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STRUCTURAL REPAIR MANUAL
REPAIR DESIGN GUIDELINE
1. General
CAUTION: THE STRUCTURAL ITEMS, FOR WHICH A REPAIR CAN BE DESIGNED USING
THESE GUIDELINES ARE IDENTIFIED IN THE SPECIFIC SRM IDENTIFICATION
AND/OR REPAIR PAGE BLOCKS.
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. In most cases only the static requirements need to be met
for the repair principles on secondary structure and only those will be
addressed in this part.
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 capa
bility 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,
spacing and margin 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.
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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.
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.
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(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 mate
rial for the tension check and to the component geometry for the
compression check.
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.
− 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.
(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.
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(b) Compression Check
For the compression check, refer to the method detailed in

Chapter 51−70−13 − Fasteners − Strength of Mechanically Joints.
This method can be used to determine pre and post allowable
loading. For calculation refer to Paragraph 2.C.
(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 follow
ing 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 insta
bility may appear at lower compressive loading.
For longer profiles (slenderness ratio one edge free a/s 12;
no edge free a/s 25) buckling failure should be investi
gated.
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 − Allow
able Local Buckling Load.
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2 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 mm2 Cross Sectional Area of the Element
ai mm External Breadth of the Element
bi mm Calculate Element Breadth (Refer to Paragraph 2.D.(1))
Ed MPa Young‘s Modulus (Compressive)
Fst,i N Element Crippling Load (Refer to Paragraph 2.D.(3))
Fst,p N Profile Crippling Load (Refer to Paragraph 2.D.(4))
Fty MPa Yield Strength at 0,2% Strain
− Dimensionless Crippling Factor (Refer to Paragraph
Ki
1.D.(2)(d)3)
L mm Profile Length
r mm Radius
si mm Element Thickness
− Dimensionless Intermediate Factor (Refer to Paragraph
xi
2.D.(2))
− Dimensionless Crippling Stress of Element (Refer to
yi
Paragraph 2.D.(2))
− Poisson‘s Ratio
kr MPa Critical Elastic Crippling Stress
st,i MPa Element Crippling Stress (Refer to Paragraph 2.D.(2))
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3 Crippling Factor − K
The crippling factor Ki is depending on the ratio L/a and ele

ment 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 = S * Ftu [N] S Concerned Material Area
Ftu Ultimate Tensile Force
(2) Reserve Factor
PtmaxRep Maximum Tensile Load of

PtmaxRep Repaired Part
R.F. = −−−−−−−−−−−−−− [ ] R.F. Reserve Factor 1.0
PtmaxOri PtmaxOri Maximum Tensile Load of
Origin Part
(3) Determination of Fastener Number
PtmaxOri Maximum Tensile Load of

PtmaxOri Origin Part
NoRow −−−−−−−−−−−−−− [ ] NoRow Number of Fastener Rows
FultimRiv FultimRiv Ultimate Handling Force of
one Row of Rivets
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B. Calculation under Shear Load
(1) Maximum Shear Load
PSmax Maximum Shear Load

Psmax = S * Ftu [N] S Concerned Material Area
Fsu Ultimate Shear Force
(2) Reserve Factor
PSmaxRep Maximum Shear Load of

PsmaxRep Repaired Part
R.F. = −−−−−−−−−−−−−− [ ] R.F. Reserve Factor 1.0
PsmaxOri PSmaxOri Maximum Shear Load of
Origin Part
PtmaxOri Maximum Shear Load of

PsmaxOri Origin Part
NoRow −−−−−−−−−−−−−− [ ] NoRow Number of Fastener Rows
one Row of Rivets
C. Verification of Bearing
(1) Ultimate Shear Force
FSu Ultimate Shear Force

n Number of Sections
c For c determination refer to
FSu = n * c * Fu [N] Chapter 51−70−13 − Fasteners −
Strength of Mechanically Joints
− Paragraph 1.F.(1)
Fu Ultimate Force
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(2) Allowable Load Based on Allowable Bearing
Pallow Allowable Load

t Thickness of Concerned Material
Pallow = t * d * FBru [N]
d Diameter of the Hole
FBru Ultimate Bearing Force
(3) Possible Load in Repaired Sections
PPos Possible Shear Load of

FSu Repaired Part
PPos = −−−−−−−−−−−−−− [MPa] FSu Ultimate Shear Force
t * d t Thickness of Origin Part
d Diameter of the Hole
PSmaxOri Maximum Shear Load of

PsmaxOri Origin Part
PPos = −−−−−−−−−−−−−− [ ] NoRow Number of Fastener Rows
one Row of Rivets
D. Calculation under Crippling Load

(1) Calculated Element Breadth bn
The calculated breadth of element 1, bi=Ai/si
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Figure 1
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(2) Calculating Element Crippling Stress
Figure 2
(3) Calculating Element Crippling Load
Fst,i Element Crippling Load

bi Calculated Element Breadth
Fst,i = bi * si * st,i [N]
si Element Thickness
st,i Element Crippling Stress
(4) Calculating Profile Crippling Load
Fst,p Profile Crippling Load

Fst,p = Fst,i [N]
Fst,i Element Crippling Load
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3. Example 1 − Riveted Flange Cutout
Repair of the Damaged Area

Figure 3
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A. Material
ITEM NOMENCLATURE QTY MATERIAL/REMARKS
1 Joining section AR To be determined per following

2 Section insert AR Use the same section and mate
rial as the original section or
equivalent material as per
Chapter 51−31−00.
3 Rivet countersink 100° AR As per existing rivet type and
diameter. Number of rivet row
and alternative type are deter
mined per following reverse
engineering method.
4 Rivet, universal HD AR Number of row, rivet and alter
native type and diameter are
determined per following reverse
engineering method.
− Structure paint AR Material No. 16−005 (Refer to
Chapter 51−35−00)
− Pretreatment for painting AR Material No. 13−002 (Refer to
− Sealant AR Material No. 09−001 (Refer to
− Cleaning agent AR Material No. 11−003 (Refer to
− Structure paint AR Material No. 16−001 or 16−006
(Refer to Chapter 51−35−00)
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(1) Notes
NOTE:
− All parts and fasteners have to be installed with PR 1436G (Mate
rial 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 spacing and margin 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
− Doubler:
(2) Material Data
Documentation SRM (Refer to Chapter 51−70−11 Table 2)

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
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(3) Fastener and Rivets
(a) Determination of allowable fastener load
Rivet Csk 100° 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 7.
Fultimate = 2330 N
The calculation is done in the original part and

covers the doubler.
Rivet universal DIA 4
NOTE: The upper flange fasteners ensure stability between the

original part and the doubler repair with cutout, by
consistency with lower flange definition, that is to say
the same number of fasteners (with same dia) and the same
materials, but rivets universal instead of rivet counter
sink.
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(5) Calculation under tensile load
Sketch of the Sections

Figure 4
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 mm2 Section = 25.92 mm2
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
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(a) Check of reserve factor
Ptens max doubler

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

=
Total load One row of rivet can handle : Fultimate: 2330 N
Ptens max orig

Number of Fasteners −−−−−−−−−−−−−−−−−−−
Fultimate
6072 N
Number of Fasteners −−−−−−−−−−−− = 2.61
2330 N
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.
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4. Example 2 − Extrusion Cutout

Figure 5
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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 acceptable
repair part. To be determined
per following reverse engineer
ing 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
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(1) Notes
NOTE:
rial No. 09−013) wet assembly

− Original Part:
Extrusion 7075−T6511 thickness 2 mm
− Doubler:
Extrusion 7075−T6511 thickness 2.5 mm
(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
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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 universal instead of rivet
countersink.
Hi−Lok DAN5 protruding 4.8 dia in extrusion

7075−T6511 − t = 2 mm
Fultimate = 8620 N
The calculation is done in the original part and covers

the doubler.
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Figure 6

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

Reserve Factor = −−−−−−−−−−−−−−−−−−− 1
Ptens max orig
23220 N
Reserve Factor = −−−−−−−−−−−−−−−−−−− = 1.12
20800 N

=
Ptens max orig

Fultimate
20800 N
8620 N
It is necessary to install 3 rows of fasteners


thickness, equal or lower width, same shape and equal or better ma
terial characteristics. The repair is covered by the original part
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5. Example 3 − Complete Extrusion Cutout

Figure 7
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23
A. Material

ing method.
engineering method.
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(1) Notes
NOTE:

− Original Part:
Extrusion 7075−T6511 thickness 2 mm
− Doubler:
(2) Material Data

Ftu 520 540
Fty 470 490
Fcy 470 490
Fsu 280 290
Fbru 940 940
Ec 73800 73800
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25
Original fasteners, rivets Csk 100° 4.8 dia,

become Hi−Lok Csk 100° DAN 6 dia 4.8 for
repair fasteners in extrusion 7075−T6511 −
t = 2.0 mm
Fultimate = 7850 N

the doubler.
Rivet universal 4 dia MS20470DD in extrusion

7075−T6511 − t = 2 mm
Fultimate = 3660 N

the doubler.
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Figure 8

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
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Ptens max doubler

Reserve Factor = −−−−−−−−−−−−−−−−−−− 1
Ptens max orig
46332 N
Reserve Factor = −−−−−−−−−−−−−−−−−−− = 1.03
44928 N

+

=
Ptens max orig

Fultimate
44928 N
11510 N

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6. Example 4 − Profile Cutout

Figure 9
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A. Material

ing method.
engineering method.
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(1) Notes
NOTE:

− Original Part:
− Doubler:
(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
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Replace existing fasteners with Hi−Lok type

fasteners
Rivet universal 4.8 dia MS20470DD in clad

sheet metal 2042−T42 − t = 1.8 mm
Fultimate = 5020 N

the doubler.
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Figure 10

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
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Ptens max doubler

Reserve Factor = −−−−−−−−−−−−−−−−−−− 1
Ptens max orig
16116.3 N
Reserve Factor = −−−−−−−−−−−−−−−−−−− = 1.03
15615.6 N

=
Ptens max orig

Fultimate
15615.6 N
5020 N
It is necessary to install 4 rows of Fasteners.
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(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.

Figure 11
(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 Fst,1 = 4144 N Refer to Chapter 51−70−14
Table 152 Table 153
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(c) Determination of profile element 2

Figure 12
Original part Doubler repair

a1 = 8 mm a1 = 10 mm
a2 = 28 mm a2 = 30 mm
s = 1.4 mm s = 1.8 mm
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
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a1 = 28 mm a1 = 30 mm
Fst,2 = extrapolation necessary Fst,2 = 13119 N Refer to Chapter 51−70−14
Table 153
(d) Extrapolation of allowable element crippling load

ax = 25 mm −−> Fst,x = 9732 N
(51−70−14 Table 152)
(next lower value of length an)
ay = 30 mm −−> Fst,y = 11079 N
(51−70−14 Table 152)
(next higher value of length an)
(Fst,y − Fst,x) * (ay − ax)
Fst,n = Fst,x + −−−−−−−−−−−−−−−−−−−−−−−−−−−−−−− [N]
ay − ax
(11079−9732) * (28−25)
Fst,n = 7563 + −−−−−−−−−−−−−−−−−−−−−−−−
(30 − 25)
Fst,n = 10540 N
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(e) Determination of element crippling load Fst,p

Figure 13
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
(f) Check of reserve factor
Fst,p doubler
Reserve Factor = −−−−−−−−−−−−−−−−−−− 1
Fst,p orig
17263 N
Reserve Factor = −−−−−−−−−−−−−−−−−−− = 1.28
13504 N
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7. Example 5 − Profile Cutout

Figure 14
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39
A. Material

ing method.
engineering method.
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(1) Notes
NOTE:

− Original Part:
Clad sheet metal 2024−T3 thickness 1.4 mm
− Doubler:
(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
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Hi−Lok Csk 100° DAN 6 dia 4.8 in clad sheet

metal 2024−T3 − t = 1.4 mm
Fultimate = 4490 N

the doubler.
Rivet universal 4 dia MS20470DD in clad sheet

metal 2024−T3 − t = 1.4 mm
Fultimate = 3660 N

the doubler.
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Figure 15

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

Reserve Factor = −−−−−−−−−−−−−−−−−−− 1
Ptens max orig
30202.2 N
Reserve Factor = −−−−−−−−−−−−−−−−−−− = 1.10
27518.4 N

+

=
Ptens max orig

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

− 4 Hi−Lok and 4 rivets.
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(a) Verification of allowable slenderness x
Sketch of the Repair

Figure 16
lc x
x = −−−−−−−−− 25 [ ]
s
24 mm 40 mm
x = −−−−−−−−−−−−−−−−−− x = −−−−−−−−−−−−−−−−−−
1.4 mm 1.8 mm
x = 17.1 x = 22.2
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(b) Calculation of profile element ...... (n)
(c) Determination of profile element 1

Figure 17
(7) Determination of allowable element crippling load

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

Figure 18
(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

a2 = 28 mm a2 = 30 mm
Fst,2 = extrapolation necessary Fst,2 = 13119 N
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47
(9) Extrapolation 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 = 7563 + −−−−−−−−−−−−−−−−−−−−−−−−
(30 − 25)
Fst,2 = 10540 N
Printed in Germany
51−70−10 NovPage01/0648
(a) Determination of element crippling load Fst,p

Figure 19
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
(b) Check of reserve factor
Fst,p max doubler

Reserve Factor = −−−−−−−−−−−−−−−−−−− 1
Fst,p max orig
17263 N
Reserve Factor = −−−−−−−−−−−−−−−−−−− = 1.28
13504 N
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49
8. Example 6 − Typical T−Profile Cutout

Figure 20
Printed in Germany
51−70−10 NovPage01/0650
A. Material

ing method.
3 Rivet, universal HD AR As per existing fastener. Number
engineering method.
Printed in Germany
51−70−10 NovPage01/06
51
(1) Notes
NOTE:

− Original Part:
Extrusion 7075−T73511 50 mm * 25 mm
thickness 2 mm
− Doubler:
Extrusion 7075−T6511 50 mm * 25 mm
thickness 2 mm
(2) Material Data
Documentation SRM (Refer to Chapter 51−70−11 Tables 5 & 6)

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
Printed in Germany
51−70−10 NovPage01/0652

For original attached flange (single shear) and free flange
(double shear).
Rivet universal 4 dia MS20470DD in extrusion

7075−T73511 − t = 2 mm
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
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
Fult double shear = 7320 N
Printed in Germany
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53
(5) Verification of bearing
Fultimate shear
Fbru max = −−−−−−−−−−−−−−−−−−− Fbru allow
thickness * dia
7320 N
Fbru max = −−−−−−−−−−−−−−−−−−− = 915 MPa
2.0 mm * 4.0 mm
Fbru max = 915 MPa >= Fbru allow = 810 MPa
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
Fultimate = 810 MPa * 2.0 mm * 4.0 mm
Fultimate = 6480 N
Printed in Germany
51−70−10 NovPage01/0654

Figure 21

Section = (50 + 23 − 2 * 4) mm * 2 Section = 2 * (25 + 23 − 2 * 4) mm
mm * 2.2 mm
Printed in Germany
51−70−10 NovPage01/06
55
Ptens max doubler

Reserve Factor = −−−−−−−−−−−−−−−−−−− 1
Ptens max orig
83200 N
Reserve Factor = −−−−−−−−−−−−−−−−−−− = 1.42
58500 N

+

=
Ptens max orig

Fultimate
58500 N
13800 N


thickness, equal or lower width, same shape and equal or better ma
terial characteristics. The repair is covered by the original part
9. Example 7 − Typical C−Type Beam upper flange Cutout
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51−70−10 NovPage01/0656

Figure 22
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57
A. Material

2 Joining Section AR To be determined per following
engineering method.
Printed in Germany
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(1) Notes
NOTE:

− Original Part:
Sheet metal 2024−T42 clad thickness 1.4 mm
− Doubler:
Sheet metal 2024−T42 clad thickness 1.6 mm
(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
Printed in Germany
51−70−10 NovPage01/06
59

metal 2024−T42 − t = 1.4 mm
Fultimate = 3270 N

the doubler.
Printed in Germany
51−70−10 NovPage01/0660

Figure 23

Section = (20 + 18.6 + 4.6) mm * 1.4 Section = (20 + 22.2 + 4.4 − 2 * 4)
mm mm * 1.6 mm
Printed in Germany
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61
Ptens max doubler

Reserve Factor = −−−−−−−−−−−−−−−−−−− 1
Ptens max orig
21307.2 N
Reserve Factor = −−−−−−−−−−−−−−−−−−− = 1.02
20865.6 N

=
Ptens max orig

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

Figure 24

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
Printed in Germany
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63
Pshear max doubler

Reserve Factor = −−−−−−−−−−−−−−−−−−− 1
Pshear max orig
29568 N
Reserve Factor = −−−−−−−−−−−−−−−−−−− = 1.5
19712 N

=
Pshear max orig

Fultimate
19712 N
3270 N
It is necessary to install 7 rows of fasteners (see Area B).
Printed in Germany
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(6) Calculation for Crippling Verification (Refer to Figure 27)
Calculation for Crippling Verification

Figure 25
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65
(7) Comparison Buckling/Crippling Allowable Load
Comparison Buckling/Crippling Allowable Load

Figure 26
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(8) Calculation For Crippling Verification
Printed in Germany
51−70−10 Pages 67/68
Nov 01/06
Figure 27
Printed in Germany
51−70−10 Pages 69/70
Nov 01/06
(9) Crippling Buckling
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71
Crippling Buckling
Figure 28
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10. Example 8 − Typical Formed Section Cutout

Figure 29
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73
A. Material

engineering method.
Printed in Germany
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(1) Notes
NOTE:

− Original Part:
Bent section 2024−T42 clad 50 mm * 25 mm

thickness 1.6 mm
− Doubler:
(2) Material Data

Ftu 390 390
Fty 230 230
Fcy 235 235
Fsu 220 220
Fbru 560 560
Ec 66900 66900
Printed in Germany
51−70−10 NovPage01/06
75
Rivet universal DIA 4 MS20470DD in clad sheet

metal 2024−T42 − t = 1.6 mm
Fultimate = 3660 N

the doubler.

metal 2024−T42 − t = 1.6 mm
Fultimate = 3660 N

the doubler.
Printed in Germany
51−70−10 NovPage01/0676

Figure 30

Section = (50 + 2 * 23.4 − 4) mm * Section = [(44 + 25.2 − 3 * 4) mm +
1.6 mm (40.8 + 20.2 − 3 * 4) mm] * 1.6 mm
Printed in Germany
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77
Ptens max doubler

Reserve Factor = −−−−−−−−−−−−−−−−−−− 1
Ptens max orig
58616 N
Reserve Factor = −−−−−−−−−−−−−−−−−−− = 1.14
51233 N

+

=
Ptens max orig

Fultimate
51233 N
14640 N

Printed in Germany
51−70−10 NovPage01/0678
11. Example 9 − Typical Formed Section Cutout

Figure 31
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79
A. Material

engineering method.
engineering method.
Printed in Germany
51−70−10 NovPage01/0680
(1) Notes
NOTE:

− Original Part:
Bent section 2024−T42 clad 50 mm * 25 mm

thickness 1.6 mm
− Doubler:
(2) Material Data

Ftu 390 390
Fty 230 230
Fcy 235 235
Fsu 220 220
Fbru 560 560
Ec 66900 66900
Printed in Germany
51−70−10 NovPage01/06
81
(a) Determination of allowable fastener for original attached

metal 2024−T42 − t = 1.6 mm
Fultimate = 3660 N

the doubler.
(a) Determination of allowable fastener load for web (double shear)

metal 2024−T42 − t = 1.6 mm
Fultimate = 3660 N
Printed in Germany
51−70−10 NovPage01/0682
(5) Calculation of double shear fastener in web
Fultimate double shear = 2 * c * Fultimate
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.
(6) Verification of bearing
Fultimate shear
thickness * dia
7320 N
Fbru max = −−−−−−−−−−−−−−−−−−− = 1144 MPa
1.6 mm * 4.0 mm
The limitation is given by bearing limitation in original

part and covers the doubler.
(7) Allowable load based on Allowable bearing
Fultimate = 3584 N
Printed in Germany
51−70−10 NovPage01/06
83
(a) Determination of allowable fastener load in free flange

metal 2024−T42 − t = 1.6 mm
Fultimate = 3660 N
The calculation is done in original part and covers the

doubler.
Printed in Germany
51−70−10 NovPage01/0684

Figure 32

Section = (50 + 23.4 + 23.4 −4) mm * Section = ((44 + 25.2 − (3 * 4)) *
1.6 mm 1.6) mm * ((38.4 * 21.8 − (3 * 4)) *
1.6) mm
Printed in Germany
51−70−10 NovPage01/06
85
Ptens max doubler

Reserve Factor = −−−−−−−−−−−−−−−−−−− 1
Ptens max orig
58167 N
Reserve Factor = −−−−−−−−−−−−−−−−−−− = 1.13
51225 N

in web
+

in attached flange
+

in free flange
=
Ptens max orig

Fultimate
51233 N
14488 N
Refer to method given in example 7, Paragraph 9.
Printed in Germany
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12. Example 10 − I−Type Beam upper flange Cutout
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87

Figure 33
Printed in Germany
51−70−10 NovPage01/0688
A. Material

3 Hi Lok AR Number of row, fastener and
Printed in Germany
51−70−10 NovPage01/06
89
(1) Notes
NOTE:

NOTE: The bend radius of repair part must be made so that the out
side radius of the inner nesting part is greater than the in
side radius of the adjacent part.
− Original Part:
− Doubler:
Bent section 2024−T42 thickness 1.6 mm
(2) Material Data
Documentation SRM (Refer to Chapter 51−70−11 Tables 2 & 6)

Ftu 490 390
Fty 420 230
Fcy 420 235
Fsu 260 220
Fbru 905 560
Ec 73800 66900
Printed in Germany
51−70−10 NovPage01/0690
(a) Calculation for Csk Hi−Lok in free flange (single shear)
Hi−Lok Csk 100° 4.8 dia HL11V−6 (DAN 6) in

clad sheet metal 2024−T42 − t = 1.6 mm
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
Fultimate = 4520 N
The calculation is done in the doubler and covers the

original part.
Printed in Germany
51−70−10 NovPage01/06
91
(5) Calculation of double shear fastener
Fultimate double shear = 2 * c * Fultimate
NOTE: For c determination refer to Chapter 51−70−13, Paragraph 1.F.
t/D = 1.6/4.8 = 0.33 >= 0.33 therefore c = 1.
t = thickness 1.6 mm, D = hole diameter 4.8 mm.
(6) Allowable load based on allowable bearing
Original part
Fultimate shear
thickness * dia
9040 N
Fbru max = −−−−−−−−−−−−−−−−−−− = 1177 MPa
1.6 mm * 4.8 mm
(7) Allowable load
Fultimate = 6950 N
Printed in Germany
51−70−10 NovPage01/0692
(8) Allowable load based on allowable bearing
Repair Doubler
Fultimate shear
thickness * dia
9040 N
Fbru max = −−−−−−−−−−−−−−−−−−− = 588 MPa
2 * 1.6 mm * 4.8 mm
(9) Allowable load
Fultimate = 560 MPa * 2 * 1.6 mm * 4.8 mm
Fultimate = 8601 N
The limitation is given by bearing in the original part

and covers the doubler.
Printed in Germany
51−70−10 NovPage01/06
93

Figure 34

Section = (50 mm + 20.4 mm) * 1.6 mm Section = ((40 + 23.4 − (2 * 4.8)) *
1.6) mm * 2 mm
Section = 112.6 mm2 Section = 172 mm2
Ptens max = 112.6 mm2 * 490 MPa Ptens max = 172 mm2 * 345 MPa
Printed in Germany
51−70−10 NovPage01/0694
Ptens max doubler

Reserve Factor = −−−−−−−−−−−−−−−−−−− 1
Ptens max orig
59340 N
Reserve Factor = −−−−−−−−−−−−−−−−−−− = 1.07
55174 N
One row of rivets includes:
2 Rivet double shear in web − Fastener 2 * 6950 N

strength limited by bearing in original
part
+

in free flange
+

in free flange
=
Ptens max orig

Fultimate
55174 N
22340 N
Printed in Germany
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95
(11) Calculation under shear load
Cutout Width = 60 mm

Figure 35

Section = 60 mm * 1.6 mm Section = ((80 − (4 * 4.8)) * 1.6)mm
* 2 mm
Printed in Germany
51−70−10 NovPage01/0696
Pshear max doubler

Reserve Factor = −−−−−−−−−−−−−−−−−−− 1
Pshear max orig
42680 N
Reserve Factor = −−−−−−−−−−−−−−−−−−− = 1.7
24960 N
One row of rivets include:
1 Rivet double shear − Fultimate single shear: 1 * 6950 N

(limited by bearing in original part)
Pshear max orig

Fultimate
24960 N
6950 N
It is necessary to install 4 fasteners in area B.


13. Example 11 − Web Repair (Limited Cutout Height)
Printed in Germany
51−70−10 NovPage01/06
97

Figure 36
Printed in Germany
51−70−10 NovPage01/0698
A. Material
1 Doubler AR As per existing web material but

of next thicker gauge. Material
gauge.
engineering method.
Printed in Germany
51−70−10 NovPage01/06
A1
(1) Notes
NOTE:

− Original Part:
Sheet metal 2024−T42 − thickness 1.4 mm
− Doubler:
(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
Printed in Germany
51−70−10 NovPage01/06A2
Rivet universal DIA 4 MS20470DD in sheet

metal 2024−T42 − t = 1.4 mm
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.
Printed in Germany
51−70−10 NovPage01/06
A3
(4) Calculation of Area A

Figure 37

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
Pshear max = Section * Ftu mini [ N ]
Printed in Germany
51−70−10 NovPage01/06A4
(a) Check of Tensile reserve factor
Ptens max doubler

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

Reserve Factor = −−−−−−−−−−−−−−−−−−− 1
Pshear max orig
13248 N
Reserve Factor = −−−−−−−−−−−−−−−−−−− = 1.14
11592 N
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:
Printed in Germany
51−70−10 NovPage01/06
A5
− 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)
R = √177662 115922 N
R = 21214 N
Capacity of 1 row of 3 fasteners:
3 * 3270 = 9810 N
21214 N
Number of Fastener rows =
−−−−−−−−−−−−−− = 2.16
9810 N
It is necessary to install 3 rows (9 fasteners).
(7) Determination of Fastener Number in Area B


3 * 3270 = 9810 N
11592 N
−−−−−−−−−−−−−− = 1.18
9810 N

14. Example 11 − Plate Repair (Unlimited Cutout Size)
Printed in Germany
51−70−10 NovPage01/06A6

Figure 38
Printed in Germany
51−70−10 NovPage01/06
A7
A. Material
1 Doubler AR As per existing web material but

of next thicker gauge. Material
gauge.
engineering method.
Printed in Germany
51−70−10 NovPage01/06A8
(1) Notes
NOTE:
− All parts and fasteners have to be installed with PR 1436G
(Material No. 09−013) wet assembly.

− Original Part:
− Doubler:
(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
Printed in Germany
51−70−10 NovPage01/06
A9
Rivet universal DIA 4 MS20470DD in sheet

metal 2024−T42 − t = 1.4 mm
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.
Page A10
Printed in Germany
51−70−10 Nov 01/06
(4) Calculation of Area A

Figure 39

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
Pshear max = Section * Ftu mini [ N ]
Page A11
Printed in Germany
51−70−10 Nov 01/06
(a) Check of Tensile reserve factor
Ptens max doubler

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

Reserve Factor = −−−−−−−−−−−−−−−−−−− 1
Pshear max orig
13248 N
Reserve Factor = −−−−−−−−−−−−−−−−−−− = 1.14
11592 N
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)
Page A12
Printed in Germany
51−70−10 Nov 01/06
(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)
R = √177662 115922 N
R = 21214 N
3 * 3270 = 9810 N
21214 N
−−−−−−−−−−−−−− = 2.16
9810 N
Printed in Germany
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01/06

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STRUCTURAL REPAIR MANUAL

REPAIR DESIGN GUIDELINE

A. Purpose of the Repair Design Guideline

Each repair on an aircraft structure has to be capable of sustaining the

A static or stress analysis is performed to make sure that the structure

(1) All details of the applied loading are known:

In this case, a detailed stress analysis of the part to be repaired

(2) No details of the applied loading are known:

In this case the REVERSE ENGINEERING METHOD may be employed to

(1) Safety Factor

The relation of the maximum allowable load without failure and

(2) Reserve Factor

The degree to which a structure can withstand the ultimate load is

(3) Margin of Safety

An other expression of the reserve factor is margin of safety (MS).

In order to restore the original structure capability, a basic

A static analysis for a repair requires normally the following

This section is the original profile section minus the area(s)

(a) Tension and Shear Check

(b) Compression Check

For the compression check, refer to the method detailed in

(c) Fastener Check

For the fastener check, the pre−damage tension and compression

(d) Allowable Compressive Load

The reverse engineering method can be used to calculate the

The calculation method assumes that the profile can be

The method is valid for crippling failure of profiles only.

For calculating the allowable buckling load refer to Paragraph

SYMBOL UNIT DESCRIPTION

The crippling factor Ki is depending on the ratio L/a and ele

If this condition is not fulfilled then

(For dimensions, refer to Paragraph 2.D.(1))

A. Calculation under Tensile Load

(1) Maximum Tensile Load

Ptmax Maximum Tensile Load

(2) Reserve Factor

PtmaxRep Maximum Tensile Load of

(3) Determination of Fastener Number

PtmaxOri Maximum Tensile Load of

B. Calculation under Shear Load

(1) Maximum Shear Load

PSmax Maximum Shear Load

(2) Reserve Factor

PSmaxRep Maximum Shear Load of

(3) Determination of Fastener Number

PtmaxOri Maximum Shear Load of

(1) Ultimate Shear Force

FSu Ultimate Shear Force

(2) Allowable Load Based on Allowable Bearing

Pallow Allowable Load

(3) Possible Load in Repaired Sections

PPos Possible Shear Load of

(4) Determination of Fastener Number

PSmaxOri Maximum Shear Load of

D. Calculation under Crippling Load

The calculated breadth of element 1, bi=Ai/si

(2) Calculating Element Crippling Stress

(3) Calculating Element Crippling Load

Fst,i Element Crippling Load

(4) Calculating Profile Crippling Load

Fst,p Profile Crippling Load

3. Example 1 − Riveted Flange Cutout

Repair of the Damaged Area