IRM - Rev I - Final - 9-24-18

The Gill Corporation Report No.
MCG IRM 9701, Revision I
The Gill Corporation

Instruction and Repair Manual
MCG IRM 9701 – Revision I
Released Sept 24, 2018
INSTRUCTIONS FOR THE FABRICATION, REPAIR, AND INSTALLATION OF

THE GILL CORP. REPLACEMENT FLOOR PANELS IN AIRBUS AIRCRAFT
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The Gill Corporation Report No. MCG IRM 9701, Revision I
1 Table of Contents
1 Table of Contents ................................................................................................................................... 2
2 Introduction ............................................................................................................................................ 3
3 Applicable Specifications and Documents ......................................................................................... 4
3.1 Airbus Specifications ...................................................................................................................... 4
3.2 Reference Specifications ................................................................................................................ 4
4 Geometrical Requirements ................................................................................................................... 5
5 Panel Identification – Marking .............................................................................................................. 5
5.1 All panels supplied by The Gill Corporation will contain the following markings: ........................... 5
6 Floor Panel Fabricator Responsibility ................................................................................................. 5
6.1 Typical insert shear strengths: ....................................................................................................... 5
6.2 Non-Slip Coating ............................................................................................................................ 5
7 Parts and Materials ................................................................................................................................ 6
7.1 Inserts ............................................................................................................................................. 6
7.2 Threaded Inserts ............................................................................................................................ 8
7.3 Insert Drawings ............................................................................................................................... 8
7.4 Adhesives ....................................................................................................................................... 9
7.5 Edge Filling Compound .................................................................................................................. 9
8 Machining of The Gill Corporation Sandwich Panel Products ........................................................ 10
8.1 Drill Bit Selection .......................................................................................................................... 11
8.2 Cutting .......................................................................................................................................... 11
8.3 Routing ......................................................................................................................................... 12
9 Repair of Replacement Floor panels .................................................................................................. 12
9.1 Determination of Repairable Damage .......................................................................................... 12
9.2 Recommended Materials ............................................................................................................. 12
9.3 Repair Procedure ......................................................................................................................... 14
10 Edge Filling Procedure ........................................................................................................................ 16
11 Insert Installation.................................................................................................................................. 18
11.1 Bulk, Container Cargo Compartment and Passenger Floors Torlon® Insert Installation ............ 19
11.2 Bulk and Container Cargo, Passenger, and Flight Compartment Aluminum Insert Installation .. 26
11.3 Hardpoint Insert Installation .......................................................................................................... 31
11.4 Threaded Insert Installation .......................................................................................................... 32
11.5 Insert Strength Test Specimen Configuration .............................................................................. 36
11.6 Forming Tool for 1-piece Aluminum Inserts TF110 and TF111 ................................................... 37
11.7 Forming Tool for 1-piece Aluminum Inserts TF20 and TF21 ....................................................... 38
11.8 Insert Schematics for Inserts ........................................................................................................ 38
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2 Introduction
This manual contains instructions for the customers of The Gill Corporation for the installation and repair of
replacement floor panels for passenger and cargo compartments of Airbus aircraft A300/B2/B4, A300-600, A310,
A318, A319, A320, A321, A330, A340, and A380. The replacement passenger floor panels are qualified to
Airbus Industrie Technical Specifications 5360 M1M 000600 and TL53/5000/79, and the cargo floor panels are
qualified to 5360 M1M 000500.
Complex floor panel configurations can be produced from the semi-finished, large sized sheet material using
relatively inexpensive and readily available tools, equipment, adhesives, and edge filling compounds; the
fabrication methods were designed for use in typical airline maintenance and repair facilities. For compliance
with the Airbus specification and approval of the floor panels, only the materials specified and described in this
manual may be used with The Gill Corporation products. Alternative components or combinations might not
afford the mechanical or flammability performance levels required by governmental airworthiness authorities
and/or Airbus Industrie. In the event of any questionable or doubtful procedure or material, the applicable Airbus
Aircraft Structural Repair Manual (SRM) is valid for the parts described in this manual.
To meet the various Airbus-specified geometrical and physical property requirements for all aircraft types, several
floor panel types are qualified and approved by Airbus; panel identification and applications are summarized in
Table 1. The panel configurations, i.e., final shape, size, openings, mounting holes, etc., can be determined
using the existing part as a template.
Because of the structural function of the floor panels, only relatively minor damage is allowed which is capable of
being repaired. Extreme care must be exercised in determining which damage is repairable and which requires
floor panel replacement; the Airbus Industrie SRM is the governing procedure, and the applicable SRM must be
consulted for repair and/or replacement procedures. The applicable Airbus SRM are for the replacement floor
panels described in this instruction manual listed in Table 2, and must be consulted to determine the extents of
repairable damage to the floor panels. However, to maintain the original integrity and fire retardant
properties of a repaired panel, only the methods and materials described specified in Section 9 may be
used to effect a repair.
This manual describes the machining and drilling, and the installation of inserts in preparation of a panel for
installation in the aircraft. The installation of inserts is very important, since the inserts are responsible for
providing the necessary mounting strength to help maintain the integrity of the airframe. First-time installers of
inserts must demonstrate the ability to properly install inserts by preparing panel test specimens, and submitting
them to The Gill Corporation for strength testing. The Gill Corporation can supply test coupons, and inserts for
assembly into test specimens, if desired.
To maintain Airbus Industrie Standards and Specifications, those materials and procedures described in this
manual may be used in the fabrication of The Gill Corporation replacement floor panels. Alternative materials
may be used, at the discretion of The Gill Corporation; similarity to the suggested materials and knowledge
of their properties will be employed in judging the acceptability of a material. In some instances, appropriate
testing might be required to verify acceptable properties.
SAFETY PRECAUTIONS
Before using any of the chemical materials specified or recommended in this manual, the manufacturer’s safety
data sheet for each product must be obtained and its safety practices observed. In all cases, direct exposure by
skin contact, inhalation, or ingestion must be avoided, requiring, at the very least, the wearing of eye protection
and protective clothing. Good ventilation and lighting are essential, and in areas where flammable solvents are in
use, sources of ignition should be eliminated.
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3 Applicable Specifications and Documents

3.1 Airbus Specifications
3.1.1 AITS 5360 M1M 000500: Floor Panels – Cargo Compartments and Freighter Aircraft
(convertible and full freighter).
3.1.2 AITS 5360 M1M 000600: Carbon Floor Panels Made of Large-Sized Plate Material for
Passenger and Flight Compartment Floor.
3.1.3 DBAA TL 53/5000/79: Glass Fibre Floor Panels for Passenger and Containerized Cargo
Compartments
3.2 Reference Specifications
3.2.1 FAR/JAR 25.853, 25.855 and 25.856(a): Passenger and Cargo or Baggage Compartments.
3.2.2 FAR/JAR 25.857 and 25.856(a)(b): Cargo Compartment Classifications.
3.2.3 FAR Part 25, Appendix F, Part III: Test Criteria and Procedures for Showing Compliance to ¶
25.853 and ¶ 25.855.
3.2.4 Airbus Industrie ABD 0031: Airbus Directive and Procedures – “Fire, Smoke, Toxicity”.
TABLE 1
Application of The Gill Corporation Replacement Floor Panels in Airbus Aircraft
The Gill Corporation Airbus Industrie Airbus Industrie Panel Application

Floor Panel Designation Panel Type Technical Specification By Aircraft
Gillfab 4405, PC3 TL53/5000/79, Iss. 8 A300/A310
Types 1 and 2*
Gillfab 4123 MDC2 5360 M1M 000500 A300/A310/A300-600
Main Deck Cargo
Gillfab 4223 BCC2 5360 M1M 000500 A300/A310/A300-600
A318/A319/A320/A321
A330/A340
Bulk Cargo Compartments
Gillfab 4523 BCC3 5360 M1M 000500 A300/A310/A300-600
A318/A319/A320/A321
A330/A340
Bulk Cargo Compartments
Gillfab 4522 CCC1 5360 M1M 000500 A300/A310/A300-600
A318/A319/A320/A321
A330/A340
Container Cargo Compartments
Gillfab 4505 PC3 5360 M1M 000600 A318/A319/A320/A321
A330/A340/A380
Passenger Compartment, Main
Aisle and Galley
Gillfab 4605 PC1 5360 M1M 000600 A318/A319/A320/A321

A330/A340/A380
Passenger Compartment, Seat
Location
*Type 2 lower facing has an additional layer of aluminum for increased flammability resistance. Locations for
panels Type 1 and 2 must correspond to the Airbus SRM.
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TABLE 2
Airbus Structural Repair Manual Application by Aircraft
Aircraft SRM
A300 53•21•00
A310/A300-600 53•10•20
A318/A319/A320/A321 53•02•00
A330/A340 53•02•00
A380 53•02•00
4 Geometrical Requirements
The Gill Corporation replacement floor panels are available in sizes up to 1829 x 3658 mm (72 X 144 inches).
The panels may be fabricated without consideration to the honeycomb core or facing orientations; i.e., panel
flight direction may be either in the transverse or ribbon honeycomb direction, allowing optimization of panel
stock usage in fabricating the various configurations of floor panels. The geometry of the replacement panel may
be duplicated from the applicable Airbus drawing, or by using the panel being replaced as a template. The
fabricated panel must be easily installed without causing damage to the panel or other structure.
The aircraft has two lower deck cargo holds, one in the forward (FWD) and one in the after (AFT) section of the
fuselage. Each hold may consist of two or more compartments, each of which contains the cargo flooring.
5 Panel Identification – Marking
5.1 All panels supplied by The Gill Corporation will contain the following markings:
5.1.1 Federal Supplier Code for Manufacturer: 22459
5.1.2 The Gill Corporation Product Designation
5.1.3 Date of Manufacture
5.1.4 Identification of Upper Side
5.1.5 Fabrication Date of Finished Floor Panel – must be marked on panel by fabricator
6 Floor Panel Fabricator Responsibility

The dimensions of the finished, replacement floor panels must match those of the original parts; panel types
must comply with the applicable Airbus SRM, and panels must not be pieced together where a single panel
section is required. As noted in the introduction, on the first installation of inserts by the panel fabricator, the
effectiveness of the installation must be demonstrated by measuring the shear strength of test specimens. At
least six test coupons must be prepared by the panel fabricator and returned to The Gill Corporation for testing
and evaluation according to the applicable Airbus specification.
6.1 Typical insert shear strengths:
The following target values should be demonstrated by test.
6.1.1 For panels Gillfab 4405 (Types 1 and 2), 4223, 4523, and 4522: 7560 N (1700 lb.)
6.1.2 For panels Gillfab 4123, 4505, and 4605: 8007 N (1800 lbs.)
All materials, machining, panel fabrication procedures, and test coupon preparation are described in the following
sections.
6.2 Non-Slip Coating
The operator is responsible for the application of a non-slip coating using an Airbus approved material so that
the installed panel meets the requirements of FAR 25.793. (See the Airbus Consumable Material List for
suitable materials)
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7 Parts and Materials

The following sections describe the parts and materials approved for use for the fabrication of The Gill
Corporation replacement floor panels; the use of alternate articles from those shown below for panel preparation
is not allowed unless specific permission is obtained from Airbus Industrie, e.g., an NTO (No Technical
Objection). Equivalent performance of any alternatives must be demonstrated to the satisfaction of Airbus.
7.1 Inserts
7.1.1 Bulk and Container Cargo Compartments: 2-Piece Torlon Inserts
The Gill Corporation Airbus Industrie Insert Insert The Gill

Replacement Panel Panel Type Type Corporation
Part No.
Gillfab 4523 BCC3 2-Piece TF073
Gillfab 4223 BCC2 2-Piece TF073
Gillfab 4522 CCC1 2-Piece TF074
TF073 and TF074 Insert Manufacturer
Marketing Masters
1871 NW Gilman Blvd, Suite 1
Issaquah, WA 98027
Phone: (425) 454-5610

Website: www.clipnuts.com
7.1.2 Bulk, Container Cargo, and Flight Compartments: 1-Piece Aluminum Inserts

Replacement Panel Panel Type Type Corporation Part
No.
Gillfab 4522 CCC1 1-Piece TF111
Gillfab 4523 BCC3 1-Piece TF110 or TF20
Gillfab 4223 BCC2 1-Piece TF110 or TF20
Gillfab 4123 MDC2 1-Piece TF21
TF110 and TF111 Insert Manufacturer
Shur-Lok Corporation
2541 White Road
Irvine, CA 92614
Phone: (949) 474-6000

Website: www.shur-lok.com
TF20 and TF21 Insert Manufacturer:

The Young Engineers, Inc.
25841 Commercentre Drive
P.O. Box 278
Lake Forest, CA 92630-0278
Phone: 949-581-9411
Website: www.youngengineers.com
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7.1.3 Container Cargo and Passenger Compartments: 2-Piece Aluminum Inserts

Replacement Panel Panel Type Type Corporation Part No.
Gillfab 4405, Types 1 and 2 PC3, Ty 1 and 2 2-Piece ALL AIRCRAFT
Gillfab 4522 CCC1 T303A plug
Gillfab 4505 PC3 T303B sleeve
Gillfab 4605 PC1 T303 Assembly
A320 FAMILY:
T307A plug
T307B sleeve
T307 Assembly
T303 and T307 Insert Manufacturer:

P.O. Box 278
Phone: 949-581-9411
7.1.4 Passenger Compartments, A320 FAMILY ONLY: 2-Piece Torlon Inserts

Replacement Panel Panel Type Type Corporation
Part No.
Gillfab 4505 PC3 2-Piece TF152A plug
Gillfab 4605 PC1 TF152B sleeve
TF152 Assembly
TF152 Insert Manufacturer
Marketing Masters
1871 NW Gilman Blvd, Suite 1
Issaquah, WA 98027
Phone: (425) 454-5610

Website: www.clipnuts.com
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7.1.5 Special Design Criteria – Hardpoint Attachments

For the installation of lower galley, lavatory, and attendant seat attachment points, specially
designed inserts must be installed if the original floor panel contains the hardpoint holes. The inserts
consist of three different types, depending on the unit to be attached, and must correspond to the
parts being replaced. The insert types are of two-piece construction of aluminum, and are described
below.
Airbus Industrie Manufacturer’s Part Number Insert The Gill

Hardpoint Insert Plug Sleeve Assembly Corporation
Type Part No
1 TYEP5330A1 TYES5330A1- TYE5330A1-380 T304
380
380
380
380
Hardpoint Insert Manufacturer:

P.O. Box 278
Phone: 949-581-9411
7.2 Threaded Inserts

The following threaded inserts have been approved with the TGC panels shown below, when
installed per ¶ 11.4. The appropriate threaded insert should be chosen according to the Airbus
drawing in question, in order to correctly integrate with the surrounding structure. Base numbers of
the inserts are listed here, exact lengths to use should be chosen appropriate to the application.
Hardware manufacturers are not listed in this document, as Airbus approved materials should be
used per the appropriate Standard Manual.
The Gill Corporation Airbus Industrie Insert

Replacement Panel Panel Type Type
Gillfab 4405, Types 1 and 2 PC3, Types 1 and 2 NAS 1833-3
Gillfab 4505 PC3 NAS 1834 C3K
Gillfab 4605 PC1 NAS 1835
NAS 1836-3
DAN401-3
7.3 Insert Drawings

Applicable drawings for the inserts and forming tools described in this manual may be obtained
directly from the manufacturers. For reference only purposes, sample drawings of selected inserts
are provided in ¶ 11.8.
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7.4 Adhesives
The following two-part epoxy adhesives may be used for potting the inserts into the floor panels; the potting
procedure is necessary to ensure that the necessary pullout strengths are achieved. Only those materials
described below may be used for the fabrication of The Gill Corporation replacement floor panels unless
approval for an alternate material is issued by Airbus Industrie or by test in association with The Gill
Corporation
7.4.1 Loctite®Hysol® EA9309.3NA
Loctite®Hysol® Manufacturer:
Henkel Loctite Corporation
1001 Trout Brook Crossing
Rocky Hill, Connecticut 06067
Telephone: 800-562-8483 (US)

Website www.loctiteproducts.com
7.4.2 Epibond 420 A/B
Epibond manufacturer:
Huntsman Advanced Materials
5121 San Fernando Road West
Los Angeles, CA 90039-1011
Telephone: 818-247-6210
Customer Service: 888-564-9318
Website: www.huntsman.com
7.4.3 Adhesive Packaging

Both of the potting adhesives described in the preceding paragraphs are available from the
manufacturer and/or distributors in a variety of packages, ranging from bulk containers to pre-
measured cartridges. The use of the different package types is described in ¶ 11, and the procedure
used depends on the availability and practice of the replacement panel fabricator.
7.5 Edge Filling Compound

The edge filling compounds are two part epoxy system used around the edges of panels to protect and
support panel edges while preventing the incursion of moisture into the honeycomb core. See ¶ 10 for
detailed instructions on edge filling of panels.
7.5.1 Alexit® FST 495-14
Alexit Manufacturer
Mankiewicz Gebr. and Co (GmbH Co.)

Georg-Wilhelm Strasse 189
D-21107 Hamburg (Willhelmsburg)
Germany
Telephone: +49 (40) 75 10 30

Website: www.mankiewicz.com
U.S. Office:
Mankiewicz Coatings L.L.C.
1200 Charleston Regional Parkway
Charleston, S.C. 29492
Telephone: (843) 654-7755

Website: www.mankiewicz.com/english
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7.5.2 Scotch-Weld EC3524 B/A

Scotch-Weld Manufacturer:
U.S. Office:
3M Corporate Headquarters
3M Center
St. Paul, MN 55144-1000
Telephone: (888) 364-3577

Website: www.3m.com
7.5.3 Scotch-Weld 3550 B/A FST

Scotch-Weld Manufacturer:
U.S. Office:
3M Corporate Headquarters
3M Center
St. Paul, MN 55144-1000
Telephone: (888) 364-3577

Website: www.3m.com
8 Machining of The Gill Corporation Sandwich Panel Products
This section contains recommendations for cutting, drilling, and routing of flooring sandwich panels. The
information can be useful for the fabrication of the unsized material into exact replacement articles.
The sandwich panels are composed of fiberglass or carbon fiber reinforced/phenolic resin facings bonded to a
Nomex/phenolic resin honeycomb core. Care must be exercised in the fabrication of replacement panels to
avoid disbondment, delamination, tearing, fuzzing of the fiber, or crushing the core. Using the proper tools and
techniques as outlined below will provide for excellent results and safe manufacturing of the panels. Following
are recommendations for the drilling, cutting, and routing of any of the Gillfab series of flooring sandwich panels.
For any work requiring center-to-center hole tolerance of ± 0.8 mm (0.03 inches) or less, the use of a drill
template with hardened steel drill bushings is recommended. Good tooling will speed production and provide
accurate repeatability of the hole pattern. For small jobs (less than 15 holes) a removable bushing (slip
renewable) may be used. It is not as accurate as pressed bushings, although the tooling cost will be reduced.
For holes requiring close tolerance diameters ± 0.13 mm (0.005 inches) or less, a pilot hole should first be drilled
through a bushing, then the hole counterbored to the final diameter. Sandwich panels with honeycomb cores
should also be back-drilled (counterbored through the back skin) since the pilot hole in soft cores will not hold the
counterbore pilot steady. Drilling a hole without the use of drill bushing will often produce egg-shaped holes
since most drill chucks do not turn in a perfectly circular path, and the operator cannot hold the drill at a perfect
90o angle to the work piece. Using a drill press or a portable drill guide will simplify drilling holes 90 o to the
material surface.
Whenever possible, many facilities drill holes slightly larger than are actually needed in order to eliminate the
need for tooling and drill bushings. Stack drilling is a fast way to drill many identical holes in several pieces, as
long as they are firmly clamped together and to the template. However, center-to-center tolerance will usually
suffer, especially on the last part in the stack. When drilling deep holes, lift the drill out occasionally to clear away
dust or chips. This will prevent galling or binding and produce a cleaner, fuzz-free hole.
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8.1 Drill Bit Selection

8.1.1 High Speed Steel
8.1.1.1 Lowest initial cost, readily available. Short drill life, especially in fiberglass.
About 500 holes between sharpening in fiberglass, which is improved if a
hard flash of chrome plating (0.003 – 0.005 inches) is put on the drill bit.
Flash chrome is recommended for large drills where carbide is too
expensive.
8.1.2 Tungsten Carbide
8.1.2.1 Higher initial cost, but longer life. May be resharpened.
8.1.2.2 a) Up to 3/16” diameter, grind drill to have slight negative rake on cutting
tip.
b) Over 3/16” diameter, use slow helix drill, ground to 55° point (sharp).
c) For blind holes 3/16” or larger, use a fast helix drill ground to a 90° point.
d) Recommended for high production requirements only.
8.1.3 Diamond-Grit Edged Drills (Hole Saws)
8.1.3.1 For fiberglass only. Most expensive, but longest lasting, fastest and
smoothest cutting. Recommended for high volume only. May be recoated
at near initial cost, 40 grit recommended for most Gill fiberglass products.
8.1.3.2 10,000 surface feet per minute is customarily available on 10,000–20,000
rpm router. Will drill a hole 3 times as fast as a carbide drill.
8.1.3.3 Dust collection system mandatory.
8.1.3.4 Cannot be used with drill bushings or slip-renewables.
8.1.4 Fiberglass Drills (known as “shear bore”, made by Carbro Corp.)
8.1.4.1 Solid carbide, fairly expensive.
8.1.4.2 Must be returned to manufacturer for sharpening.
8.1.4.3 Produces clean fuzz-free holes in most fiberglass without delamination,
especially in thin (less than 0.060 inch) fiberglass.
8.1.4.4 Excellent for drilling clean, accurate holes in low resin content Kevlar®,
unidirectional S-glass, carbon sheets, and panels to 0.750 inches thick.
Cuts quickly without tearing, delaminating, or fuzzing the fibers around the
hole.
8.2 Cutting
8.2.1 Band Saws
Band saws are not recommended because the cut is slow and too difficult to control; however, band
saws can be used for rough cuts to loose tolerances. A fence should be used to control the cut as
much as possible. Most products may be cut with a standard 8-10 tooth/inch band saw. It will dull
rapidly, but even when dull it gives a fair cut and is inexpensive to replace.
8.2.2 Circular Saws
For worker comfort and general housekeeping, a good vacuum system to collect dust right at the
saw blade is a must. Normally, 12” to 16” diameter carbide tipped or diamond saw blades are used.
Diamond blades are coated at 40 grit. Carbide blades, which have gullets between the teeth, are
used for difficult-to-cut materials, such as metal faced sandwich panels or thick aluminum. The more
teeth per inch on a saw blade, the finer the cut. 12” blades with 60 to 72 teeth, alternating raker set,
are used at the The Gill Corporation. Recommended blade speeds are shown below.
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RECOMMENDED BLADE SPEEDS
Blade Revolutions Surface Feet

Diameter Per Minute Per Minute
8 4500 9400
10 4000 10500
12 3600 11300
16 3450 14500
The performance of common type saw blades for fiberglass reinforced laminates is given in the table
below.
Diamond grit Best
Carbide grit Does similar job as diamond but wears and clogs sooner,
is less expensive
Carbide tip Not recommended. Dulls rapidly, delaminates material at
cut edge
8.3 Routing
8.3.1 Entire Panel

For the shaping of a replacement panel to the finished configuration, only a diamond grit router
should be used. All others are unsuitable because they can cause delamination, excessive fuzzing
of the reinforcing fibers, or tearing.
8.3.2 Panel Core
The Nomex core can be routed by a variety of router bits, ranging from high speed steel to solid
carbide. Single or multiple fluted bits have shown satisfactory core removal without excessive
tearing; two-fluted carbide is best in this respect. Care must be exercised not to cut into or tear the
fiberglass panel facings. The purpose of routing the core is to provide a channel for an edge filling
material.
9 Repair of Replacement Floor panels

9.1 Determination of Repairable Damage
The applicable Airbus SRM is the governing specification for determining the extent of damage which may be
repaired; once this assessment has been made, the following sections describe the recommended materials and
procedures to be followed to return a damaged floor panel to service.
9.2 Recommended Materials
The following materials are recommended for repairing damaged floor panels; alternative materials may be
substituted with the approval of the The Gill Corporation
9.2.1 Paste Adhesive: EA9309.3NA, manufactured by Loctite/Hysol.
9.2.2 Honeycomb Core: Gillcore HD365, Nomex® honeycomb core, 3/16” (4.8 mm) cell size, 6 lb/ft 3
density, manufactured by the The Gill Corporation
9.2.3 Cargo Liner Laminate: Gillfab 1367, 1367A, 0.050 – 0.060” (1.3 – 1.5 mm) thick, manufactured by
The Gill Corporation
9.2.4 Aluminum Sheet Stock: Aluminum alloy 2024-T3 (3.1364T3) stock, 0.050” (1.3 mm) thick.
9.2.5 Fire Retardant Additive: This is a 3:1 mixture of Firemaster 2100RM to Nyacol A1582, added to the
EA9309.3NA adhesive mixture. The powder fire retardant mix is incorporated at a level of 20% by
weight of the 2-component adhesive system and thoroughly mixed to obtain a homogeneous paste
adhesive. Fire retardant materials are:
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Decabromodiphenyl ethane, aka 1,1’-(1,2-ethanediyl)bis[2,3,4,5,6 pentabromo]benzene, sold as

Firemaster 2100RM
From:
Chemtura Corp
710 Bussey Rd
El Dorado, AR 71730
(870) 862-9100
www.chemtura.com
Colloidal Antimony pentoxide, aka diantimony pentoxide, sold as Nyacol A1582

From:
Nyacol Products, Inc.
211 Megunko Rd
Ashland, MA 01721
(508) 881-2220
www.nyacol.com
9.2.6 Portable Sander: A hand-held belt, orbital, or reciprocating sander for sanding the honeycomb core
plug to the correct thickness for the panel type and extent of damage. This will eliminate the need to
stock many different core thicknesses, and can expedite and ensure the correct repair procedure
while reducing the complexity of inventoried materials.
9.2.7 Heating Blanket and/or Heat Gun: Optional items; these may be used to reduce the cure time of the
adhesive (normally 5 – 7 days at room temperature).
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9.3 Repair Procedure

9.3.1 Remove the facing and honeycomb core from the damaged area, taking care not to damage the
lower facing; make the cut larger than the damage, and of a uniform shape, e.g., circular. If the
lower face is damaged, also, cut this facing away, but at least 1 ½ ins (38 mm) smaller in diameter
so that a reinforcing laminate can be bonded to the edges of the lower opening. If the facings
removed are not circular, make sure there is at least a ¾ in (19 mm) shelf around the edges to
support the laminate. Make certain that the cut out area is still within the allowable damage
limits specified in the Airbus SRM.
9.3.2 If both faces are damaged, cut a piece Gillfab 1367 or 1367A, described above (¶ 9.2.3), to the size
of the opening in the upper facing, so the laminate is supported by the edges of the lower facing. If
only the upper facing is damaged, there is no need for the laminate – the intact lower facing will
provide the necessary reinforcement.
9.3.3 Continue preparation of the laminate by lightly sanding the back edges (non-Tedlar® side), and
wiping the faces with solvent (acetone is suggested) to remove all debris, and contamination.
9.3.4 Prepare a second laminate patch to overlap the edges of the upper opening by at least ¾ in (19
mm), and sand the back side of the laminate; wipe with solvent to remove any debris.
9.3.5 Cut a piece of honeycomb core (¶ 9.2.2, above) to the size of the opening in the upper facing.
Sand the core to the thickness required so that it is flush with the upper surface of the panel;
the core will be bonded to the lower facing or patch in a subsequent step. Remove all loose
fiber and dust with a stream of clean air.
9.3.6 In an appropriate disposable container, such as a 16-oz plastic cup, weigh out 240.0 +/- 2.4 grams
of EA9309.3NA adhesive mixture at a 100:22 Part A:Part B ratio, already mixed per manufacturer’s
instructions. Add 36.0 +/- 3.6 grams of decabromodiphenyl ethane and 12.0 +/- 1.2 grams of
colloidal antimony pentoxide to the container. Mix thoroughly at room temperature by hand with a
wooden tongue depressor or metal spatula for at least one minute. Check to ensure that there are
no visible streaks or pockets of powder. If there are, mix again for at least one minute. Repeat this
process until no streaking or visible powder remains.
9.3.7 Mix only the amount of adhesive which can be used in about 30-40 minutes. It may be helpful to
allow the adhesive to stand for a few minutes to allow it to thicken so it will stay in place when
applied to the panel. Adhesive should be applied by means of a trowel or small spatula.
9.3.8 If a lower patch is used, spread adhesive around the edges, and place it on the edges of the lower
facing; spread adhesive over the entire upper surface of the patch, or the interior of the lower facing
if no patch is required. Apply approximately 0.060 lbs/ft2 (293 g/m2) to all the bonding surfaces.
9.3.9 Apply adhesive around the edges of the honeycomb core plug, and place it in the opening in the
panel, on top of the adhesive on the lower surface.
9.3.10 Spread adhesive on the back of the upper patch and place it on the upper facing and core plug,
making sure that the patch overlaps the opening by at least ¾ in (19 mm). Place a weight on the
patch to hold it in place; allow the adhesive to cure overnight, or at least 8 hours. The adhesive will
develop the maximum strength after 5 – 7 days at room temperature, but this time may be shortened
by postcuring at 175 – 200°F (79 – 93°C) with a heat gun or heating blanket. Do not exceed a
temperature of 200°F (93°C).
9.3.11 The following diagram shows the configuration of a finished repair in which both facings were
damaged. Note that cargo floor panel repair must follow the Airbus SRM, a brief description of these
tasks are included below the diagram.
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Single Aisle
TASK 53-02-00-300-015 Repair for Perforation Damage in Zone B and C (Upper Skin or Both Skins
Penetrated)
Long Range
TASK 53-02-00-300-010 Repair of Perforation Damage to both Skins (Upper and Lower) and Core in
Zone B
Zone B and Zone
Zone B and Zone C
TASK 53-02-00-300-017 Repair for Impact Damage with Visible Cracks and/or Holes in Zone C (Both
Skins Penetrated)
A380
TASK 53-02-00-338-813- Cargo Compartment Floor Panels - Permanent Repair for Perforation
A01 Damage up to 250 mm (9.843 in) in the Upper Skin and 150 mm (5.906 in) in
the Lower Skin
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10 Edge Filling Procedure

All of the replacement flooring panels must be edge-filled with one of the compounds described above, ¶ 7.5.
The edge filling provides protection and support of the panel edges, and also prevents the incursion of moisture
into the honeycomb core. A broad range of epoxy materials is available, but only those that are approved and
demonstrate high levels of fire retardance, moisture resistance, and strength retention can be used for sealing
the liner edges.
For adequate adhesion and integration of the filling compound into the panel edges, it is necessary to remove the
honeycomb core to the extent of a minimum of 6 mm (approximately ¼ inch). Refer to ¶ 8.3.2 for a satisfactory
tool for removing the Nomex honeycomb core. It is necessary to rout the core to a depth of at least 6 mm
(0.24 inches) to provide the necessary burn-through and moisture resistance. Preferably, a depth controlling
tool is attached to the router assembly to obtain a uniform depth of cut; care must be exercised to prevent cutting
back or thinning of the panel facings. A vacuum probe or stream of clean, dry air can be used to remove the dust
and debris caused by the routing operation; care must be exercised to insure the removal of all loose material in
the router area to optimize the bonding of the filler material to the panel edges.
The edge filling compounds are two-part systems, which must be thoroughly mixed together according to the
manufacturer’s instructions. The adequately mixed edge filling material will be uniform in color (i.e., no streaks or
blotches in the mixture) and will be the consistency of a viscous putty that can be used to fill the panels without
slumping or running out. A spatula or putty knife can be used to spread or trowel the material into the panel
edge, taking care to fill the honeycomb channels as completely as possible (no core material may be visible).
While still pliable, the excess filling can be removed by using the edge of the application tool, followed by
smoothing the material flush with the panel edges. If the filling hardens before finishing the edges, a sander can
be used to remove and smooth the excess. Edge filling must also be applied to the exposed edges of any cut-
outs made in the panel.
The edge filling will cure at room temperatures in 24 hours, but a shorter cure can be obtained by heating at 70oC
for 2 hours after the material gels completely; follow the manufacturer’s instructions for reduced cure times.
The mixed edge filling compound has a working life of 1-1½ hours, and care must be taken to use the material
before it begins to harden appreciably. Obtain and follow the precautions in the manufacturer’s Safety Data
Sheets for the epoxy edge fill material.
NOTE: The edge fillings described in ¶ 7.5 (Alexit 495-14, Scotch-Weld EC3524 B/A, and Scotch-Weld
3550 B/A FST) are the recommended materials for use with Gillfab 4405, 4123, 4223, 4523, 4522, 4505,
and 4605 sandwich panels, and will meet all of the requirements of FAR/JAR 25.855 and Airbus
Specification ABD 0031. The Gill Corporation must issue permission to use alternate materials.
See illustrations in Figure 2, for procedure for installing the edge filling, and reference Figure 1, below, for a
sketch of an edge-filled panel.
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Figure 2
Edge Filling Procedure
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11 Insert Installation
The use of inserts in replacement floor panels offers a reinforced method for attaching the floor panels to the
aircraft’s structural members, and provides a means for transferring high-stress loads to the airframe. The
strength required to resist premature pullout and failure of the insert is obtained by a combination of bonding the
insert flange to the panel facing, and potting, or embedding the insert, into the panel using high strength epoxy
adhesives. The potting technique is especially important in providing the necessary pullout strength. It also
offers a barrier to the penetration of fluids, such as water, cleaning solvents/solutions, contaminants, etc., which
have the potential for damaging the interior of the panel and reducing its integrity. Therefore, it is important to
exercise care and to follow the procedures described in this manual for insert installation. The geometry of the
replacement floor panels may be duplicated as shown in the applicable Airbus drawing (if available), or by using
the panel being replaced as a template. The fabricated replacement panel must be able to be installed easily,
without causing damage to the panel or surrounding structure.
To obtain optimum properties of the adhesive system, cleanliness is extremely important, and great care must
be taken to ensure all areas to be bonded or potted are clean and free of contamination such as oil, grease,
water, dust, etc. (the presence of a fingerprint can significantly reduce bond strengths). Commonly available
solvents, such as acetone or isopropanol may be used to remove oily deposits, but the cleaned area must be
thoroughly dry before any further bonding procedure. Similarly, the inserts must be cleaned, and submerging
them in a suitable solvent will remove mill scale, lubricants, and oil. Again, the inserts must be completely dry
before proceeding with the installation. (Commonly used solvents are flammable, and suitable precautions
must be taken to prevent fires; the solvent vapors can be harmful if inhaled, and the manufacturer’s
recommendations for handling these materials should be followed. The hazards and handling procedures are
given in detail in the supplier’s Safety Data Sheet (SDS) for the particular material being used.)
Any holes drilled through the panel for installing inserts must be free of debris and any loose material from the
drilling or routing operation; thin-nose pliers may be used to remove loose particles, or a stream of clean, dry,
compressed air can be used to remove any dust. If a panel surface has been roughened by sandpaper or
emery cloth, the area must be wiped with a clean, dry cloth to remove debris.
The following sections describe procedures and materials for installing inserts; it is important to use only those
materials specified in this manual for The Gill Corporation replacement panels.
Permission from The Gill Corporation must be obtained for the substitution of any material specified in
this manual.
As noted in Section 2, first-time installers of inserts must demonstrate satisfactory procedures for installation;
test coupons, adhesive, and inserts will be provided by The Gill Corporation. Strength measurements must be
done by The Gill Corporation and a test report will be issued showing compliance with requirements.
The following instructions are accompanied by illustrations for demonstrating the recommended procedures for
installation of the different types of inserts.
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11.1 Bulk, Container Cargo Compartment and Passenger Floors Torlon® Insert Installation
11.1.1 Two-Piece Molded Torlon® Inserts for Cargo floors
The two-piece, molded Torlon® inserts for Cargo floors described in ¶ 7.1.1. and shown in Figure
23, provide a flush-mounted installation in the upper surface, i.e., the insert does not protrude above
the level of the floor panel.
The following instructions are accompanied by photos on the following pages to illustrate the various
steps; the illustrations show the preparation of test specimen coupons, but the same techniques
apply to the full-sized floor panels. The panels should be cut to finished size and edge-filled before
installing inserts (edge filling procedure is described in ¶ 10).
Use a drill diameter of 15 mm (19/32 or 0.590”) for these inserts.
(Refer to ¶ 8 for machining floor panel recommendations).
The following steps ¶ 11.1.1.1 – ¶11.1.1.5 describe the preparation of the panel for the installation of
all inserts types. Care must be taken not to damage the panel or inserts during handling and
machining.
11.1.1.1 Mark the locations of all holes to be drilled. See Fig 3, Step 1.
11.1.1.2 Carefully drill the holes taking care not to cause excessive fuzzing or fiber
damage in the faces. If drilling by hand, be sure the drill bit is as
perpendicular as possible to the panel surface. See Fig 3, Step 2.
11.1.1.3 Remove 3 to 5 mm (1/8 to 3/16 inches) of the honeycomb core
between the facings; use a high speed rotary tool (Dremel®, or
equivalent), and be careful not to damage the facings. The routed- out
area will allow sufficient potting adhesive to surround the insert barrel to
provide the high pullout strengths required. See photo, Fig. 3, Steps 3
and 4, for the appearance of the hole with adequate honeycomb core
removed.
11.1.1.4 Lightly sand the lower facing of the panel where the insert flange will be
bonded, and wipe away any dust. The lower facing of the panel is the
thinner facing. See Fig. 3, Step 5.
11.1.1.5 Clean the insert parts by immersion or wiping with a suitable solvent
(acetone is recommended). See Fig. 3, Step 6. After panel preparation,
cleaning and sorting, the inserts are ready to be installed. For the
following procedures, refer to Fig. 4.
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FIGURE 3
Preparation of Floor Panels for Installation of Inserts
Step 3, below, is very important; to allow for a sufficient amount of the potting adhesive to bond the insert
and provide structural integrity, make sure the routed-out cavity is large enough. Do not remove or
otherwise damage the facings. The potting adhesive also provides a barrier against moisture and other
liquids.
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11.1.1.6 Before installing the insert in the panel, the method to be used for
potting with adhesive must be decided; if the necessary equipment
and/or adhesive packaging are not available, the adhesive must be applied
to the routed-out hole before installing the insert parts into the panel. If the
adhesive can be injected through the holes in the bottom insert part, it is
not necessary to apply adhesive inside the hole cavity until after the insert
has been fitted into the panel.
11.1.1.7 If the potting adhesive cannot be injected through the hole in the bottom
insert, the adhesive must be applied to the routed out area to fill as
completely as possible the entire cavity before installing the insert in the
panel.
11.1.1.7.1 Potting Adhesive Application Before Insert Installation:
Mix the two-part adhesive according to the manufacturer’s instructions – see ¶ 7.4
for the approved adhesives and suppliers; mix only the amount of adhesive which
can be used in about 30 – 40 minutes. It may be helpful to allow the adhesive to
stand for a few minutes to allow it to thicken so it will stay in place when applied to
the panel.
In the absence of materials to inject the potting adhesive through the flange holes,
adhesive must be applied by means of a trowel or small spatula to the routed-out
area in the panel. See Fig. 4, Steps 1 and 2. Make sure there is sufficient
adhesive to encapsulate the insert when it is installed. Apply adhesive to the
flange of the insert sleeve (bottom part) before installing it in the panel. See Fig. 4,
Steps 3 and 4 for an illustration of the insert and application of adhesive to
the flange area.
11.1.1.7.2 Installation of Insert in Floor Panel:
(A) Place the insert sleeve, with the flange, into the lower face (the face of lesser
thickness) of the panel, then place the plug in the upper face, making sure to align
the parts so they can be pressed together without damaging them. See Fig. 4,
Steps 5 and 6.
(B) The insert sections can be pressed together by gently tapping with a hammer
(Fig. 5, Step 1) or by using an arbor press (Fig. 5, Step 2). Use only enough
pressure to bring the insert plug flush with panel surface and to seat the insert
flange to the back of the panel. A small quantity of adhesive should be squeezed
out from underneath the flange, but enough should be left to provide an adequate
bond to the face.
(C) Remove any excess adhesive from the upper and lower facings using a cloth,
dry or slightly dampened with solvent, and use a cotton swab to remove any
adhesive in the hole through the insert; the installation should appear as shown in
the illustration (Fig. 5, Steps 3 and 4). Allow 3- 5 days at 23°C (73°F) curing time
for the adhesive to develop adequate strength. Cure can be accelerated by using
elevated temperature – follow manufacturer’s instructions; a commonly used cure
schedule is 2 hours at 60°C (140°F). Do not exceed 82°C (180°F).
A cross-sectional drawing of the installed insert is shown in Figure 6.
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FIGURE 4
Installation of Molded Torlon® Inserts – Cargo Floors
Step 1: Application of potting adhesive to Step 2: Apply a generous quantity of adhesive
routed-out area of panel to the panel interior.
Step 1: Application of potting adhesive 1
Step 3: Two-piece molded Torlon® insert. Step 4: Apply adhesive to the inside of the
flange.
Step 5: Install insert sleeve (with adhesive on Step 6: Install plug in upper facing; be sure to
flange) in lower facing. align parts to prevent breakage when parts are
sealed.
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FIGURE 5
Seating of Molded Torlon® Inserts
Step 1: Place panel/insert assembly on a firm Step 2: If available, an arbor press is preferred
base, and tap insert plug (tap) gently with a for seating the insert. Use only enough pressure
hammer until it is flush with panel surface. to mount the insert plug flush with panel surface.
Step 3: Insert must be flush with panel surface; Step 4: Remove excess adhesive from insert
remove any adhesive which might have sleeve and bottom of panel. Insert flange should
squeezed out from around insert plug. be seated firmly against lower face. Ensure that
flange is not broken.
FIGURE 6
Molded Torlon® Insert as Installed – Cargo Floor
(Note: figure not to scale; sleeve with flange must be bonded to the lower facing of panel)
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11.1.1.7.3 Potting Adhesive Application After Insert Installation:
Follow the procedure described in ¶ 11.1.1.1 - ¶ 11.1.1.5 and Figure 3 for

panel preparation; for potting adhesive applied by injecting through the insert
holes, apply adhesive to the flange and insert the parts into the panel as
shown in Figure 4, Steps 4 and 5. Do not apply adhesive to the routed-out
area of the panel – potting will be done after the inserts are installed and
seated in the panel. Seat the inserts, with adhesive on the flange, as shown
in Figure 5, Steps 1 or 2. Different procedures for injecting the adhesive
may be available, depending on the equipment and materials available.
The adhesive injection procedures are faster and result in more uniform
insert encapsulation, and are the preferred technique for accomplishing this
important task.
(A) If adhesive is available in a two-cartridge package, a hand operated gun
and mixing nozzle can be used to inject adhesive through the potting holes in
the bottom insert section. The cartridge assembly dispenses the correct ratio
of components, so weighing of the ingredients is not necessary. See Fig. 7,
Method 1.
The injection hole diameter in the insert flange is 2.3mm (0.092 ins.), and the
cartridge nozzle must fit into the hole to allow proper encapsulation and avoid
wasting adhesive and difficult cleanup.
(B) Insert the mixing nozzle into one of the injection holes, and squeeze the
gun handle to inject the adhesive; apply adhesive until it flows out of the
opposite hole, and no air bubbles are ejected with the excess adhesive.
Wait a minute or two to help eject any more air bubbles, then inject more
adhesive through the hole from which the adhesive was ejected. Again,
inject until no more air bubbles exit the vent hole. This procedure helps to
ensure optimum encapsulation of the insert, providing the high pullout
strengths required for this structural component.
(C) For adhesive injection by air-pressure operated gun or hand-operated
syringe, the adhesive must be pre-mixed before loading the applicator
chamber; the procedure for potting is the same as ¶ (B), above. See Fig 7,
Methods 2 and 3. A syringe needle diameter of 1.8 mm. (0.072 ins.) is
recommended. Remove any excess adhesive from the upper and lower
facings, and use a swab to remove adhesive from the insert hole, and wipe
off excess adhesive with a dry clean cloth. A cross-sectional drawing of the
installed insert is shown above, Fig. 6.
While the insert installation procedures are the same for all panel types; the
correct insert must be used with the exact panel type involved. The insert
part numbers are shown in ¶ 7.1.1. and ¶ 7.1.4.
11.1.1.7.4 Weight of Installed Insert

The approximate weight of the installed, potted insert is 4.5 – 5.5 grams
(0.010 – 0.012 lbs.).
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FIGURE 7
Injection of Adhesive Through Potting Holes in Insert Sleeve
Method 1: Injection using a hand operated Method 2: Injection using an air-operated gun;
cartridge gun; pre-packaged adhesive adhesive components must be pre-weighed and
components must be used in this procedure. mixed before adding to the reservoir.
Method 3: Injection using a hand operated syringe;

Adhesive components must be pre-weighed and
mixed before adding to the syringe barrel.
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11.1.2 Two-Piece Molded Torlon® Inserts for Passenger floors

The inserts for Passenger floors described in ¶ 7.1.4 and shown in Figure 28 has a plug that
protrudes above the panel. Installation instructions shown in ¶ 11.1.1 apply for this insert type, but
note that the plug and sleeve will both be flanged. Follow steps ¶ 11.1.1.1 – ¶11.1.1.5 for
preparation of the panel for the installation of inserts. Install insert per ¶11.1.1.7.2, noting that while
the plug appearance will differ from that shown in Figure 4, the general process of seating the insert
into the panel is the same. Ensure that the insert plug, which does NOT have injection holes, is
installed in the panel face.
Injection of adhesive through the potting holes, described in ¶11.1.1.7.3, is recommended. The
installed insert appearance should match that shown in Figure 7A.
FIGURE 7A
Molded Torlon® Insert as Installed – Passenger Floor
Plug, no injection holes, installed on the panel face Sleeve with injection holes, installed on panel back
11.2 Bulk and Container Cargo, Passenger, and Flight Compartment Aluminum Insert Installation
11.2.1 One-Piece Aluminum Inserts TF110 and TF111
The one-piece aluminum inserts TF110 and TF111 described in ¶ 7.1.2, schematic shown in Figure
24, provide a flush-mounted installation in the upper facing of the panel with a special forming tool,
while the flange is bonded to the lower facing of the panel. (The special forming tool is available from
The Gill Corporation or can be machined per the specification drawing shown in Figure 21.) The
procedure described below is the same for both the bulk (Gillfab 4523, Airbus Type BCC3 and
Gillfab 4223, Airbus Type BCC2) and cargo container floor (Gillfab 4522, Airbus Type CCC1).
The Gill Corporation part number for the bulk floor insert is TF110, the cargo compartment floor insert
is TF111. Follow the panel preparation procedures described in ¶11.1.1.1 – 11.1.1.5.
Use a drill diameter of 12.7 mm (1/2 in., 0.500 in.) for inserts TF110 and TF111.
Since the TF110 and TF111 inserts do have potting adhesive injection holes, the procedure for potting
the panels is the same as that outlined for molded Torlon inserts in ¶11.1.1.6 – 11.1.1.7, except that a
special forming tool with an arbor press should be used to install the insert into the panel. The forming
tool is not the same tool used for TF20 and TF21 inserts, but the installation process is similar to that
described below in ¶11.2.2.2 – 11.2.2.5 and shown in Figure 9. See Figure 8 for photos of the TF110
insert before and after installation.
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11.2.2 One-Piece Aluminum Inserts TF20 and TF21

The one-piece aluminum inserts TF20 and TF21 described in ¶ 7.1.2 and shown in Figures 25 and
26 provide a flush-mounted installation in the upper surface of the panel by forming a rolled flange
with a special forming tool. (The special forming tool is available from The Gill Corporation or can be
machined per the specification drawing shown in Figure 22.) The procedure described below is the
same for both the bulk (Gillfab 4523, Airbus Type BCC3 and Gillfab 4223, Airbus Type BCC2) and
main deck cargo (Gillfab 4123, Airbus Type MDC2). The Gill Corporation part number for the bulk
floor insert is TF20, the main deck cargo floor insert is TF21. Follow the panel preparation procedures
described in ¶ 11.1.1.1 – 11.1.1.7.
Use a drill diameter of 11.1 mm (7/16 in., 0.4375 in.) for inserts TF20 and TF21.
11.2.2.1 The one-piece aluminum inserts do not have potting adhesive injection
holes, and it is necessary to apply the adhesive by trowel or spatula to the
routed-out area of the panel. See Fig. 4, Steps 1 and 2.
11.2.2.2 Apply adhesive to the flange of the one-piece insert, and install the insert
through the bottom of the panel; see Figure 9, Steps 1 and 2.
11.2.2.3 Place the panel-insert assembly on a firm surface, and use the special
forming tool to seat the insert and form the rolled flange on the upper
surface. The flange can be formed by placing the tool into the insert and
tapping carefully with a hammer, but the preferred method is by means of an
arbor press, if available. See Figure 9, Steps 3 and 4. Be careful not to
damage the panel or insert during the seating process.
11.2.2.4 Clean all excess adhesive from around the lower flange, upper surface, and
the bolt hole through the insert (a cotton swab works well for cleaning the
hole).
11.2.2.5 The rolled flange of the insert should be flush, or slightly below the
panel surface; see Figure 9, Step 5.
NOTE: IT IS IMPORTANT TO FOLLOW CAREFULLY THE PROCEDURES DESCRIBED ABOVE FOR

INSTALLING INSERTS IN THE BULK CARGO FLOOR PANEL. THE HIGH PULLOUT STRENGTHS
REQUIRED RELY ON THE BONDING OF THE INSERT FLANGE TO THE LOWER FACING, AND THE
POTTING OF THE INSERT TO THE INTERIOR OF THE PANEL.
The installation of two-piece aluminum inserts in the containerized cargo and passenger floors follows the same
general procedures shown above, and is described in ¶11.2.3.
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FIGURE 8
Installation of One-Piece Aluminum Inserts TF110 and TF111 in Cargo Floor Panels
Figure 8-1: A TF110 insert before installation. Figure 8-2: Applying adhesive on the flange
of the TF110 insert. Follow the potting
instructions given in ¶11.1.1.6 – 11.1.1.7.
Figure 8-3: Appearance of the back side Figure 8-4: Appearance of the face side of
of the panel (flange side) with the installed the panel with the installed TF110 insert.
TF110 insert.
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FIGURE 9
Installation of One-Piece Aluminum Inserts TF20 and TF21 in Bulk Cargo Floor Panels
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11.2.3 Two-Piece Aluminum Inserts

The two piece inserts described in ¶ 7.1.3 and shown in Figure 27 are used in the passenger floor
(Gillfab 4405/4505 and 4605, Airbus types PC3 and PC1, respectively) and the containerized
floor (Gillfab 4522, Airbus Type CCC1). The Gill Corporation part numbers for the two-piece insert
are T303A and T303B, for the plug and sleeve, respectively. A320 family floors can also use T307A
and T307B.
Follow the panel preparation procedures described in ¶ 11.1.1.1 – 11.1.1.7. The panels should be
cut to finished size and edge-filled before installing inserts. Refer to ¶ 8 for recommendations for
machining floor panels and ¶ 10 for the edge filling procedure.
Use a drill diameter of 11.1 mm (7/16 or 0.4375”) for these inserts.
Other than the drill diameter used for these inserts, the installation process is very similar to that
used for two-piece plastic inserts. See ¶ 11.1 for details on installation. One important difference is
that these inserts do not have holes in the insert sleeve, so it will not be possible to add potting
adhesive after installing the insert into the panel.
The Gill Corporation recommends routing out the core as shown in Figure 3, step 3 and described
in ¶ 11.1.1.3 and adding potting adhesive around the hole as described in ¶ 11.1.1.6 and ¶ 11.1.1.7
with these two-piece aluminum inserts. It is possible to achieve adequate insert strength without
these steps, and if this is a desired outcome strengths using this process must be demonstrated as
outlined in ¶ 6. The Gill Corporation has found that routing out the core yields higher and more
consistent insert strengths.
The completed insert cross-section is shown in Figure 10. Note that the insert plug and sleeve are
engaged sufficiently to provide complete bonding contact between the flanges and the respective
panel surfaces.
FIGURE 10
Cross-Section of Installed Two-piece Aluminum Insert
Note: this drawing is not necessarily to scale. Some panels are unbalanced constructions in which the upper
facing is thicker compared to the lower facing. The insert plug is always bonded to the upper (top) facing of the
panel. In the case of balanced constructions, the upper facing will bear a label indicating so. Take care to install
the inserts properly.
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FIGURE 11
Installed Two-piece Aluminum Insert –Upper Facing
Note that the flange appearance, shown in Figure 11, will be similar on both the upper facing and the lower facing
of the installed insert, except that the upper facing will contain the countersunk plug part of the insert. The
countersunk plug flange should always be bonded to the thicker facing of the panel, in case of unbalanced
constructions; or to the facing clearly marked as the upper facing by The Gill Corporation. It is important to
always maintain the identity of the upper facing in the event the label is lost or destroyed.
11.3 Hardpoint Insert Installation

The installation of special hardpoint inserts to provide reinforced attachment points, schematics shown in
Figures 29 to 32, generally follows the installation procedure outlined for two-piece inserts in section ¶
11.2.3. The larger diameter of the insert barrel will probably require the use of a hole saw or router bit to
form the hole in the panel without damaging the facings. A diagram of a finished hardpoint insert installation
is shown in Figure 12.
Use a drill diameter of 31.75 mm (1 ¼ or 1.25”) for these inserts.
FIGURE 12
Cross-section of Installed Hardpoint Insert
(See note above for figure 10)
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11.4 Threaded Insert Installation

All threaded inserts shown in ¶ 7.2 are added directly into TGC panels without the need for composite
plugs. Tooling selection, tool use, insert degreasing and general principles for working with composite
panels, adhesives and edge fill should align with ¶ 7, ¶ 8, ¶ 9 and ¶ 11. In all cases, insert, adhesive and
edge fill manufacturer’s instructions should be followed for mixing and curing of adhesives and edge fill.
Hole sizes below are listed for convenience, but note that insert manufacturer’s instructions for hole size
should be followed in case of any discrepancy.
For all threaded insert types, solutions below have been shown with the faceskins remaining on the panel.
Please note that the same general process can be followed in cases where the Airbus drawing shows a
step-down solution with the faceskin removed and edge filling placed into the core, as shown in Figure 13.
Remove the faceskin and fill the exposed core with edge filler prior to installing the inserts in these cases.
FIGURE 13
Step-Down Installation of Threaded Inserts
11.4.1 NAS 1833 and 1834

In the desired location, drill a hole 14.2 – 14.4mm in diameter (0.561 – 0.566”) through the panel.
Prepare the panel location as described in ¶ 11.1.1.1 and ¶11.1.1.2. Clean inserts as shown in
¶11.1.1.5. Place manufacturer tabs on top of the insert and place the insert into the hole. Place any
suitable masking or barrier tape to the opposite side of the panel to prevent adhesive loss in the next
step. Masking tape is sufficient for this purpose, but alternate tape choices that support the same
function, do not inhibit cure of the adhesive and do not cause damage to the panel when removed are
allowed.
Mixed adhesive as defined in ¶ 7.4 should be injected into the insert tab holes until a small stream of
adhesive is expelled from the opposite hole. After 12 hours of wait time at room temperature ambient
conditions, the tab and tape should be gently removed. Excess adhesive remaining on top of the
insert should be removed, and the installation cured per adhesive manufacturer recommendation.
FIGURE 14
Tabbed Insert Placed in Panel
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FIGURE 15
Adhesive Added Through Insert Tab Hole
FIGURE 16
Excessive Adhesive Removed
An alternate installation method allowed is to drill the hole sized 14.2 – 14.4mm in diameter (0.561 –
0.566”) through the panel, remove core between the faceskins as shown in ¶ 11.1.1.3, apply edge fill
into the routed undercut area, smooth surface of the edge fill, and cure per edge fill manufacturer’s
instructions. The insert can now be installed with potting adhesive as described above.
11.4.2 NAS 1835

This procedure should be identical to the description for NAS1833 / NAS1834 shown above in ¶
11.4.1, except that holes sized 17.4 – 17.6mm (0.686 – 0.691”) should be drilled through the panel in
the appropriate location.
An alternate installation method allowed is to drill the hole sized 17.4 – 17.6mm (0.686 – 0.691”)
through the panel, remove core between the faceskins as shown in ¶ 11.1.1.3, apply edge fill into the
routed undercut area, smooth surface of the edge fill, and cure per edge fill manufacturer’s
instructions. The insert can now be installed with potting adhesive as described in ¶ 11.4.1.
- 33 -, Revision I
11.4.3 NAS 1836

This procedure should be identical to the description for NAS1833 / NAS1834 shown above in ¶
11.5.1, except that holes sized 11.5 – 11.6mm (0.452 – 0.457”) should be drilled through the top
facing of the panel in the appropriate location, taking care not to drill through the bottom faceskin.
Core should be removed so that ≤ 1.27mm (0.05”) of core remained from the bottom faceskin, at the
same diameter as the hole. Test that sufficient core has been removed by ensuring the insert can be
installed flush to the top face of the panel. Continue insert installation as described in ¶ 11.4.1.
An alternate installation method allowed is to drill the hole sized 11.5 – 11.6mm (0.452 – 0.457”) as
described above, remove core between the faceskins as shown in ¶ 11.1.1.3, apply edge fill into the
routed undercut area, smooth surface of the edge fill, and cure per edge fill manufacturer’s
instructions. The insert can now be installed with potting adhesive as described in ¶ 11.4.1.
11.4.4 DAN401-3
Holes sized 14.4 – 14.6mm (0.567 – 0.575”) should be drilled through the panel in the appropriate
location as described in ¶ 11.1.1.1 and ¶ 11.1.1.2. Because the DAN401-3 insert is significantly
smaller on the top than the bottom, and it is important to use the inner threads after installation, a
temporary method should be used to block adhesive ingression during insert installation. One
possible method is to place a protected screw into the threads during adhesive addition. Poly tape
was found to be sufficient for this purpose, as shown below in Figures 17, 18, and 19, but alternate
methods that prevent adhesive ingression are allowed.
Inserts were cleaned according to ¶ 11.1.1.5. Manufacturer tabs were placed on bottom of the insert
and the insert placed into the hole.
Mixed adhesive should be added into the hole until full. After 12 hours of wait time at room
temperature ambient conditions, the tab and screw should be gently removed. The installation should
be cured per adhesive manufacturer recommendation.
An alternate installation method allowed for DAN401-3 inserts is to use edge fill instead of potting
adhesive, keeping all other installation instructions the same.
FIGURE 17
Preventing Adhesive Ingression into Threading
- 34 -, Revision I
FIGURE 18
Preventing Adhesive Ingression into Threading: Adhesive Set-Up
FIGURE 19
After Adhesive Cure, Check of Clean Threading
- 35 -, Revision I
11.5 Insert Strength Test Specimen Configuration

As discussed in section 2, any first-time installers of inserts must demonstrate the ability to properly install
inserts by preparing panel test specimens and submitting them to The Gill Corporation for strength testing.
Test specimens should have the configuration shown in Figure 20 below. The Gill Corporation can supply
test coupons and inserts for assembly into test specimens, if desired.
Figure 20
Test Specimen Configuration – Insert Shear
1. AEP Molded Torlon Inserts, TF073, TF074 and TF152: 15 mm (19/32 or 0.590 in)
2. TYE Aluminum Inserts, TF20, TF21, T303 and T307: 11.1 mm (7/16 or 0.4375 in)
3. Shur-Lok Aluminum Inserts, TF110 and TF111: 12.7mm (1/2 or 0.500 in)
- 36 -, Revision I
11.6 Forming Tool for 1-piece Aluminum Inserts TF110 and TF111
The 1-piece aluminum inserts TF110 used in 4223 (BCC2) panels and TF111 used in 4522 (CCC1) panels
described in ¶11.2.1 require a special forming tool to install. The tool can be obtained from The Gill
Corporation or can be machined according to the specification schematic shown below in Figure 21. Note
that this is not the same forming tool used for TF20 and TF21 inserts.
Figure 21
1-piece Aluminum Insert Forming Tool for TF110 and TF111
- 37 -, Revision I
11.7 Forming Tool for 1-piece Aluminum Inserts TF20 and TF21
The 1-piece aluminum inserts TF20 used in 4223 (BCC2) panels and TF21 used in 4123 (MDC2) panels
described in 11.2.2 require a special forming tool to install. The tool can be obtained from The Gill
Corporation or can be machined according to the specification schematic shown below in Figure 22. Note
that this is not the same forming tool used for TF110 and TF111 inserts.
Figure 22
1-piece Aluminum Insert Forming Tool for TF20 and TF21
11.8 Insert Schematics for Inserts

Shown below are diagrams detailing the specifications to which each insert is manufactured. These are
given for reference purposes and are not given as machining instructions to the panel fabricator. ONLY
AIRBUS APPROVED COMPONENTS MAY BE USED IN PANEL FABRICATION.
- 38 -, Revision I
Figure 23
2-Piece Molded Torlon® Inserts TF073, TF074 Schematic
- 39 -, Revision I
Figure 24
1-Piece Aluminum Insert TF110 and TF111 Schematic
- 40 -, Revision I
Figure 25
1-Piece Aluminum Insert TF20 Schematic
- 41 -, Revision I
Figure 26
1-Piece Aluminum Insert TF21 Schematic
- 42 -, Revision I
Figure 27
2-Piece Aluminum Insert T303 and T307 Schematic
- 43 -, Revision I
- 44 -, Revision I
Figure 28
2-Piece Torlon Insert TF152 Schematic (A320 Family Aircraft Only)
- 45 -, Revision I
- 46 -, Revision I
FIGURE 29
Hardpoint Insert T304 Schematic
- 47 -, Revision I
FIGURE 30
- 48 -, Revision I
FIGURE 31
- 49 -, Revision I
FIGURE 32
- 50 -, Revision I

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The Gill Corporation Report No.

MCG IRM 9701, Revision I

The Gill Corporation

Released Sept 24, 2018

INSTRUCTIONS FOR THE FABRICATION, REPAIR, AND INSTALLATION OF

3 Applicable Specifications and Documents

The Gill Corporation Airbus Industrie Airbus Industrie Panel Application

Gillfab 4605 PC1 5360 M1M 000600 A318/A319/A320/A321

6 Floor Panel Fabricator Responsibility

7 Parts and Materials

The Gill Corporation Airbus Industrie Insert Insert The Gill

TF073 and TF074 Insert Manufacturer

Phone: (425) 454-5610

The Gill Corporation Airbus Industrie Insert Insert The Gill

TF110 and TF111 Insert Manufacturer

Phone: (949) 474-6000

TF20 and TF21 Insert Manufacturer:

7.1.3 Container Cargo and Passenger Compartments: 2-Piece Aluminum Inserts

The Gill Corporation Airbus Industrie Insert Insert The Gill

T303 and T307 Insert Manufacturer:

7.1.4 Passenger Compartments, A320 FAMILY ONLY: 2-Piece Torlon Inserts

The Gill Corporation Airbus Industrie Insert Insert The Gill

TF152 Insert Manufacturer

Phone: (425) 454-5610

7.1.5 Special Design Criteria – Hardpoint Attachments

Airbus Industrie Manufacturer’s Part Number Insert The Gill

Hardpoint Insert Manufacturer:

7.2 Threaded Inserts

The Gill Corporation Airbus Industrie Insert

7.3 Insert Drawings

Telephone: 800-562-8483 (US)

7.4.3 Adhesive Packaging

7.5 Edge Filling Compound

Mankiewicz Gebr. and Co (GmbH Co.)

Telephone: +49 (40) 75 10 30

Telephone: (843) 654-7755

7.5.2 Scotch-Weld EC3524 B/A

Telephone: (888) 364-3577

7.5.3 Scotch-Weld 3550 B/A FST

Telephone: (888) 364-3577

8 Machining of The Gill Corporation Sandwich Panel Products

8.1 Drill Bit Selection

RECOMMENDED BLADE SPEEDS

Blade Revolutions Surface Feet

8.3.1 Entire Panel

9 Repair of Replacement Floor panels

Decabromodiphenyl ethane, aka 1,1’-(1,2-ethanediyl)bis[2,3,4,5,6 pentabromo]benzene, sold as

Colloidal Antimony pentoxide, aka diantimony pentoxide, sold as Nyacol A1582

9.3 Repair Procedure

10 Edge Filling Procedure

11.1.1.7.1 Potting Adhesive Application Before Insert Installation:

11.1.1.7.3 Potting Adhesive Application After Insert Installation:

Follow the procedure described in ¶ 11.1.1.1 - ¶ 11.1.1.5 and Figure 3 for

11.1.1.7.4 Weight of Installed Insert

Method 3: Injection using a hand operated syringe;

11.1.2 Two-Piece Molded Torlon® Inserts for Passenger floors

11.2.2 One-Piece Aluminum Inserts TF20 and TF21

NOTE: IT IS IMPORTANT TO FOLLOW CAREFULLY THE PROCEDURES DESCRIBED ABOVE FOR

11.2.3 Two-Piece Aluminum Inserts

11.3 Hardpoint Insert Installation

11.4 Threaded Insert Installation

11.4.1 NAS 1833 and 1834

11.4.2 NAS 1835