The Gill Corporation

Instruction and Repair Manual

TGC IRM 9701 – Revision L

Released July 7, 2021

Instructions for the Fabrication, Repair and Installation of

The Gill Corporation Replacement Floor Panels in Airbus Aircraft
 The Gill Corporation IRM 9701 – Revision L

1 Table of Contents
1 Table of Contents ........................................................................................................................... 2
1.1 Revision History....................................................................................................................... 5
2 Introduction ..................................................................................................................................... 6
3 Applicable Specifications and Documents ...................................................................................... 7
3.1 Airbus Specifications ............................................................................................................... 7
3.2 Reference Specifications ......................................................................................................... 7
3.3 Airbus Structural Repair Manual Application by Aircraft ........................................................... 7
3.4 Application of The Gill Corporation Replacement Floor Panels in Airbus Aircraft ..................... 8
4 Geometrical Requirements ............................................................................................................. 9
5 Panel Identification – Marking ......................................................................................................... 9
6 Insert Installation Approval ............................................................................................................ 10
6.1 Test Specimen Configuration – Insert Shear.......................................................................... 10
7 Floor Panel Fabricator Responsibility............................................................................................ 11
7.1 Typical Insert Shear Strengths ............................................................................................... 11
7.2 Non-Slip Coating ................................................................................................................... 11
7.3 Re-Use of Serviceable Parts.................................................................................................. 11
8 Parts and Materials ....................................................................................................................... 11
8.1 Inserts.................................................................................................................................... 12
8.1.1 Cargo Compartments: 2-Piece Torlon: TF073 and TF074 .............................................. 12
8.1.2 Passenger Compartment A320 Family Only: 2-Piece Torlon: TF152 .............................. 12
8.1.3 Cargo Compartments: 1-Piece Aluminum: TF20, TF21, TF110 and TF111 .................... 13
8.1.4 Cargo and Passenger Compartments: 2-Piece Aluminum: T303 and T307 .................... 14
8.2 Special Design Criteria: Hardpoint Attachments: T304, T306, T305 and T308....................... 15
8.3 Threaded Inserts ................................................................................................................... 16
8.4 Adhesives .............................................................................................................................. 17
8.4.1 Loctite®Hysol® EA9309.3NA ......................................................................................... 17
8.4.2 Epibond 420 A/B............................................................................................................. 17
8.5 Edge Filling Compounds ........................................................................................................ 18
8.5.1 Alexit® FST 495-14 ........................................................................................................ 18
8.5.2 Scotch-Weld EC3524 B/A ............................................................................................... 18
8.5.3 Scotch-Weld 3550 B/A FST ............................................................................................ 18
9 Machining The Gill Corporation Composite Products .................................................................... 19
9.1 Drilling ................................................................................................................................... 19

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9.1.1 Tooling Recommendations for Drilling ............................................................................ 19

9.1.2 Drilling Template with Bushings ...................................................................................... 20
9.2 Cutting and Routing ............................................................................................................... 21
9.2.1 Tooling Recommendations for Cutting and Routing ........................................................ 21
9.3 Deburring............................................................................................................................... 21
10 Edge Filling Procedure .............................................................................................................. 22
10.1 Instructions for Edge Filling.................................................................................................... 22
10.2 Cross-Section of Edge Filled Sandwich Panel ....................................................................... 22
10.3 Illustrations of Edge Filling Procedure .................................................................................... 23
11 Insert Installation ....................................................................................................................... 24
11.1 Instructions for Panel Preparation .......................................................................................... 24
11.2 Illustrations of Panel Preparation ........................................................................................... 25
11.3 Insert Installation Details ........................................................................................................ 26
11.3.1 2-Piece Torlon® Inserts for Cargo Floors: TF073 and TF074 ......................................... 26
11.3.1.1 Instructions for Adhesive Injection ........................................................................... 27
11.3.1.2 Illustrations of Insert Installation ............................................................................... 28
11.3.1.3 Illustration of Adhesive Injection .............................................................................. 30
11.3.1.4 Instructions for Spatula Method ............................................................................... 31
11.3.1.5 Illustration of Spatula Method for Potting Adhesive .................................................. 32
11.3.1.6 Cross-Section of Installed Insert .............................................................................. 32
11.3.2 2-Piece Torlon® Inserts for A320 Passenger Floors: TF152 ........................................... 33
11.3.2.1 Illustration of Installed Insert .................................................................................... 33
11.3.3 1-Piece Aluminum Inserts for Cargo Floors: TF20, TF21, TF110 and TF111 .................. 33
11.3.3.1 Instructions for Adhesive Injection ........................................................................... 34
11.3.3.2 Illustration of Insert Installation ................................................................................ 35
11.3.3.3 Instructions for Spatula Method ............................................................................... 37
11.3.4 2-Piece Aluminum Inserts for Passenger and Cargo Floors: T303 and T307 .................. 38
11.3.4.1 Illustration of Insert as Installed – Upper Facing ...................................................... 38
11.3.4.2 Cross-Section of Insert as Installed ......................................................................... 38
11.4 Hardpoint Insert Installation ................................................................................................... 39
11.4.1 Drawing of Installed Hardpoint ........................................................................................ 39
11.5 Threaded Insert Installation ................................................................................................... 39
11.5.1 Illustration of Step-Down Installation ............................................................................... 40
11.5.2 NAS 1833 and 1834 ....................................................................................................... 40
11.5.2.1 Illustrations of Tabbed Inserts .................................................................................. 40

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11.5.3 NAS 1835 ....................................................................................................................... 41

11.5.4 NAS 1836 ....................................................................................................................... 41
11.5.5 DAN401-3....................................................................................................................... 41
11.5.5.1 Illustration of Adhesive Ingression Prevention ......................................................... 42
11.5.6 ABS1006 ........................................................................................................................ 43
11.6 No-Insert Installations ............................................................................................................ 43
11.6.1 Example, A330 Cargo Floor 12mm hole ......................................................................... 43
11.7 Non-Standard Insert Installation Locations ............................................................................ 44
11.7.1 Example, A320 Family Main Deck .................................................................................. 44
11.8 Forming Tool for 1-piece Aluminum Inserts TF110 and TF111 .............................................. 45
11.9 Forming Tool for 1-Piece Aluminum Inserts TF20 and TF21 .................................................. 46
11.10 Insert Schematics............................................................................................................... 46
11.10.1 2-Piece Torlon® Inserts TF073, TF074 ....................................................................... 47
11.10.2 2-Piece Torlon® Insert TF152 ..................................................................................... 48
11.10.3 1-Piece Alumium Inserts TF110 and TF111 ................................................................ 50
11.10.4 1-Piece Aluminum Insert TF20 .................................................................................... 51
11.10.5 1-Piece Aluminum Insert TF21 .................................................................................... 52
11.10.6 2 Piece Aluminum Inserts T303 and T307................................................................... 53
11.10.7 Hardpoint Insert T304 ................................................................................................. 55
11.10.8 Hardpoint Insert T306 ................................................................................................. 56
11.10.9 Hardpoint Insert T305 ................................................................................................. 57
11.10.10 Hardpoint Insert T308 ................................................................................................. 58
12 Repair of Replacement Floor Panels ......................................................................................... 59
12.1 Determination of Repairable Damage .................................................................................... 59
12.2 Recommended Repair Materials............................................................................................ 59
12.3 Repair Procedure .................................................................................................................. 60
12.4 Cross-Section Diagram of Repaired Floor Panel ................................................................... 61
12.5 Reference Airbus Repair Documentation ............................................................................... 62

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1.1 Revision History

Revision Date Notes

E 2003-03-10 Revision history capture in 2020 started with this version as

baseline. Sections shown are as existing in revision J.

F 2003-06-20 Add A318 referencing (section 2). Add insert types TF111 and
TF110 (sections 8.1.3). Add insert manufacturer information for AEP
and Shur-Lok (sections 8.1.3 and 8.1.4).

G 2008-05-27 Add BCC3 (4523) panel (section 3.4). Add information on non-slip
floor coatings (section 7.2) and repair of panels (section 12).
Remove datasheets for adhesives and edge fills from appendix
[available on TGC website].

H 2017-12-14 Add T307 smaller diameter insert version of T303 for A320 family
(section 8.1.4). Add new edge fill types and removal of one
discontinued edge fill (sections 8.5.2 and 8.5.3). Add hardpoint T308
(section 11.10.10). Add A380 related usage (section 2). Update
information for adhesive and edge fill vendors (sections 8.4 and 8.5).
Insert drawings update (section 11.10). Capture name change from
M.C. Gill to The Gill Corporation throughout.

I 2018-09-24 Addition of TF152 Torlon inserts for passenger floors of A320 family
aircraft (section 8.1.2). Addition of multiple threaded inserts in
passenger floors (section 8.3).

J 2020-08-31 Add threaded inserts for cargo panels and ABS1006 insert (section
8.3). Add no-insert and non-standard insert examples (sections 11.6
and 11.7). Add Revision History (section 1.1). Add re-use of
serviceable parts (section 7.3). Overall formatting to improve
reading the document.

K 2021-02-16 Corrected federal supplier code from 22459 to 22457 (section 5).
Updated insert reference drawing for TF073/TF074 (section
11.10.1)

L 2021-07-07 Updated Section 3.4

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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. Fabrication methods were designed for use in typical airline maintenance and repair
facilities. To comply with 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 deliver 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 geometric 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 section 3.4 The panel configurations can be determined using the existing
part as a template. This includes configurations such as the final shape, size, openings, and mounting
holes of the existing part. When the original panel includes built in plugs for attachment points, potted
holes or inserts can often be used instead. Some examples are provided in sections 11.6 and 11.7.
Because of the structural function of the floor panels, only relatively minor damage is allowed to
be repaired. Extreme care must be exercised in determining whether damage is repairable or requires
floor panel replacement. The Airbus Industrie SRM is the governing procedure, and the applicable SRM
per section 3.3 must be consulted for repair and replacement limits and procedures.
Attention: In order to maintain the original integrity and fire resistant properties in a repaired panel, only the methods and
materials described in Section 12 may be used to complete a repair.
Note: Cross-sections in this document are for illustration purposes and are not to scale.
Safety Precautions
Before using any of the chemical materials specified or recommended in this manual, the
manufacturer’s material safety data sheet for each product must be obtained and its safety practices
observed. Safety Data sheets for the products used in this document can be found on The Gill
Corporation website. In all cases, direct exposure by skin contact, inhalation, or ingestion must be
avoided, at the very least requiring the use of eye protection and protective clothing. Good ventilation
and lighting are essential. In areas where flammable solvents are in use, sources of ignition should be
eliminated. Local safety requirements should be followed.

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3 Applicable Specifications and Documents

3.1 Airbus Specifications
• AITS 5360 M1M 000500: Floor Panels – Cargo Compartments and Freighter Aircraft (convertible and full freighter).
Made out of Large-Sized Plate Material.
• AITS 5360 M1M 000600: Carbon Floor Panels Made of Large-Sized Plate Material for Passenger and Flight
Compartment Floor
• DBAA TL 53/5000/79: Glass Fibre Floor Panels for Passenger and Containerized Cargo Compartments Made out
of Large-Sized Plate Material (Semi-Finished Product)
3.2 Reference Specifications
• FAR/JAR §25.853, §25.855, and §25.856(a): Passenger and Cargo or Baggage Compartments.
• FAR/JAR §25.857 and §25.856(a)(b): Cargo Compartment Classifications.
• FAR Part 25, Appendix F, Part III: Test Criteria and Procedures for Showing Compliance to §25.853 and §25.855.
• Airbus Industrie ABD 0031: Airbus Directive – Fireworthiness Requirements Pressurized Section of Fuselage
3.3 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/A380 53•02•00

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3.4 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 TL 53/5000/79 A300/A310
Types 1 and 2*

A300/A310/A300-600
Gillfab 4123 MDC2 5360 M1M 000500
Main Deck Cargo

A300/A310/A300-600
BCC2 A318/A319/A320/A321
Gillfab 4223 5360 M1M 000500
BCCS6 A330/A340
Bulk Cargo Compartments

A300/A310/A300-600
BCC3 A318/A319/A320/A321
Gillfab 4523 BCCS8 5360 M1M 000500
A330/A340
BCCS8A Bulk Cargo Compartments

CCC1 A300/A310/A300-600
CCC2 A318/A319/A320/A321
Gillfab 4522 5360 M1M 000500
CCCS3 A330/A340
CCCS3A Container Cargo Compartments

PC3 A318/A319/A320/A321
PCE2/3 A330/A340/A380
Gillfab 4505 5360 M1M 000600
PCE4 Passenger Compartment,
PCE4A Main Aisle and Galley

A318/A319/A320/A321
PC1 A330/A340/A380
Gillfab 4605 5360 M1M 000600
PCE1 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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4 Geometrical Requirements
The Gill Corporation replacement materials are available in sizes up to 1829 x 3658 mm (72 x
144 inches). Floor panels may be fabricated without consideration of the honeycomb core or facing
orientation (ribbon versus transverse direction does not matter). This can help to optimize the usage of
the panel when cutting out parts. However, face side versus back should be considered.
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 replacement panel must be easy to
install without causing damage to the panel or other structure.

5 Panel Identification – Marking

All panels supplied by The Gill Corporation will contain the following markings, resistant to liquids
and detergents normally used in aircraft.
• The Gill Corporation name
• Federal supplier code for the manufacturer: 22457
• The Gill Corporation product designation
• Date of manufacture
• Batch number
• Identification of the upper side
Replacement part markings must also include information added by the part fabricator:
• Original AI part number and part number of the manufacturer
• Fabrication date of the finished floor panel

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6 Insert Installation Approval

This manual describes the procedures for machining, drilling, and insert installation to prepare a
panel for installation in the aircraft. The installation of inserts is very important for providing the mounting
strength necessary to maintain the integrity of the airframe. First-time installers of inserts must
demonstrate their ability by submitting prepared insert panel test specimens to The Gill Corporation for
strength testing. If the test specimens meet the strength requirements then The Gill Corporation will
provide the fabricator with a Certificate of Compliance.
The Gill Corporation can supply kits with test coupons and inserts for assembly into test
specimens. For more information on the proper installation of inserts, please see sections 9 and 11.
Supplementary instructional videos are also available on The Gill Corporation website.
6.1 Test Specimen Configuration – Insert Shear
AEP Molded Torlon Inserts, TF073, TF074 and TF152: 15 mm (19/32 or 0.590 in)
TYE Aluminum Inserts, TF20, TF21, T303 and T307: 11.1 mm (7/16 or 0.4375 in)
Shur-Lok Aluminum Inserts, TF110 and TF111: 12.7mm (1/2 or 0.500 in)

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7 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. Panels must not be pieced together where a
single panel section is required. As noted in section 6, the panel fabricator must demonstrate the ability
to install inserts properly by sending at least 6 test specimens to The Gill Corporation that meet the target
values below, prior to preparing parts.
7.1 Typical Insert Shear Strengths
The following target values should be demonstrated by test:
• For panels Gillfab 4405 (Types 1 and 2), 4223, 4523, and 4522: 7560 N (1700 lbf)
• For panels Gillfab 4123, 4505, and 4605: 8007 N (1800 lbf)
All materials, machining, panel fabrication procedures, and test coupon preparation are described in the
following sections.
7.2 Non-Slip Coating
Whenever applicable, the operator is responsible for the application of a non-slip coating using
Airbus approved material so that the installed panel meets the requirements of FAR §25.793.
Note: See the Airbus Consumable Material List for suitable non-slip coating materials.
7.3 Re-Use of Serviceable Parts
Hardware or other parts attached to a floor panel being replaced can be re-used on The Gill
Corporation panels. Re-used parts must remain in good condition, per the fabricator’s discretion and in
alignment with the Airbus SRM. Examples of serviceable parts can include:

• Insulation foams

• Connection Sheets

• Provisions (for entertainment systems or etc.)

• Other parts that remain in serviceable condition

8 Parts and Materials

The following sections describe the parts and materials approved for the use in 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 such as an NTO (No Technical Objection) is
obtained from Airbus Industrie. Equivalent performance of any alternatives must be demonstrated to the
satisfaction of Airbus.

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8.1 Inserts
8.1.1 Cargo Compartments: 2-Piece Torlon: TF073 and TF074

The Gill Corporation Airbus Industrie The Gill Corporation

Insert Type
Replacement Panel Panel Type Insert Part Number

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
8.1.2 Passenger Compartment A320 Family Only: 2-Piece Torlon: TF152

The Gill Corporation Airbus Industrie The Gill Corporation

Insert Type
Replacement Panel Panel Type Insert Part Number

TF152A Plug
Gillfab 4505 PC3
2-piece TF152B Sleeve
Gillfab 4605 PC1
T152 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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8.1.3 Cargo Compartments: 1-Piece Aluminum: TF20, TF21, TF110 and TF111

The Gill Corporation Airbus Industrie The Gill Corporation

Insert Type
Replacement Panel Panel Type Insert Part Number

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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8.1.4 Cargo and Passenger Compartments: 2-Piece Aluminum: T303 and T307

The Gill Corporation Airbus Industrie The Gill Corporation

Insert Type
Replacement Panel Panel Type Insert Part Number

All Aircraft:
T303A Plug
T303B Sleeve
Gillfab 4405, Types 1 and 2 PC3, TY 1 and 2
T303 Assembly
Gillfab 4522 CCC1
2-piece
Gillfab 4505 PC3
A320 Family:
Gillfab 4605 PC1
T307A Plug
T307B Sleeve
T307 Assembly

T303 and T307 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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8.2 Special Design Criteria: Hardpoint Attachments: T304, T306, T305 and T308
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 which depend on the unit to be attached and must correspond to the parts
being replaced. The insert types are 2-piece constructions of aluminum and are described below.

Manufacturer’s Part Number

Airbus Industrie The Gill Corporation
Hardpoint Insert Type Insert Part Number
Plug Sleeve Assembly

1 TYEP5330A1 TYES5330A1-380 TYE5330A1-380 T304

2 TYEP5331A2 TYES5331A2-380 TYE5331A2-380 T306

3 TYEP5332A2 TYES5332A2-380 TYE5332A2-380 T305

4 TYEP5330A2 TYES5330A1-380 TYE5330A2-380 T308

Hardpoint 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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8.3 Threaded Inserts

All Gill Corporation Panels shown here have been approved with these threaded inserts. The
inserts should be installed according to their instructions in section 11.5. Choose the appropriate threaded
insert according to the applicable Airbus drawing or removed part in order to correctly integrate with the
surrounding structure. Base numbers of the inserts are listed below. The exact depths used should be
chosen to match the application. Hardware manufactures for these threaded inserts are not listed, as
Airbus approved materials should be used per the appropriate Standard Manual.

The Gill Corporation Airbus Industrie Threaded

Replacement Panel Panel Type Insert Part Number

Gillfab 4405, Types 1 and 2 PC3, TY 1 and 2

NAS 1833-3
Gillfab 4123 MDC2
NAS 1834 C3K
Gillfab 4223 BCC2
NAS1835
Gillfab 4523 BCC3
NAS 1836-3
Gillfab 4522 CCC1
DAN401-3
Gillfab 4505 PC3
ABS1006
Gillfab 4605 PC1

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8.4 Adhesives
The following two-part epoxy adhesives are for potting inserts into floor panels. The potting
procedure is necessary to ensure that the required 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.
The adhesive potting materials describe below are available from the manufacturers or
distributors in a variety of packages, ranging from bulk containers to pre-measured cartridges. The use
of adhesives for installation is detailed in section 11. The procedure used will depend on the availability
and practice of the replacement panel fabricator.
8.4.1 Loctite®Hysol® EA9309.3NA
Loctite®Hysol® Manufacturer:
Henkel Loctite Corporation
One Henkel Way
Rocky Hill, Connecticut 06067
Phone: (800) 562-8483
Website: www.loctiteproducts.com
8.4.2 Epibond 420 A/B
Epibond Manufacturer:
Huntsman Advanced Materials
5121 San Fernando Road West
Los Angeles, California 90039-1011
Phone: (818) 247-6210
Customer Service: (888) 564-9318
Website: www.huntsman.com

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8.5 Edge Filling Compounds

The edge filling compounds are two-part epoxy systems used around the edges of panels. The
edge filling provides protection and support of the panel edges, and also prevents moisture from entering
into the honeycomb core. Detailed instructions for application of edge fill is described in section 10.
8.5.1 Alexit® FST 495-14
Alexit Manufacturer:

German Office:
Mankiewicz Gebr. and Co (Gmbh Co.)
George-Wilhelm Strasse 189
D-21107 Hamburg (Willhelmsburg)
Germany
Phone: +49 (40) 75 10 30
Website: www.mankiewicz.com
US Office:
Mankiewicz Coatings L.L.C.
1200 Charleston Regional Parkway
Charleston, South Carolina 29492
Phone: (843) 654-7755
Website: www.mankiewicz.com/english
8.5.2 Scotch-Weld EC3524 B/A
Scotch-Weld Manufacturer:

US Office:
3M Corporate Headquarters
3M Center
St. Paul, Minnesota 55144-1000
Phone: (888) 364-3577
Website: www.3m.com
8.5.3 Scotch-Weld 3550 B/A FST
Scotch-Weld Manufacturer:

US Office:
3M Corporate Headquarters
3M Center
St. Paul, Minnesota 55144-1000
Phone: (888) 364-3577
Website: www.3m.com

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9 Machining The Gill Corporation Composite Products

This section contains recommendations for cutting, drilling, and routing of flooring sandwich
panels. The information can be useful for the fabrication of the semi-finished material into exact
replacement articles. Fabricators can select different tools and techniques as long as the resulting quality
remains high. Techniques ranging from hand work to CNC machining can all be successfully used with
appropriate care.
The sandwich panels are composed of fiberglass or carbon fiber reinforced/phenolic resin facings
bonded to Nomex/phenolic resin honeycomb core. Care must be taken in the fabrication of replacement
panels to avoid disbonding, delamination, tearing, burning, fuzzing of the fiber, or crushing of the core.
9.1 Drilling
9.1.1 Tooling Recommendations for Drilling

Drill Type Information

- Lowest initial cost, readily available.
- Short drill life, especially in fiberglass.
High Speed
- About 500 holes in fiberglass between sharpening.
Steel
- Improved with a hard flash of chrome plating (0.003" - 0.005") is put on the drill bit.
- Flash chrome is recommended for large drills where carbide is too expensive.
- Higher initial cost but longer life. May be re-sharpened.
Tungsten - Up to 3/16" diameter, grind drill to have a slight negative rake on the cutting tip.
Carbide - Over 3/16" diameter, use slow helix dill, ground to 55° point (sharp).
- Recommended for high production requirements only.
- 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.
Diamond-Grit
- 10,000 surface feet per minute is customarily available on 10,000-20,000 rpm router.
Edged Drills
- Will drill a hole 3 times as fast as a carbide drill.
- Dust collection system mandatory.
- Cannot be used with drill bushings or slip-renewables.
- Solid carbide, fairly expensive.
- Must be returned to manufacturer for sharpening.
Fiberglass
- Produces clean fuzz-free holes in most fiberglass without delamination, especially in thin
Drill/Router
(less than 0.060") fiberglass.
- Cuts quickly without tearing, delaminating, or fuzzing the fibers around the hole.

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9.1.2 Drilling Template with Bushings

For work requiring center to center hole tolerance of ± 0.03 inches (0.8 mm) or less, the use of a
drill template with hardened steel 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, but the tooling cost is reduced.
For holes requiring close tolerance diameters ± 0.005 inches (0.13 mm) 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 a bushing may 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 90° angle to the work piece. Using a drill press or a portable drill guide will simplify
drilling holes at 90° to the material surface. Whenever possible, many facilities drill holes slightly larger
than they are actually needed in order to eliminate the need for tooling and drill bushing.
It can also be useful to place an extra layer of undrilled cardboard, chip board, or excess laminate
beneath the bottom layer being drilled. This helps prevent fuzzing on the last layer.

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9.2 Cutting and Routing

9.2.1 Tooling Recommendations for Cutting and Routing

Method Information
- Not recommended, slow cut, difficult to control, but can be used for rough cut on loose tolerances.
Band - Will dull rapidly, but gives a fair cut even when dull and is inexpensive to replace.
Saws - Fence should be used to control the cut as much as possible
- Most The Gill Corporation products may be cut with a standard 8-10 tooth/inch band saw.

- Typically, 12” to 16” diameter carbide tipped or diamond saw blades are used.
- Diamond blades are coated 40 grit.
Circular - Extra care must be taken to ensure that the laminates do not delaminate or singe.
Saw
- For worker comfort and general good housekeeping, a good vacuum system for dust collection is a must.
- Recommended blade speeds are shown in the table below

- Laminates can be cut with a mechanical shear, available in many maintenance shops.

Shearing - For the thickest laminates, a heavy-duty, sharp blade shear is required to prevent delamination or tearing
(Laminates - The thinner laminates (0.025” and below) can be cut by means of heavy-duty handheld scissors.
Only) - Extra care must be taken to tearing, delamination, or fuzzing of the fibers.
- Reduces the amount of dust generated.

Recommended Router Bits are as followed:

Fiberglass Router – Best, inexpensive, can be sharpened. Best with rigid laminates.
Routing Diamond Grit – Will cut and clog; longest life; can be cleaned.
Carbide Tip – Dulls rapidly, not recommended.
Burr Mill – Best when performing CNC routing

Circular Saw Recommended Blade Speeds

Blade Diameter Revolutions per Minute Surface Feet per Minute
8 4500 9400
10 4000 10500
12 3600 11300
16 3450 14500

9.3 Deburring
All machined and cut edges of the panel must be deburred to remove fibers exposed during
machining operations to ensure a clean, debris-free surface for subsequent bonding or edge filling
procedures.

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10 Edge Filling Procedure

Replacement flooring panels must be edge-filled. Edge fill protects and supports the panel edges
and prevents moisture incursion into the honeycomb core. Only edge fills listed in section 8.5 are
approved for use with The Gill Corporation panel applications described in this manual. The Gill
Corporation must issue permission for alternate material use.
10.1 Instructions for Edge Filling

Step Reference Instruction

1 9.2 & 10.3 step Remove a minimum of 0.24 inches (6 mm) of honeycomb core from the panel edge. A depth
1 controlling tool can be attached to the router to maintain 0.24 inches. Do not cut into or thin
the panel skins.
2 - Remove dust and debris to ensure optimal bonding.

Note: Follow edge fill manufacturer instructions for mixing two-part materials. Look for uniform color free of
streaks or blotches. Do not mix more than can be used within the limited working life of the material.
3 10.3 step 3 Spread edge fill putty into the panel edge with a spatula or putty knife. Fill the honeycomb as
completely as possible. Panel edges and any cut-out exposed edges must be filled.
4 - Remove excess edge fill with the spatula, smoothing material flush with the panel edges.
5 - The edge fill will cure at room temperature in 24 to 48 hours. If a shorter cure time is needed,
follow manufacturer’s instructions for accelerated cure. 12 hours at room temperature should
allow inspection and sanding.
6 10.3 step 4 Verify that all edges are filled, and the quality of work. If needed, edges can be lightly sanded
to smooth.

10.2 Cross-Section of Edge Filled Sandwich Panel

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10.3 Illustrations of Edge Filling Procedure

Step 1: Rout panel edges to a depth of 6 mm. A Step 2: Thoroughly mix two-part edge fill material
high speed rotary tool is shown. Be careful not according to the manufacturer’s instructions. The
to remove any facing material – only the core. resulting mix should be uniform in color, and have
the consistency of putty.

Step 3: Apply edge fill and around all edges of Step 4: Edge filling should be smooth and flush
the panel. Smooth with a trowel or spatula with the edges of the panel.
before it hardens. Mix only enough for 30 – 40
minutes.

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11 Insert Installation
Inserts offer a reinforced attachment of floor panels to the aircraft structure, for stress transfer to
the airframe. Strength to resist pullout and shear failure is created by bonding the insert flange to the
panel facing and potting the insert into the panel with adhesive. Potting is especially important for pullout
strength. Potting also offers a barrier to fluid penetration. Follow insert procedures carefully and use
only the materials specified. The Gill Corporation must issue permission for alternate material use.
Keep all bonding areas clean and free of contamination, including oil, grease, water, dust,
fingerprints, etc. Commonly available solvents such as acetone or isopropyl alcohol may be used for
cleaning, as long as all surfaces are allowed to dry prior to bonding.
Photos illustrating processes of installing inserts show test specimen coupons. The same
techniques are used for full-sized parts. Cut panels to their finished size and apply edge fill before
installing inserts.
Caution: Commonly used solvents are flammable and potentially harmful if inhaled. Follow manufacturer’s
recommendations from Safety Data Sheets when handling any materials.
11.1 Instructions for Panel Preparation
The following steps describe the preparation of the panel for all insert types. Take care not to
damage the panel facings or inserts during handling and machining. Refer to section 9 for machining
recommendations.

Step Reference Instruction

1 11.2 step 1 Mark the locations of all holes to be drilled.
2 11.2 step 2 Drill holes. Take care not to cause excessive fuzzing or fiber damage. Keep the drill bit as
perpendicular as possible to the panel surface. Ensure holes drilled are free of debris and
loose material prior to bonding. Thin-nose pliers may be used to remove loose particles. A
stream of clean, dry compressed air can be used to remove dust.
3 11.2 step 3 Remove 3 to 5 mm (1/8 to 3/16 inches) of the honeycomb core between the facings. For hand
and 4 work, use a high speed rotary tool (Dremel® or equivalent). See photo for a hole with enough
honeycomb core removed.
4 - Ensure that debris and dust is removed from the hole.
5 11.2 step 5 Lightly sand the lower facing of the panel where the insert flange will be bonded with
sandpaper or emery cloth. Wipe away any dust with a clean, dry cloth to remove debris. For
non-symmetric panels, the lower facing is thinner.
6 11.2 step 6 Clean insert parts by immersion or wiping with acetone (or equivalent solvent).
7 - Allow inserts to dry.

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11.2 Illustrations of Panel Preparation

Step 1: Mark locations for drilling 38mm (1.5 Step 2: Drill holes of the needed size in desired
inch) from each end of the test specimen. For locations. Ensure holes are perpendicular to the
replacement parts, SRM drawings or the panel surface.
existing panel determine where to drill.

Note: Step 3 is very important. The routed out cavity must be large enough to provide structural
integrity to the bonded insert. Do not remove or damage skins.

Step 3: Rout core to undercut 3-5mm (1/8-3/16 Step 4: Check amount of core removed and quality
inch) or about one cell. A high speed rotary of hole. Depth shown is about 4mm (5/32 inch)
tool is shown.

Step 5: Lightly sand facing in the area of the Step 6: Degrease inserts by immersion in clean
insert flange. For inserts where both sides are solvent. Acetone is recommended.
flanged, sand both sides.

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11.3 Insert Installation Details

Subsequent sections describe installation of different inserts, with illustrations for demonstration
purposes. For all insert types, ensure that you are using the correct insert for the type of panel, per section
8.1. Determine whether to use the injection or spatula method for potting the insert before starting, and
ensure all necessary equipment is available. If injecting, determine whether adhesive pre-mixing is
required. The approximate weight of the installed, potted insert is 4.5 – 5.5 grams (0.010 – 0.012 lbs).

Note: Whenever potting material cannot be injected through a hole in the bottom insert, adhesive must be applied using
the spatula (without injection) method.

11.3.1 2-Piece Torlon® Inserts for Cargo Floors: TF073 and TF074
Note: Use a drill diameter of 15mm (19/52 or 0.590 inches) for these inserts.
TF073 and TF074 inserts described in section 8.1.1. and shown in section 11.10.1 provide a flush-
mounted installation in the upper surface. This will leave the insert level with the top face of the floor
panel.

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11.3.1.1 Instructions for Adhesive Injection

Adhesive injection is a faster and more uniform technique for installation, preferred by most
customers. Instructions when using the injection method for potting are:

Step Reference Instruction

1 11.1 & 11.2 Prepare panels, inserts and holes and adhesive as previously described
2 - If needed, pre-mix adhesive per manufacturer’s instructions.
A: When using a two-cartridge adhesive package, a hand-operated dispensing gun and
mixing nozzle can inject adhesive through the potting holes. Pre-weighing is not necessary
B: When using a hand-operated syringe or air-pressure operated gun, adhesive must be
pre-mixed and loaded into the applicator.
Note: An applicator diameter of approximately 1.8mm (0.072 inch) is recommended for either injection technique. If
using a different diameter, make sure the tip fits into the insert hole to allow proper encapsulation. This will avoid
wasting adhesive and difficult cleanup.
3 11.3.1.2 step 2 Apply adhesive to the flange of the insert sleeve (bottom) before installing in the panel. Do not
place adhesive inside the panel.
4 11.3.1.2 step 3 Place the insert sleeve with flange into the lower face (the thinner face for non-symmetric
panels)
5 11.3.1.2 step 4 Place the plug into the upper face
6 - Align the plug and sleeve so that they can be pressed together without damage
7 11.3.1.2 step 5 Press the insert sections together with an arbor press or hammer. Use only enough pressure
or 6 to make the insert plug flush with the panel surface and seat the insert flange to the back of the
panel.
8 - Verify that only a small quantity of adhesive squeezed out from underneath the flange, so that
enough adhesive remains to provide an adequate bond to the panel.
9 11.3.1.3 Put the mixing nozzle into one of the 2.3mm (0.092 inch) insert holes and inject adhesive until
it flows out the opposite hole and no air bubbles come out. Wait a minute for more air, then
inject more adhesive into the opposite hole.
10 11.3.1.3 Remove excess adhesive from upper and lower facings using a dry cloth. If necessary, a slight
amount of solvent can be added to the cloth in order to help. Do not apply solvent directly to
the panel.
11 - Use a cotton swab to remove adhesive in the hole through the insert.
12 - Inspect that the insert seated properly, the flange is not broken, the insert hole is clear and the
panel is reasonably clean.
13 - Allow the panel to cure at room temperature or use accelerated temperature, per
manufacturer’s instructions, so that the adhesive develops adequate strength prior to use.
Typical cure times are 3-5 days at 23°C (73°F) or 2 hours at 60°C (140°F). Do not exceed
82°C (180°F).

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11.3.1.2 Illustrations of Insert Installation

Step 1: Cleaned 2-piece Torlon® insert Step 2: Apply adhesive to the inside of the flange.

Step 3: Install insert sleeve (with adhesive on Step 4: Install plug in upper facing. Align pieces
flange) in lower facing. to prevent breakage when parts are sealed.

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Step 5: Use an arbor press to seat the insert. Step 6: If an arbor press is not available, place
Use only enough pressure to mount the insert panel/insert assembly on a firm base, and tap
plug flush with panel surface insert plug gently with a hammer until it is flush
with panel surface.

Step 7: Insert must be flush with panel surface;

remove any adhesive which might have
squeezed out from around insert plug.

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11.3.1.3 Illustration of Adhesive Injection

Method 1: Injection using a hand operated Method 2: Injection using an air-operated gun.
cartridge gun. Pre-packaged adhesive cartridge Pre-weigh and mix adhesive before adding to the
does not require pre-weighing. reservoir.

Method 3: Injection using a hand operated All Methods: Remove excess adhesive. Insert
syringe. Pre-weigh and mix adhesive before flange should be seated firmly against lower face.
adding to the syringe barrel. Ensure that flange is not broken.

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11.3.1.4 Instructions for Spatula Method

When using the without injection spatula method for potting, follow these instructions:

Step Reference Instruction

1 11.1 & 11.2 Prepare panels, inserts and holes as previously described
2 - Mix adhesive per manufacturer’s instructions. Make only the amount that can be used in 30-
40 minutes.
3 11.3.1.5 step 1 Apply adhesive with a small spatula or trowel to the routed out areas of the panel.
4 11.3.1.5 step 2 Check that there is sufficient adhesive applied in the panel to encapsulate the installed insert
completely.
4 11.3.1.2 step 2 Apply adhesive to the flange of the insert sleeve (bottom) before installing in the panel.
5 11.3.1.2 step 3 Place the insert sleeve with flange into the lower face (the thinner face for non-symmetric
panels)
6 11.3.1.2 step 4 Place the plug into the upper face
7 - Align the plug and sleeve so that they can be pressed together without damage
8 11.3.1.2 step 5 Press the insert sections together with an arbor press or hammer. Use only enough pressure
or 6 to make the insert plug flush with the panel surface and seat the insert flange to the back of
the panel.
9 - Verify that only a small quantity of adhesive squeezed out from underneath the flange, so that
enough adhesive remains to provide an adequate bond to the panel.
10 11.3.1.3 Remove excess adhesive from upper and lower facings using a dry cloth. If necessary, a
slight amount of solvent can be added to the cloth in order to help. Do not apply solvent
directly to the panel.
11 - Use a cotton swab to remove adhesive in the hole through the insert.
12 - Allow the panel to cure at room temperature, or use accelerated temperature, per
manufacturer’s instructions, so that the adhesive develops adequate strength prior to use.
Typical cure times are 3-5 days at 23°C (73°F) or 2 hours at 60°C (140°F). Do not exceed
82°C (180°F).

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11.3.1.5 Illustration of Spatula Method for Potting Adhesive

Step 1: Application of potting adhesive to Step 2: Apply a generous quantity of adhesive to
routed-out area of panel the panel interior.

11.3.1.6 Cross-Section of Installed Insert

(Note: sleeve with flange must be bonded to the lower facing of panel)

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11.3.2 2-Piece Torlon® Inserts for A320 Passenger Floors: TF152

Inserts for passenger floors described in section 8.1.2 and shown in section 11.10.2 have a plug
that protrudes above the panel. Installation instructions from section 11.3.1 apply for this insert type and
must be followed. Since the plug and sleeve are both flanged, add adhesive to both flanges. Make sure
the insert plug, which does not have injection holes, is installed in the panel face. Final appearance
should match section 11.3.2.1.

11.3.2.1 Illustration of Installed Insert

Plug, no injection holes, installed on the panel Sleeve with injection holes, installed on panel
face back

11.3.3 1-Piece Aluminum Inserts for Cargo Floors: TF20, TF21, TF110 and TF111
1-piece aluminum inserts TF20, TF21, TF110 and TF111 described in section 8.1.3 and shown
in sections 11.10.3 to 11.10.5 will be flush to the upper panel surface after installation. The level surface
is achieved by forming a rolled flange with a special forming tool. The forming tool is available from The
Gill Corporation, or can be machined per the appropriate specification drawing shown in sections 11.8 or
11.9.
The procedures described below are valid for all panel types and locations allowed for use with
these inserts per section 8.1.3. TF20 and TF21 inserts without injection holes must follow the spatula
method per 11.3.3.3. TF110 and TF111 with injection holes can follow either 11.3.3.1 or 11.3.3.3.
Note: Use a drill diameter of 11.1mm (7/16 or 0.4375 inches) for these inserts.

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11.3.3.1 Instructions for Adhesive Injection

Adhesive injection is a faster and more uniform technique for installation, preferred by most
customers. Instructions when using the injection method for potting 1-piece inserts are:

Step Reference Instruction

1 11.1 & 11.2 Prepare panels, inserts and holes and adhesive as previously described
2 - If needed, pre-mix adhesive per manufacturer’s instructions.
A: When using a two-cartridge adhesive package, a hand-operated dispensing gun and
mixing nozzle can inject adhesive through the potting holes. Pre-weighing is not necessary
B: When using a hand-operated syringe or air-pressure operated gun, adhesive must be
pre-mixed and loaded into the applicator.
Note: An applicator diameter of approximately 1.8mm (0.072 inch) is recommended for either injection
technique. If using a different diameter, make sure the tip fits into the insert hole to allow proper
encapsulation. This will avoid wasting adhesive and difficult cleanup.
3 11.3.3.2 step 2 Apply adhesive to the flange of the insert (bottom) before installing in the panel. Do not place
adhesive inside the panel.
4 11.3.3.2 step 4 Place the insert with flange into the lower face (the thinner face for non-symmetric panels)
5 - Place the panel insert assembly on a firm surface, with the flange down
6 11.3.3.2 step 5 Align the forming tool with the insert
7 11.3.3.2 step 5 Form the rolled flange of the insert against the top face of the panel with an arbor press so that
or 6. the insert is flush or slightly below the panel surface. If not available, carefully tap the forming
tool with a hammer to form the rolled flange. Take care not to damage the panel or insert.
8 - Verify that only a small quantity of adhesive squeezed out from underneath the flange, so that
enough adhesive remains to provide an adequate bond to the panel.
9 11.3.1.3 Put the mixing nozzle into one of the 2.3mm (0.092 inch) insert holes and inject adhesive until
it flows out the opposite hole and no air bubbles come out. Wait a minute for more air, then
inject more adhesive into the opposite hole.
10 11.3.1.3 Remove excess adhesive from upper and lower facings using a dry cloth. If necessary, a slight
amount of solvent can be added to the cloth in order to help. Do not apply solvent directly to
the panel.
11 - Use a cotton swab to remove adhesive in the hole through the insert.
12 11.3.3.2 steps Inspect that the insert seated properly, the flange is not broken, the insert hole is clear and the
7 and 8 panel is reasonably clean.
13 - Allow the panel to cure at room temperature or use accelerated temperature, per
manufacturer’s instructions, so that the adhesive develops adequate strength prior to use.
Typical cure times are 3-5 days at 23°C (73°F) or 2 hours at 60°C (140°F). Do not exceed
82°C (180°F).

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11.3.3.2 Illustration of Insert Installation

Step 1: Clean insert before installation. (TF110 Step 2: Apply adhesive on the flange (injection
shown) method).

Step 3: Apply adhesive to insert flange and Step 4: Place insert in bottom panel skin. Do not
barrel (spatula method) squeeze out too much adhesive

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Step 5: Form the rolled flange with an arbor Step 6: If needed, a hammer can be used to form
press the rolled flange. Tap carefully to avoid damage.

Step 7: Appearance of the back side of the panel Step 8: Appearance of the face side of the panel
(flange side) with the installed insert. (TF110 with the installed insert. (TF110 shown)
shown)

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11.3.3.3 Instructions for Spatula Method

Step Reference Instruction

1 11.1 & 11.2 Prepare panels, inserts and holes as previously described
2 - Mix adhesive per manufacturer’s instructions. Make only the amount that can be used in 30-
40 minutes.
3 11.3.1.5 step 1 Apply adhesive with a small spatula or trowel to the routed out areas of the panel.
4 11.3.1.5 step 2 Check that there is sufficient adhesive applied in the panel to encapsulate the installed insert
completely.
4 11.3.3.2 step 3 Apply adhesive to the flange of the insert (bottom) and around the barrel before installing in
the panel.
5 11.3.3.2 step 4 Place the insert with flange into the lower face (the thinner face for non-symmetric panels)
6 Place the panel insert assembly on a firm surface, with the flange down
7 11.3.3.2 step 5 Align the forming tool with the insert
8 11.3.3.2 step 5 Form the rolled flange of the insert against the top face of the panel with an arbor press so that
or 6 the insert is flush or slightly below the panel surface. If not available, carefully tap the forming
tool with a hammer to form the rolled flange. Take care not to damage the panel or insert.
9 - Verify that only a small quantity of adhesive squeezed out from underneath the flange, so that
enough adhesive remains to provide an adequate bond to the panel.
10 11.3.1.3 Remove excess adhesive from upper and lower facings using a dry cloth. If necessary, a slight
amount of solvent can be added to the cloth in order to help. Do not apply solvent directly to
the panel.
11 - Use a cotton swab to remove adhesive in the hole through the insert.
12 11.3.3.2 steps Inspect quality of insert installation.
7 and 8
13 - Allow the panel to cure at room temperature, or use accelerated temperature, per
manufacturer’s instructions, so that the adhesive develops adequate strength prior to use.
Typical cure times are 3-5 days at 23°C (73°F) or 2 hours at 60°C (140°F). Do not exceed
82°C (180°F).

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11.3.4 2-Piece Aluminum Inserts for Passenger and Cargo Floors: T303 and T307
2-piece aluminum inserts T303A plug/T303B sleeve and T307A plug/T307B sleeve described in
section 8.1.4 and shown in section 11.10.6.have a plug that protrudes above the panel surface after
installation. The procedures described below are valid for the panel types and locations allowed for use
with these inserts. These inserts do not have injection holes and must follow spatula method instructions
as described in 11.3.1.4. Since the plug and sleeve are both flanged, add adhesive to both flanges. Make
sure both flanges completely bond to the panel surfaces. Take care that the insert plug is bonded to the
top face of the panel so that the countersunk part of the insert allows attachment on the aircraft.
Note: Use a drill diameter of 11.1mm (7/16 or 0.4375 inches) for these inserts.
It is possible to generate desired outcome strengths from T303A/B and T307A/B without routing
the core and adding potting adhesive. Fabricators wanting to skip those recommended steps must
demonstrate insert shear strength compliance via testing. The process outlined in section 6 must be
repeated to skip these steps. The Gill Corporation has found that routing the core and potting with
adhesive provides higher and more consistent insert strength.
11.3.4.1 Illustration of Insert as Installed – Upper Facing

11.3.4.2 Cross-Section of Insert as Installed

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11.4 Hardpoint Insert Installation

Hardpoint Inserts provide reinforced attachment points and generally follow the installation
procedure for 2-piece inserts in section 11.3.1. The larger diameter of the insert likely requires the use
of a hole saw or router bit to avoid damaging skins while machining.
Note: Use a drill diameter of 31.75mm (1 ¼ or 1.25 inches) for T304, T305 and T308 inserts. Use a drill diameter of
38.1mm (1 ½ or 1.50 inches) for T306.
11.4.1 Drawing of Installed Hardpoint

(Note: figure not to scale.)

11.5 Threaded Insert Installation

All threaded inserts shown in section 8.3 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 sections 9, 10 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; insert manufacturer’s instructions for hole size
should be followed in case of any discrepancy.
For all threaded insert types, procedures below have been shown with the faceskins remaining
on the panel. The same general process is followed in cases where the Airbus drawing shows a step-
down solution with the faceskin removed and edge fill placed into the core, as shown in section 11.5.1.
Remove the faceskin and fill the exposed core with edge filler prior to installing the inserts in these cases.

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11.5.1 Illustration of Step-Down Installation

11.5.2 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 and inserts as described in section 11.1. Place 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.
Adhesive mixed per manufacturer instructions is slowly 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 are gently removed. Excess adhesive remaining on
top of the insert is removed, and the installation cured per adhesive manufacturer recommendation.
11.5.2.1 Illustrations of Tabbed Inserts

Tabbed insert placed in panel Adhesive added Excess adhesive removed

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An alternate installation method is allowed. Drill a hole sized 14.2 – 14.4mm in diameter (0.561 –
0.566”) through the panel, remove core between the faceskins per section 11.2 step 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.
11.5.3 NAS 1835
This procedure should be identical to the description for NAS1833 / NAS1834 in section 11.5.2,
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 section 11.2 step 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 section 11.5.2.
11.5.4 NAS 1836
This procedure should be identical to the description for NAS1833 / NAS1834 from section 11.5.2,
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. Core remaining is for a panel that is 9.5mm thick (0.374”), adjust appropriately for other panel
thicknesses. 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 section 11.5.2.
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 section 11.2 step 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 section 11.5.2.
11.5.5 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 section 11.1. 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 in section 11.5.5.1, but alternate methods that prevent adhesive ingression are
allowed.
Inserts were cleaned according to section 11.1. 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.

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11.5.5.1 Illustration of Adhesive Ingression Prevention

Preventing adhesive
ingression into threading

Adhesive set-up while

preventing ingression into
threading

After adhesive cure, check of

clean threading

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11.5.6 ABS1006
Install ABS1006 inserts with the same methodology used for NAS 1836 in section 11.5.4. Hole
sizing and depth of core removal should be appropriately adjusted.
11.6 No-Insert Installations
At times, original equipment may include build in attachment points that do not exactly match the
repair solutions described with inserts. Small holes using built in plugs in original equipment can typically
be repaired with a routed through hole with edge filler. As small hole routing depth is limited, the following
guidelines are provided for long range cargo compartments with panel type CCC1.
Hole Diameter Size Routing Depth Minimum
mm mm
4-8 1.5
8-13 3
>13 6

11.6.1 Example, A330 Cargo Floor 12mm hole

In this example, the original CCC1 panel contained a 12mm through hole on a panel joint with a
25mm built in plug as shown below.

To replace this feature with The Gill Corporation panels, drill a 12mm diameter hole, remove 3mm
of core by routing per section 9.2, adding an approved edge filler from section 8.5 into the routed area.
After curing, smooth edges if needed and use the hole as before, with no insert required.

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11.7 Non-Standard Insert Installation Locations

Attachment points to brackets or other locations requiring shear load transfer to the floor will
require inserts, and might initially appear exotic in their configuration. These can be replaced with 2-piece
aluminum inserts as described in section 11.3.4.
11.7.1 Example, A320 Family Main Deck
In this case, the design solution of the floor panel includes later assembly with a bracket.

2-piece aluminum inserts can be used for this situation where the original design used a
composite plug. The smaller diameter flange of T307 can at times be preferred. Because these inserts
are countersunk on the upper face, please use the appropriately angled screw or bolt for attachment.

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11.8 Forming Tool for 1-piece Aluminum Inserts TF110 and TF111
The 1-piece aluminum inserts TF110 and TF111 described in section 11.3.3 require a special forming tool to
install. Note that this is not the same forming tool used for TF20 and TF21 inserts. The tool can be obtained
from The Gill Corporation or can be machined according to this schematic:

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11.9 Forming Tool for 1-Piece Aluminum Inserts TF20 and TF21
The 1-piece aluminum inserts TF20 and TF21 described in section 11.3.3 require a special forming tool to
install. Note that this is not the same forming tool used for TF110 and TF111 inserts. The tool can be obtained
from The Gill Corporation or can be machined according to this schematic:

11.10 Insert Schematics

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.

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11.10.1 2-Piece Torlon® Inserts TF073, TF074

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11.10.2 2-Piece Torlon® Insert TF152

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11.10.3 1-Piece Alumium Inserts TF110 and TF111

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11.10.4 1-Piece Aluminum Insert TF20

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11.10.5 1-Piece Aluminum Insert TF21

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11.10.6 2 Piece Aluminum Inserts T303 and T307

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11.10.7 Hardpoint Insert T304

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11.10.8 Hardpoint Insert T306

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11.10.9 Hardpoint Insert T305

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11.10.10 Hardpoint Insert T308

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12 Repair of Replacement Floor Panels

12.1 Determination of Repairable Damage
The applicable Airbus SRM is the governing specification for determining the extent of damage
which may be repaired. The following sections describe the recommended materials and procedures to
be followed to return a damaged floor panel into service.
12.2 Recommended Repair Materials
The following materials are recommended for repairing damaged floor panels. Alternative
materials may be substituted with the approval of The Gill Corporation.

Paste Adhesive Loctite Hysol EA9309.3NA, manufactured by Loctite/Henkel

Gillcore HD365, Nomex honeycomb core, 3/16” (4.8 mm) cell size, 6 lb/ft³ density, manufactured
Honeycomb Core
by The Gill Corporation

Gillfab 1367, 1367A or 1369A, 0.050 – 0.060” (1.3 – 1.5 mm) thick, manufactured by The Gill
Cargo Liner Laminate
Corporation

Aluminum Sheet Stock Aluminum alloy 2024-T3 (3.1364T3) stock, 0.050” (1.3 mm) thick [or equivalent]

Use a 3:1 mixture of Firemaster 2100RM to Nyacol A1582, added to the EA9309.3NA adhesive
mixture at 20% by weight of the 2 component adhesive system. Mix well to obtain a
homogeneous paste adhesive.

Trade Name: Firemaster 2100RM

Decabromodiphenyl ethane { 1,1’-(1,2-ethanediyl)bis[2,3,4,5,6 pentabromo]benzene }
Chemtura Corp
Fire Retardant Additives 710 Bussey Rd
El Dorado, Arizona 71730
(870) 862-9100
www.chemtura.com

Trade Name: Nyacol A1582

Colloidal Antimony Pentoxide

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Nyacol Products, Inc.

221 Megunko Rd
Ashland, Massachusetts 01721
(508) 881-2220
www.nyacol.com

A hand-held belt, orbital, or reciprocating sander can be used to sand the honeycomb core plug
Portable Sander
to the correct thicknesses. This can ensure the correct repair procedure while reducing the
(Optional)
complexity of inventoried materials.

Heating Blanket or Heat These may be used to reduce the cure time of the adhesive (normally 5 – 7 days at room
Gun (Optional) temperature).

12.3 Repair Procedure

1. Remove the facing and honeycomb core from the damaged area without damaging the lower facing.
Make the cut larger than the damage in a uniform shape (circle, square, rectangle). If the lower facing
is damaged, remove that damage also, leaving at least 0.75 inch (19 mm) shelf of undamaged lower
skin with only the core and top skin removed. This will allow for a reinforcing laminate to be bonded
to the lower skin.
Attention: Make certain that the cut out area is still within the allowable damage limits specified in the Airbus SRM.
2. If both faces are damaged , cut a piece of cargo liner laminate, described in section 12.2, 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 as the intact lower facing will
provide the necessary reinforcement.
3. Prepare the laminate by lightly sanding the back edges (non-Tedlar® side). Wipe the faces with a
solvent, such as acetone, to remove all debris and contamination.
4. Prepare a second laminate patch to overlap the edges of the upper opening by at least 0.75 inches
(19 mm), and sand the back side of the laminate. Wipe the with solvent to remove any debris.
5. Cut a piece of honeycomb core (section 12.2) 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.
6. In an appropriate disposable container, such as a 16-oz plastic cup, weigh out the desired amount of
adhesive and fire retardants. Mix thoroughly by hand at room temperature for at least one minute.
Use an appropriate mixing tool, such as a wooden tongue depressor or metal spatula. Check to
ensure that there are no visible streaks or pockets of powder. Continue mixing until no streaking or
visible powder remains.
Example: Using 240.0 ± 2.4 grams of EA9309.3NA adhesive mixture at a 100:22 Part A:Part B ratio, mixed per
manufacturer’s instructions, add 36.0 ± 3.6 grams of decabromodiphenyl ethane and 12.0 ± 1.2 grams of colloidal
antimony pentoxide.

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7. Mix only the amount of adhesive that can be used in about 30-40 minutes. Adhesive should be applied
using a trowel or small spatula.
Note: It may be helpful to let the adhesive to sit for a few minutes before application. This will allow the adhesive to
thicken up a bit, so that it will stay in place when applied to the panel.
8. If only one side of the panel is being patched, then spread adhesive over the entire interior surface
of the lower facing. If a patch is used for the both surfaces, first spread adhesive only around the
exterior facing edges of the lower patch, and place it on the interior facing edges of the lower facing
shelf. Then, spread adhesive over the entire interior surface of the patch. Apply approximately 0.060
lb/ft² (293 g/m²) to all bonding surfaces.
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.
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 0.75 inches (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 banket.
Attention: Do not exceed a temperature of 200°F (93°C) when postcuring the adhesive.
12.4 Cross-Section Diagram of Repaired Floor Panel
This 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 is
included in section 12.5.

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12.5 Reference Airbus Repair Documentation

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

TASK 53-02-00-300-012 Repair of Perforation Damage to both Skins (Upper and Lower) and Core
in Zone B and Zone C

TASK 53-02-00-300-015 Repair of Perforation Damage to both Skins (Upper and Lower) and Core
in 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

Attention: Only Airbus can provide this documentation as The Gill Corporation does not have access to these procedures.

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