BGA AIRWORTHINESS AND MAINTENANCE PROCEDURES PART 2, LEAFLET 13 COMPLEX MAINTENANCE TASKS DEFINITION AND AUTHORITY TO CARRY OUT COMPLEX TASKS General 1. Definition Part M (M.A.801) requires that complex tasks are released by a person authorised by a Part M subpart F maintenance Organisation. Only in the case of ELA 1 aircraft where the certification is by a Part 66 Licensed Engineer is a subpart F not required. The BGA inspector authorisation although recognised by the CAA is not equivalent to a Part 66 licence hence subpart F authorisation is required. The BGA BCAR A8-24 approval (replacing M3) requires that any complex task as described below carried out on an annex II powered aircraft is approved by this procedure. Complex tasks are described in Part M Appendix vii, however this description does not lend its self to sailplanes or light aircraft easily. To assist BGA inspectors and owners the BGA has developed the following guidance. 2. Complex airframe tasks. Identifying what tasks would be considered by EASA or the CAA as complex tasks falling into the Part M Appendix vii category, needs to be accomplished before work is started. The lists below will assist you in categorising the task. Should a task fall into the complex task category application must be made in accordance with section 4 of this leaflet. If the task is identified as "non applicable" then all that is needed is proper recording on worksheets and an entry in the log book. The modification, repair or replacement by riveting, bonding, laminating or welding of any of the following airframe parts: The examples do not constitute a complete list, please use it as a guide to the complexity of the task when making the assessment. "Complex Tasks" Part M Appendix vii – requirement applicable to EASA and Annex II powered aircraft "Complex Tasks" BGA part/task definition - examples Approval required "Non Complex Tasks" Non applicable parts/task - examples Approval not required A Box Beam Fuselage wing carry through Fairings, alignment guides. structure and wing attachment Repair of secondary tubes or Replacement or repair of centre stiffening bulkheads not carrying section member or frame primary structure B Wing stringer or chord member Wing stringer that has structural Stringers and formers that are loads or supporting flying used for carrying fabric or skin. controls. Small non primary structure Composite or monocoque repairs. construction wing repair greater than 15cm in any direction before scarffing C Spar Wing main spar, rear spar, False spar, trailing edge. Spar auxiliary spar. repairs on wooden structure AMP 2-13/Jan 2014 BGA AMP Part 2, Leaflet 2-13, page 1 Broken or damaged spar repairs. wings that do not require the use Repair of spar web. Any major of an alignment fixture or jig. repair that required a jig or fixture Minor spar repairs outboard of to maintain aerofoil alignment. the aileron cut out D Spar flange Spar upper or lower flange or Spar flange repairs outboard of attachment or location. the aileron cut out Repair of spar joint or spigot E Member of a truss type beam Framework and supporting Member used to support fabric, or structure. fairings. Repair of wing support, landing Repair of cowling or fairing gear support, empennage support, supports. engine support structures. F Web of a beam Web of a spar or rib that is Minor reinforcements. primary structure. Aileron cut out reinforcement Repair of a tail plane mounting repair rib. Repair of a spar extension G Keel or chine of a flying boat hull Not applicable or float H Corrugated sheet compression Not applicable member in a wing or tail surface I Main wing rib Ribs used to support flying Ribs used to support fabric, skin controls or attachment points. or profile. Composite or monocoque Repair of up to 2 wooden wing construction wing repair more ribs. Repair of a GRP end rib not than 15 cm in any direction or used for wing location involving a structural member. Repair to 3 or more wooden wing ribs J Wing or tail brace strut Brace strut or wire Fairings and attachment brackets Replacement of load bearing end not forming main load path fitting Replacement of cable guide or fairing bracket K Engine mount Mount, pylon, brace struts, Accessory and fairing mountings attachment points, extension Repair of exhaust or ancillary structure, pivot points. equipment mounting Repair of pylon or engine mounting frame. L Fuselage longeron or frame Main longeron, keel tube. Longeron, fabric or skin supports. Composite or monocoque Secondary non primary structure. construction repair more than 15 Repair to fuselage secondary cm in any direction or involving a tube. Minor fuselage GRP repair structural member Major fuselage repair M Member of a side truss, Load carrying bulkhead or frame Non load bearing formers. horizontal truss or bulkhead Fuselage stiffening bulkhead Repair of non primary structural repair bulkheads and equipment shelves Repair of instrument panels. N Seat support brace or bracket Main seat fixings, harness Seat pan or back support, fairings attachments. or panels, secondary seat Repair of seat harness attachment backs/bases mounting points Repair of seat harness guide and location attachments O Seat rail replacement Seat attachment rails Seat base or back locations. Repair of seat attachment rails Repair of peg location holes or adjustment slots P Landing gear strut or brace strut Frame and mounting structure. Door or brake attachment, fairing Repair of landing gear load attachments. bearing mounting. Repair of u/c doors and hinges. AMP 2-13/Jan 2014 BGA AMP Part 2, Leaflet 2-13, page 2 Q Axle R Wheel S Ski or ski pedestal Main wheel, nose/tail wheel axle Weld repair of main wheel axle. Main wheel, nose/tail wheel Weld repair of a wheel Not applicable Wing tip wheels Repair of wing tip wheel axle location points Wing tip wheels Any repairs The modification or repair of any of the following parts Appendix vii BGA part/task definition Non applicable parts/task A Aircraft skin or the skin of a float Any work that requires the use of Repair work to aircraft skin or if the work requires the use of a a alignment jig or fixture, broken frame that does not require support, jig or fixture wings, broken fuselage, broken alignment of the aircraft. tail plane. Non primary structure repairs. Major structural repairs on Minor repairs to the skin or fabric/wooden skin aircraft trailing edge of a control surface involving the use of a alignment where mass balancing is not jig or fixture. required. Cutting and repair of Repair of control surfaces where access holes in composite skins mass balancing is required to gain access to internal components not exceeding 15 cm in any direction. B Aircraft skin that is subject to Not applicable pressurisation loads C Load bearing part of a control Including control system Repair of control cables. system including control column. mountings and moving parts. Replacement of control rod Pedal, shaft, quadrant, bell crank, Primary control system repairs fittings by riveting or bolting. torque tube, control horn and Secondary control system repairs forged or cast brackets, but excluding (i) the swaging of a repair splice or cable fitting (ii) the replacement of a push-pull tube end fitting that is attached by riveting D Any other structure not listed As identified in the manufacturers Any repair identified as a minor above that the manufacturer has manuals or Technical Notes (SB) repair by the manufacturer and identified as primary structure in or Airworthiness Directives not listed above its maintenance manual, structural Any repairs identified by the repair manual or instructions for manufacturer as a Major repair. continued airworthiness E BGA additional requirements Substantial repair or re-gelling/re Refinishing not requiring the applicable to EASAaircraft and finishing of a GRP/FRP aircraft, removal of all the old gel or Annex II powered aircraft as the fuselage, wing or tail plane where surface finish. requirements do not consider the old gel or surface finish is to A wing minor repair or re-gel GRP/FRP composite structures. be substantially or completely outboard of the aileron cut out. removed on inner/lower 2/3 of a Fin or tail plane minor repair or wing, stabiliser, fin section or re-gel on outer/upper 1/3. fuselage between the wing and tail intersections. Fuselage minor repair or refinish forward of the wing or aft/ below Aerofoil, control or fuselage the fin intersections or in the repairs involving significant lower fuselage section (wheels structural damage. up landing type damage, tail or nose wheel heavy landing Repairs to tail booms and fin damage without significant attachments. structural damage and not adjacent to a structural AMP 2-13/Jan 2014 BGA AMP Part 2, Leaflet 2-13, page 3 Multiple minor damage repairs to a single aerofoil, control or fuselage that extends more than 500mm in any direction intersection) F BGA additional requirements Replacement, recovering or Fabric repairs up to 3 bays (4 applicable to EASA aircraft and substantial repair of fabric or main ribs) or 1 meter in any Annex II powered aircraft as the partially fabric covered aerofoil directions. requirements do not consider or fuselage. fabric covered aircraft On powered aircraft replacement Fabric repairs in excess of 3 bays of rib stitching not exceeding 4 (4 main ribs) or 1 meter in any ribs in total. direction. Replacement of rib stitching on Replacement of rib stitching on sailplane or powered sailplane. powered aircraft exceeding 4 ribs. Recovering or repair of a flying Recovering of a flying control on control on sailplane or powered powered aircraft. sailplane. Partial recover of flying control of less than 50% area on powered aircraft. In case of doubt please contact the CTO or RTO for guidance. Notes; (1) The above tasks are identified by EASA as Complex Tasks and apply to the actions identified at the start of the lists i.e. riveting, bonding, laminating or welding. It does not include replacement by normal processes such as bolting, disassembly where complex task approval would not be required. (2) The task list above assumes that the certifier holds the appropriate BGA authorisation i.e. CR, WR, MR, SS, MG or a part 66 licence or BCAR Section L licence and where appropriate BGA Senior Inspector authorisation (3) Some tasks above will require a independent inspection where it involves an item of sensitive maintenance, control system, critical bolted joint e.g. engine mount, landing gear mount, wing attachment (if not designed for disassembly after flight) (4) If a repair is determined as not needing authorisation but subsequently develops into a task identified above, the work must be halted until authorisation is gained. (5) Authorisation to carry out the repair does not substitute the requirement for an approved repair scheme published in the maintenance or repair manual, generic repair manual if specified by the aircraft type certificate holder as approved data, or DOA approved repair scheme. 3. Authority to carry out complex tasks There are two ways to be issued with authorisation to carry out complex tasks · List 1 Approved Complex Maintenance sites Inclusion in the BGA Airworthiness Exposition under "List 1". "Approval to carry out complex tasks" AMP 2-13/Jan 2014 BGA AMP Part 2, Leaflet 2-13, page 4 This is designed for professional maintainers who carry out complex tasks routinely on a regular basis. The approval involves a formal application process and CAA audit and oversight. For details of how to apply and costs please contact the BGA. · List 2 maintenance sites (un-listed) BGA Internal application process. This is designed for all other then List 1 site inspectors who wish to carry out complex tasks but on an ad-hoc basis probably only a few occasions each year. The application process and requirements are described below. These inspectors will be under BGA Quality oversight. Inspectors in List 2 who carry out a significant number of complex tasks may be asked to apply for List 1 approval. If you are not list 1 then you are automatically included in list 2. The only exceptions are where you hold an EASA company approval to carry out complex maintenance tasks e.g. Part 145 with the aircraft type within your scope of approval or you are certifying the work on an ELA 1 aircraft using the authority of a Pat 66 license. Senior Inspectors If a task involves a substantial major repair probably involving jugging or alignment of the aircraft fuselage, wing, tail plane or powerplant, a BGA Senior Inspector is required to certify these tasks. Authority to carry out a complex task does not grant senior inspector privileges. 4. Application to carry out complex tasks Application for list 2 BGA inspectors is on application form BGA 277. 5. BGA 277 will require the aircraft details, the description of the work, name of certifying inspector and location 6. To carry out the work you will be required to provide a description of the facilities including any special environmental requirements such as heat, dust extraction, humidity control etc. that will be available for the repair/work 7. You will also be required to describe the equipment and tools that are available to carry out the work 8. .You must provide details of the approved repair data including repair scheme, manual references, “no technical objections” or repair approval from the manufacturers, drawing numbers and standard publications as appropriate. These will be reviewed as part of the approval process. Note: The BGA Complex Task approval is a facility approval and for quality oversight. An approved repair scheme from the aircraft type certificate holder or approved publication is also required 9. The application should be sent to the BGA office where it will be forwarded to the CTO who will assess the application and supporting documentation and approve. The approval process may require a visit prior to the work starting and/or during work in progress, applicants will be advised. 10. There is a fee structure for authority to carry out complex tasks and will depend on the degree of oversight required. Details will be published in the BGA Fees and Charges on the BGA web site or by contacting the BGA office. Note: this is a single approval for a specific task, subsequent tasks or repairs will require separate applications. AMP 2-13/Jan 2014 BGA AMP Part 2, Leaflet 2-13, page 5 11. All applications will require a closure review prior to releasing the aircraft back to service. Please advise the CTO at least two weeks prior to completing the work so arrangements can be made. 12. It is the responsibility to whom the approval is given to advise the BGA CTO of any changes requiring an amendment to the Complex Task approval whilst the work is underway, for example; increased scope of repair, change to the repair scheme, change of certifying personnel, change of location etc. AMP 2-13/Jan 2014 BGA AMP Part 2, Leaflet 2-13, page 6