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Caap 100-5-01 v1 Maintenance of Aircraft General Requirements

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39 views20 pages

Caap 100-5-01 v1 Maintenance of Aircraft General Requirements

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© © All Rights Reserved
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CIVIL AVIATION

ADVISORY PUBLICATION
CAAP 100.5-01 v1.2

Maintenance of aircraft -
general requirements

Date December 2022


File ref D17/380699

v1.2 – December 2022


MAINTENANCE OF AIRCRAFT - GENERAL REQUIREMENTS

This Civil Aviation Advisory Publication (CAAP) provides guidance, interpretation and explanation on complying with
the Civil Aviation Regulations 1988 (CAR) or a Civil Aviation Order (CAO).
This CAAP provides advisory information to the aviation industry in support of a particular CAR or CAO. Ordinarily, the
CAAP will provide additional ‘how to’ information not found in the source CAR, or elsewhere.
Civil Aviation Advisory Publications should always be read in conjunction with the relevant
regulations/orders.

Audience
This Civil Aviation Advisory Publication (CAAP) applies to any person who is responsible for the
management of continuing airworthiness or maintenance of aircraft where Part 42 of the Civil
Aviation Safety Regulations 1998 (CASR) does not apply and includes:

• certificate of approval (COA) holders carrying out maintenance of aircraft and aircraft
components
• Part 66 licence holders carrying out maintenance on aircraft
• registered operators and owners of aircraft.

Purpose
The purpose of this CAAP is to provide guidance for maintainers, owners and operators of aircraft
that are subject to the requirements set out in CAO 100.5.
This CAAP is intended to:

• assist readers to find the relevant maintenance information applicable to their intended
operations
• provide policy clarification where interpretational difficulties have been previously
identified by users.

For further information


For further information on this CAAP, contact CASA’s Airworthiness and Engineering Branch
(telephone 131 757).

Status
This version of the CAAP is approved by the Branch Manager, Airworthiness and Engineering.
Note: Changes made in the current version are not annotated. The document should be read in full.

Version Date Details

v1.2 December Administrative review only.


2022

v1.0 December Initial version.


2018

CAAP 100.5-01 v1.2 December 2022 Page 1


MAINTENANCE OF AIRCRAFT - GENERAL REQUIREMENTS

Contents
1 Reference material 3
1.1 Acronyms 3
1.2 References 4
1.3 Forms 4
2 Introduction 5
2.1 Background 5
3 Maintenance schedules and systems of maintenance 7
3.1 Status 7
3.2 Application clarification 7
3.3 Retention of maintenance records 7
4 Instructions for use of a maintenance release 8
4.1 Class A aircraft 8
4.2 Class B aircraft 8
5 Maintenance authorisations 10
5.1 Composite aircraft structures 10
5.2 General aviation recovery devices 10
5.3 Airframe parachutes 11
6 Maintenance requirements, data and exclusions 12
6.1 Requirements 12
6.2 Data 12
6.3 Exclusions 13

CAAP 100.5-01 v1.2 December 2022 Page 2


MAINTENANCE OF AIRCRAFT - GENERAL REQUIREMENTS

1 Reference material

1.1 Acronyms
The acronyms and abbreviations used in this CAAP are listed in the table below.

Acronym Description
AD airworthiness directive
ADF automatic direction finder

APF Australian Parachute Federation


AWB Airworthiness bulletin
AWL airworthiness limitation

CAAP Civil Aviation Advisory Publication


CAR Civil Aviation Regulations 1988
CASA Civil Aviation Safety Authority

CASR Civil Aviation Safety Regulations 1998


CAO Civil Aviation Order
CMR certification maintenance requirement

COA certificate of approval


COR certificate of registration
GARD general aviation recovery devices

GNSS global navigation satellite system


LAME licensed aircraft maintenance engineer
MR maintenance release

MSG-3 maintenance steering group -3


NAA National Aviation Authority
PPE personal protection equipment
MSDS material safety data sheet

SOM system of maintenance


STC supplementary type certificate
TC type certificate

VHF very high frequency


VOR VHF omni-directional radio range (OMNI)

CAAP 100.5-01 v1.2 December 2022 Page 3


MAINTENANCE OF AIRCRAFT - GENERAL REQUIREMENTS

1.2 References
Legislation
Legislation is available on the Federal Register of Legislation https://www.legislation.gov.au/

Document Title
Part 4A of CAR Maintenance
Part 66 of CASR Continuing airworthiness - aircraft engineer licences and ratings
Part 66 Manual of Standards
Civil Aviation Order General requirements in respect of maintenance of Australian aircraft
(CAO) 100.5

Advisory material
CASA's advisory materials are available at https://www.casa.gov.au/publications-and-resources/guidance-materials
Federal Aviation Administration (FAA) Advisory Circulars are available at https://drs.faa.gov/browse

Document Title
FAA1 AC 43.13-1B Acceptable Methods, Techniques and Practices - Aircraft Inspection and
Repair

1.3 Forms
CASA’s forms are available at http://www.casa.gov.au/forms

Form number Title


Form 918 Maintenance release (included flight and technical records)
Form 924 Aircraft maintenance certification log (order printed form)
Form 928 Recurring maintenance control (order printed form)
Form 958 Log book statement part 2 (order printed form)
Form DA 741 Superseded maintenance release form

1
United States of America Federal Aviation Administration.

CAAP 100.5-01 v1.2 December 2022 Page 4


MAINTENANCE OF AIRCRAFT - GENERAL REQUIREMENTS

2 Introduction

2.1 Background
2.1.1 Civil Aviation Order (CAO) 100.5 contains the general maintenance requirements for
aircraft where Part 42 of the Civil Aviation Safety Regulations 1998 (CASR) does not
apply. It is intended to be read in conjunction with Part 4A of Civil Aviation Regulations
1988 (CAR), and applicable aircraft manufacturers' maintenance instructions.
2.1.2 In a previous amendment2 CASA incorporated additional maintenance requirements
that were previously set out in airworthiness directives (ADs) with the aim of removing
obsolete ADs and consolidating all relevant maintenance requirements that flow out of
Part 4A of the CAR into one document.
2.1.3 The following changes have been made to CAO 100.5 in the latest (2018) amendment:
− amended the definition of 'covered by a maintenance schedule'
− amended retention requirements for maintenance records
− introduced a provision for using computerised maintenance tracking print-outs for
the purpose of listing required maintenance on a maintenance release (MR)
− provide for some flexibility in for the specified duration between required
maintenance actions
− directions for use of a CASA MR in the form of a direction given under regulation 43
of CAR have been added to Appendix 3
− added a provision for CASA to issue maintenance authorisations for maintenance
of composite aircraft structures under subregulation 42ZC(6) of CAR
− deleted redundant Table 1, which contained a list of specified composite structure
aircraft
− clarified requirements for maintainers of airframe parachute systems used in
general aviation recovery devices
− specified that life limitations issued by manufacturers of turbine engines (stated as
either maintenance manual amendments or service bulletins) are to be treated as
mandatory instructions
− clarified that an aircraft engaged in flying training must be maintained as if it were
an aerial work aircraft
− clarified that certain database updating activities, such as updating a map database
in a global navigation satellite system (GNSS) system, are not regarded as
maintenance of aircraft
− clarified that CAO 100.5 does not over-ride approved systems of maintenance
− specified that guidance material issued by CASA in the form of a CAAP or
airworthiness bulletin (AWB) may be treated as approved data (subject to
conditions)
− removed the requirement to perform regular calibration checks on fuel quantity
indication systems that are not float actuated or that have a self-test function which
verifies that the system is functioning within manufacturers stated tolerances
− removed the requirement to perform routine testing of emergency exits

2
(Civil Aviation Order 100.5 Amendment instrument 2015 (No 1))

CAAP 100.5-01 v1.2 December 2022 Page 5


MAINTENANCE OF AIRCRAFT - GENERAL REQUIREMENTS

− amended instructions for maintenance of towing release systems


− specified standards for replenishing of aircraft oxygen systems
− amended instructions for testing fire protection systems in toilet areas
− removed requirements to test automatic direction finder (ADF) and very high
frequency (VHF) omnidirectional radio range (OMNI) (VOR) systems in aircraft not
engaged in instrument flight rules flight
− removed requirements to carry out maintenance on combustion type aircraft cabin
heaters. This topic is now adequately addressed by the relevant manufacturers'
data and state of design ADs
− removed certain requirements relating to maintenance of aircraft engaged in
approved single-engine turbine aeroplane operations.

CAAP 100.5-01 v1.2 December 2022 Page 6


MAINTENANCE OF AIRCRAFT - GENERAL REQUIREMENTS

3 Maintenance schedules and systems of maintenance

3.1 Status
3.1.1 Other than those specified in clauses 16 and 17, additional maintenance requirements
set out in Appendix 1 of CAO 100.5 do not apply to an aircraft if the aircraft is covered
by a maintenance schedule (schedule) or system of maintenance (SOM) and they make
provision for the requirements contained in the Appendix.

3.2 Application clarification


3.2.1 Where a discrepancy exists between the requirements in CAO 100.5 and the
instructions in an aircraft's schedule or SOM, the schedule or SOM will prevail.
3.2.2 If the schedule or SOM is silent on a maintenance requirement that is called for in
Appendix 1 of CAO 100.5, then the requirement in the CAO will apply.

3.3 Retention of maintenance records


3.3.1 For purposes of clarity and to avoid doubt, copies of documents referred to in an
aircraft's log book, such as details of a maintenance organisation's work package, are
not required to be retained by the certificate of registration (COR) holder unless
sections of the work package are provided for the purpose of meeting the final
certification requirements set out in Part 4 of Schedule 6 of CAR.
3.3.2 If a certificate of approval (COA) holder provides a work package or sections of a work
package as part of a maintenance record, the COR holder must retain the records for
the period of 1 year after the aircraft’s operating life has ended or the aircraft has been
permanently removed from the Register of Australian Aircraft.3
3.3.3 If a COA holder carries out a modification, then subparagraph 5.2 (e) of CAO 100.5
requires that copies of the approved modification data must be given to the COR holder
and retained for the life of the aircraft's maintenance records. This requirement does not
apply if the data is on public record or otherwise publicly available. For example, if
design data is provided in an AD and fully describes the modification or repair, a copy of
that data is not required to be retained with the aircraft's maintenance records.

3.3.4 Retention of documents by a certificate of approval holder


3.3.4.1 Maintenance records created by a COA holder, such as work recording sheets and
internal certification records that are used during an inspection or repair of an aircraft,
are required under section 5A of CAO 100.5 to be retained by the COA holder for a
period of two years after the final certification has been made for the maintenance.

3
In accordance with Section 5 of CAO 100.5.

CAAP 100.5-01 v1.2 December 2022 Page 7


MAINTENANCE OF AIRCRAFT - GENERAL REQUIREMENTS

4 Instructions for use of a maintenance release

4.1 Class A aircraft


4.1.1 Section 6 of CAO 100.5 allows for the use of computer printouts that have been
generated by a computerised maintenance tracking and management system. The
print-outs may be attached to a MR. This will satisfy the requirement to record all
forecast maintenance requirements in the 'Maintenance Required' section of a MR
document. The print-out must be securely fixed to the MR and it should be marked with
the identification number of the MR to which it is attached.4
4.1.2 If an operator of a Class A aircraft has a system comprising an approved maintenance
control manual that includes a procedure for tracking and recording time-in-service and
required maintenance, then that system, whether it is a paper or electronically managed
system, is approved for the purpose of subparagraphs 6.5 (d), (e) and (f) of CAO 100.5.

4.2 Class B aircraft


4.2.1 The COR holder of a Class B aircraft may use the CASA MR, or an alternative form
approved by CASA.
4.2.2 If using the CASA MR document, the operator and all persons who are involved in
issuing the MR, making an endorsement, clearing an endorsement or making a record
on the MR must comply with the instructions for its use in Appendix 3 of CAO 100.5. A
summary of those instructions is provided inside the front cover of the CASA Form 918
maintenance release book for use as a quick reference.
4.2.3 The instructions in Appendix 3 of CAO 100.5 also apply to the superseded MR form DA
741. Maintainers may continue to use until their existing stocks of the form until they are
exhausted.

4.2.4 Additional considerations


4.2.4.1 As a result of the recent changes to CAO 100.5, the operator should consider the
following:
− For the purpose of listing maintenance that may be required during the period of
validity of the MR, a print-out generated by a computerised maintenance tracking
and management system may be fixed to Part 1 of the MR. If the print-out does not
cover the full calendar period of the MR then it must be updated in a timely manner
so that, at all times, a pilot can determine whether maintenance is due before
commencing a flight or will become due during a flight.
− If sequential print-outs are used during the life of the MR, it is not necessary to
retain the earlier versions of the printouts with the MR.

4.2.5 Supplementary pages


4.2.5.1 For the purpose of extending Parts 1, 2 and 3 of the MR, supplementary pages may be
fixed to the MR.

4
In accordance with paragraph 6.6 of CAO 100.5.

CAAP 100.5-01 v1.2 December 2022 Page 8


MAINTENANCE OF AIRCRAFT - GENERAL REQUIREMENTS

4.2.5.2 The supplementary pages may be in the form of a photocopy of a blank table or a page
that has been ruled up to match the columns of the appropriate section and includes the
relevant headings.
4.2.5.3 If supplementary pages are to be used:
− a notation is required to be made at the bottom of each extended Part and each
supplementary page of that Part stating that a supplementary page is attached
− each supplementary page is required to be identified with the unique serial number
for the MR mentioned in Part 1 of the MR
− each supplementary page is required to be securely attached to the MR.
Note: Sample supplementary pages at Annexes A, B and C to this CAAP may be copied for use with a MR.

CAAP 100.5-01 v1.2 December 2022 Page 9


MAINTENANCE OF AIRCRAFT - GENERAL REQUIREMENTS

5 Maintenance authorisations

5.1 Composite aircraft structures


5.1.1 The Part 66 Manual of Standards states that a holder of a category B1 licence may
inspect composite aircraft for the purpose of issuing a MR or complying with an AD
provided that the inspection does not require the use of specialised equipment or
training.5 The carrying-out of repairs to composite strucures is not a privilege of a B1
licence unless the licence holder is also a specially qualified person as defined in
paragraph 7A.1 of CAO 100.5.
5.1.2 Composite maintenance is defined in paragraph 7.A.1 of CAO 100.5 as maintenance of
the composite structures of a composite structure aircraft. This does not include non-
structural composite components of an airframe such as fairings, fillets and wingtips.
5.1.3 CASA has made provision for a person to be issued with a composite maintenance
authorisation under subregulation 42ZC (6) of CAR. Appendix A provides guidance for
in-house training that can be provided by a COA holder for the purpose of qualifying a
licensed aircraft maintenance engineer (LAME) for issue of a composite maintenance
authorisation by CASA.
5.1.4 A composite maintenance authorisation under subregulation 42ZC(6) of CAR may be
issued by CASA if an applicant has completed the training program set out at Appendix
A of this CAAP and provides evidence of having carried out 6 months' of supervised
composite maintenance.
5.1.5 The training provisions set out in this CAAP do not include hot bonding repairs.
Authorisations issued on the basis of training delivered under these provisions will be
limited to cold bonding repairs.
Note: CAO 104.0 provides for a COA holder who holds a delegation under subregulation 42ZC(6) to issue a
certification authorisation for the purpose of composite maintenance.

5.2 General aviation recovery devices


5.2.1 General aviation recovery devices (GARD) are made up of an airframe parachute and a
deployment system, each of which require special qualifications to be held by a person
carrying out maintenance on them.
5.2.2 CAO 100.5 specifies that maintenance of GARD equipment including the airframe
parachute may only be provided by a Part 145 organisation or a CAR 30 organisation.
5.2.3 Maintenance of parachute deployment devices and associated control systems may
only be carried out by a specially qualified LAME.6

5
May be incorporated by sub-sub-subparagraphs 66.A.20 (a) 4. (ii) (F), (G) and (H) of the Part 66 Manual
of Standards Amendment Instrument 2016 (No. 5).
6
In accordance with paragraph 8A.1 of CAO 100.5.

CAAP 100.5-01 v1.2 December 2022 Page 10


MAINTENANCE OF AIRCRAFT - GENERAL REQUIREMENTS

5.3 Airframe parachutes


5.3.1 The airframe parachute may only be inspected or packed by a person holding a valid
qualification as a parachute Packer B or Parachute Rigger issued by the Australian
Parachute Federation (APF) or an equivalent qualification approved by CASA.
5.3.2 Repairs to an airframe parachute may only be carried out by a person holding a valid
qualification as a Parachute Rigger issued by the APF or an equivalent qualification
approved by CASA.7 A qualified parachute packer or rigger is not required to hold a
Part 66 licence to perform the maintenance and may certify for the maintenance using
their qualification number.
5.3.3 If a holder of a category B1 licence wishes to obtain a Packer B or Rigger qualification,
the APF has advised CASA that on receipt of an application and payment, the APF will
make a position available for the LAME on the next available course.

7
In accordance with subparagraph 8A.3 (b) (iii) of CAO 100.5.

CAAP 100.5-01 v1.2 December 2022 Page 11


MAINTENANCE OF AIRCRAFT - GENERAL REQUIREMENTS

6 Maintenance requirements, data and exclusions

6.1 Requirements

6.1.1 Compliance with airworthiness limitations and certification maintenance


requirements
6.1.2 A COR holder for an aircraft is required to comply with maintenance requirements that
have been identified as either certification maintenance requirements (CMRs) or
airworthiness limitations (AWLs).
6.1.3 CMRs and /or AWLs are maintenance requirements that have been approved by the
state of design National Aviation Authority (NAA) as part of the design approval of an
aircraft, engine, propeller or component.

6.2 Data

6.2.1 Information published by foreign countries and CASA


6.2.1.1 The NAA of a number of foreign countries have published useful information for the
guidance of aircraft maintainers. The information is intended to supplement that which is
provided by manufacturers of aircraft and aircraft components, but is not to be used if
the information contradicts a manufacturer's instructions. For example, the Federal
Aviation Administration (FAA) AC 43.13-1B, is approved in section 9 of CAO 100.5 for
use as maintenance data for the purpose of paragraph 2A (2) (e) of CAR provided that:
− maintenance data mentioned in paragraphs 2A (2) (a) to (d) of CAR are inadequate
for the purpose
− the information described above is appropriate to the work being carried out and is
not inconsistent with any higher-level maintenance data that may be applicable.
Higher level maintenance data includes manufacturer's data or data mentioned in
paragraphs 2A (2) (a) to (d) of CAR.
6.2.1.2 The list of approved data in subsection 14 of CAO 100.5 has been expanded in the
latest amendment to include guidance material that is published by:
− CASA
− the European Aviation Safety Authority
or
− the NAA of a recognised country.8
6.2.1.3 Information published by a CASA recognised NAA in the form of ACs, bulletins,
directions, advisory publications or any other format may be used.
6.2.1.4 Approved maintenance data, within the context of regulation 2A of CAR, is data that
describes how a maintenance task is to be carried out. CAR 2A approved data is
neither an approval to carry out a modification or a repair, nor a requirement to carry out
an inspection, repair or modification. Approved maintenance data should be read in
conjunction with any applicable maintenance instruction such as in an inspection
8
Countries listed in regulation 21.010B of CASR.

CAAP 100.5-01 v1.2 December 2022 Page 12


MAINTENANCE OF AIRCRAFT - GENERAL REQUIREMENTS

schedule, or a modification approval issued under subpart 21.M of CASR, an


airworthiness directive, or an STC.

6.3 Exclusions

6.3.1 Global navigation satellite system


6.3.1.1 A global navigation satellite system (GNSS) database and its upkeep is an operational
responsibility of the COR holder.
6.3.1.2 CASA does not regard the upkeep of a GNSS maps database as a maintenance
function provided that no special tooling is required and the updating does not require
dismantling of the navigational device or removal of aircraft panels for access purposes.
6.3.1.3 GNSS databases are normally updated by insertion of a removable memory device and
in some cases are carried out automatically via wireless link. It is the responsibility of
the person carrying out the update to ensure that the COR holder or operator has
authorised the update. It is the responsibility of the COR holder or operator to ensure
that the person performing the update is familiar with the process and competent to
perform it.

6.3.2 Fuel calibration checks


6.3.2.1 The requirement in Clause 6 of Appendix 1 of CAO 100.5 has been amended to
exclude aircraft that do not rely on float type fuel gauge systems or that have built-in
self-test functions. This means that it is no longer a requirement to carry out fuel
calibration checks on the majority of turbine powered aircraft that use capacitance type
systems for sensing fuel quantity levels.
6.3.2.2 If an aircraft utilises a float type system but also has a built-in self-test system that
verifies correct functioning of the fuel quantity measurement system within the aircraft
manufacturers stated tolerances, then it is also excluded from the recalibration
requirement.

6.3.3 Combustion type aircraft cabin heaters


6.3.3.1 CAO 100.5 no longer specifies maintenance requirements for combustion type cabin
heaters. Manufacturers' maintenance instructions and state of design airworthiness
directives adequately provide for safe and effective maintenance of these components.

CAAP 100.5-01 v1.2 December 2022 Page 13


MAINTENANCE OF AIRCRAFT - GENERAL REQUIREMENTS

Training in a certificate of approval -


composite maintenance

CAAP 100.5-01 v1.2 December 2022 Page 14


MAINTENANCE OF AIRCRAFT - GENERAL REQUIREMENTS

A.1 Composite aircraft repairs

A.1.1 Course objectives


A.1.1.1 On completion of this training, a B1 Part 66 licence holder will be proficient in the
application of hand skills and knowledge and the use of maintenance publications to
inspect and repair aircraft composite structures and components to an acceptable
standard of airworthiness.

A.1.2 Reference material


A.1.2.1 The B1 Part 66 licence holder should use the following reference material:
− FAA AC 43-13: current edition
− MEA367 - Repair/modify aircraft composite structure using cold bonding
− applicable aircraft maintenance data
− specific material instructions where applicable.

A.1.3 Theoretical knowledge


A.1.3.1 Theory training will be given either informally as an exchange between the person
providing the training or in a classroom environment at the discretion of the training
provider.
A.1.3.2 A trainee will be trained to understand the types of composite materials that are used in
aircraft construction, their properties, strengths and limitations and attain the knowledge
levels listed in section A.3.
A.1.3.3 A trainee will be required to demonstrate knowledge of the following topics to the
knowledge level shown in column 2 of Table 1.

A.1.4 Training provider


A.1.5 Training should be provided by a person who holds a recognised qualification in aircraft
composite maintenance.
A.1.6 The trainer qualifications could be a relevant trade training background, military
qualifications or civil qualifications recognised by CASA or the national aviation authority
of a country mentioned in regulation 21.010B of CASR.

CAAP 100.5-01 v1.2 December 2022 Page 15


MAINTENANCE OF AIRCRAFT - GENERAL REQUIREMENTS

Table 1: Knowledge elements

Topic Level Achieved

Y/N Date and signature

How to obtain relevant material safety data sheet (MSDS) 2

The use of applicable items of personal protection equipment 2


(PPE)

Work health and safety (WHS) procedures 2

Aircraft construction principles 2

Differences between epoxy and polyester resin systems 1

Defining composite terminology 2

Composite component construction methods, including 3


structural assembly fastener identification.

Storage requirements for prepreg materials 2

With regard to various resins and hardeners, their: 2


• limitations
• storage requirements
• mixing precautions
• spreading requirements
• assembly times
• clamping/vacuum bagging/heat curing requirements
• environmental protection requirements
• compatibilities.

CAAP 100.5-01 v1.2 December 2022 Page 16


MAINTENANCE OF AIRCRAFT - GENERAL REQUIREMENTS

A.1.7 In order to be eligible for a composite aircraft maintenance authorisation, a LAME must
satisfactorily complete each of practical tasks in Table 2 at least once.

Table 2: Practical task training

Task Competent

Y/N Date and Signature

Using aircraft components or panels that simulate aircraft components:

perform a cold layup using one of the following materials:


• Carbon graphite
• Kevlar
• Fibreglass
• Aluminium.

perform a repair to a honeycomb core panel using aluminium, Nomex or


foam

perform composite component repairs using:


• external patch repair
• scarf repair
• stepped repair
• wet layup repair.

perform composite fastener hole repair

perform metal to metal and metal to composite bonding

CAAP 100.5-01 v1.2 December 2022 Page 17


MAINTENANCE OF AIRCRAFT - GENERAL REQUIREMENTS

A.2 Assessment of performance standard


A.2.1 A trainee’s performance of each of the maintenance tasks in Table 2 will be assessed
against the criteria specified in Table 3.

Table 3: Performance standard assessment criteria

Assessment topic Satisfactory

Y/N Date/Signature

General

Trainee:
• applies relevant WHS procedures, including the use of MSDS and PPE
uses approved maintenance documentation and aircraft publications
relating to aircraft structure
• identifies composite component applications in aircraft structures
• identifies various aircraft composite materials/resins and their basic
properties by interpretation of markings and visual means
• handles and stores composite materials to industry standards
• assesses composite component damage using visual and tap test
methods
• correctly interprets and/or produces repair scheme/modification
drawings/sketches
• uses appropriate hand tools and machines to disassemble and assemble
aircraft composite components, parts, sections and skin, including
extraction/installation equipment, drilling/cutting equipment and material
fasteners.

Planning and preparing for the repair or modification

While performing practical tasks listed in Table 2, the trainee will be assessed
against the following elements:
• Extent of damage is correctly assessed to assist in determining repair
procedure
• Structure is supported and prepared in accordance with the applicable
maintenance manual to ensure personnel safety and freedom from
damage
• Appropriate modification or repair scheme is identified in accordance with
structural repair manual and/or approved data
• Specialist advice is obtained in establishing an approved repair scheme
where a standard repair scheme cannot be identified or damage criteria is
out of limits
• All materials and equipment required are organised.

Preparation of components for cold bonding

• Components are prepared in accordance with applicable process


specification (provided by the manufacturer)
• Bagging (if applicable) is checked to ensure vacuum seal is correct
• Equipment is checked for serviceability to ensure safety in application.

Performing cold bonding repair or modification

• Lay-up of materials is checked to confirm that components meet required


specifications and bagging equipment is correctly installed and operated
• Curing cycle and recording of operating cycle data are monitored as
required by approved procedures to ensure specifications are met

CAAP 100.5-01 v1.2 December 2022 Page 18


MAINTENANCE OF AIRCRAFT - GENERAL REQUIREMENTS

Assessment topic Satisfactory

• Blemishes are sealed, potted or filled, where necessary, in accordance


with applicable process specification
• Component assemblies, including test pieces, requiring further or special
treatment are made ready for the appropriate processes
• Required maintenance documentation is accurately completed and
correctly processed
• Completed assemblies are tagged, sealed or packaged, as required.

A.2.2 At the successful completion of the training and assessment in all tasks, the employee
will be issued with a document stating they have satisfactorily completed the course of
training to the required standard. Under subregulation 42ZC (6) the employee may
submit the document to CASA in support of an application for a maintenance
authorisation.

A.3 Explanation of knowledge levels

A.3.1 Level 1
A.3.1.1 A familiarity with the principal elements of the topic such that the following trainee
objectives are met:
− familiar with the basic elements of the topic
− able to give a simple description of the topic, using common words and examples
− able to use typical terms.

A.3.2 Level 2
A.3.2.1 A general knowledge of the theoretical and practical aspects of the topic and an ability
to apply that knowledge, such that the following trainee objectives are met:
− understand the theoretical fundamentals of the topic
− give a general description of the topic using typical examples, as appropriate
− demonstrate awareness of practical applications of the topic.

A.3.3 Level 3
A.3.3.1 A detailed knowledge of the theoretical and practical aspects of the topic, and a
capacity to combine and apply the separate elements of knowledge in a logical and
comprehensive manner, such that the following trainee objectives are met:
− Describe the underlying intent and implications of the topic
− Give a detailed description of the topic using theoretical fundamentals and specific
examples
− Explain in detail the theoretical and practical application of the topic
− The employee is required to demonstrate a comprehensive understanding of the
maintenance manuals and other data related to the training which is being given.

CAAP 100.5-01 v1.2 December 2022 Page 19

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