Part

B. Calculation under Shear Load

PSmax Maximum Shear Load

PsmaxRep PSmaxRep Maximum Shear Load of Repaired Part

PsmaxOri PtmaxOri Maximum Shear Load of Origin Part

Fds Fastener Allowable in Double Shear

Print Date: February 01, 2021 Page 4 of 110

c For c determination refer to Chapter 51-70-13 - Fasten-

Pallow Allowable Load

Fbru max Max Bearing Stress from Fastener in Double

(4). Determination of Fastener Number

PsmaxOri PSmaxOri Maximum Shear Load of Origin Part

Print Date: February 01, 2021 Page 5 of 110

FORMED PROFILES EXTRUDED PROFILES

Figure 001 (sheet 1) / 51-70-10

Print Date: February 01, 2021 Page 6 of 110

(2). Calculating Element Crippling Stress

Print Date: February 01, 2021 Page 7 of 110

y 1.4 0.628 x WHEN x 1.095

y F MPa ELEMENT CRIPPLING STRESS

Figure 002 (sheet 1) / 51-70-10

Print Date: February 01, 2021 Page 8 of 110

(3). Calculating Element Crippling Load

Fst,i = bi * si * st,i [N] Fst,i Element Crippling Load

Fst,p Profile Crippling Load

Print Date: February 01, 2021 Page 9 of 110

Figure 003 (sheet 1) / 51-70-10 Repair of the Damaged Area

Print Date: February 01, 2021 Page 10 of 110

ITEM NOMENCLATURE QTY MATERIAL/REMARKS

NOTE: Except specified, respect the following SRM rules:

- Fastener hole and drill data (Refer to Chapter 51-44-00).

Clad Sheet metal 2024-T42 thickness 1.6 mm

Clad Sheet metal 2024-T42 thickness 1.8 mm

Print Date: February 01, 2021 Page 11 of 110

Documentation SRM (Refer to Chapter 51-70-11, Table 3)

Table 016 - Material Data

(3). Fastener and Rivets

Rivet Csk 1005 DIA 4 MS20426AD in sheet metal 2024-T42 - t = 1.6 mm

Quantity = 1 each per row of fasteners

From Chapter 51-70-13 Table 007.

Rivet universal DIA 4

Quantity = 1 each per row of fasteners

(5). Calculation under tensile load

Print Date: February 01, 2021 Page 12 of 110

CUTOUT ORIGINAL PART DOUBLER REPAIR

Figure 004 (sheet 1) / 51-70-10 Sketch of the Sections

Print Date: February 01, 2021 Page 13 of 110

Cutout Original Part Doubler Repair

Ptens max doubler

1Rivet single shear - Fultimate single 1 * 2330 N

Total load One row of rivet can handle : Ful- 2330 N