Non-Conformities of Insulation Blankets - Airbus Manual

AM2205.
8
Manual Issue: C
Handling of Non-Conformities on Primary

Insulation Blankets ATA 25-80
<SUMMARY_BEGIN>SUMMARY :
PURPOSE:
This Manual defines who decides and describes the course of actions when non-conformities are detected
on Insulation Blankets during Final Installation.
It provides the requirements, acceptance criteria and instructions for handling of non-conformities in terms
of documentation needs.
SCOPE:
This Airbus Manual is applicable for all AC types and models.
<SUMMARY_END>
Owner’s Approval: Authorization:
Name: KLEIN Bernd Name: SCHAWALLER Bernd

Function: Head of Ventilation System - EDYVV Function: Delegated Process Owner
Manufacturing Non-Conformance
Process - QYA
© AIRBUS S.A.S. 2010. ALL RIGHTS RESERVED. CONFIDENTIAL AND PROPRIETARY DOCUMENT.
Q10_Manual_FM0400730_v2.2 Printed Copies are not controlled. Confirm this is the latest issue available through the Portal.
Page 1 of 18
Electronically validated - Released on 10 May 2010
Handling of Non-Conformities on AM2205.8
Primary Insulation Blankets ATA 25-80 Issue: C
TABLE OF CONTENTS
1 About this Document ........................................................................................................... 4
1.1 Background ......................................................................................................................... 4
1.2 Detailed Purpose ................................................................................................................. 4
1.3 Organisation of the Document ............................................................................................. 4
2 Decision Frame ................................................................................................................... 5
3 Evaluation Scheme for Insulation Blankets Non-Conformities ............................................ 6
4 Applicability and Limitations ................................................................................................ 7
5 Types of Non-Conformities on Primary Insulation Blankets ................................................ 8
5.1 Tear in Insulation Blanket Covering Foil .............................................................................. 8
5.1.1 Non-Conformity Assessment (Not Applicable for ABS 5429F008A in FAR §
25.856(b) Affected Areas) .......................................................................................... 8
5.1.2 Non-Conformity Assessment (Applicable only for ABS 5429F008A in FAR §
25.856(b) Affected Areas) .......................................................................................... 9
5.2 Glass Wool Crack Inside Insulation Blanket ...................................................................... 10
5.2.1 Non-Conformity Assessment (Not Applicable in FAR § 25.856(b) Affected
Areas) ....................................................................................................................... 10
5.2.2 Non-Conformity Assessment (Applicable Only for FAR § 25.856(b) Affected
Areas) ....................................................................................................................... 11
5.3 Traces of Felt-Tip Pen on Covering Foil ............................................................................ 12
5.3.1 Non-Conformity Assessment ................................................................................... 12
5.4 Spots of Varnish for Electrical & Mass Bonding Installation on Blanket Covering Foil ...... 13
5.4.1 Non-Conformity Assessment (Only Applicable for ABS 5429A004A and ABS
5429B005A) ............................................................................................................. 13
5.5 Spots of Structure Water Repellent Product on Covering Foil .......................................... 14
5.6 Fall Down of Glass Wool Inside the Cover Foil Cabin Window Blanket ............................ 15
5.7 Adherence of Insulation Blankets on Primary Structure .................................................... 16
5.7.1 Non-Conformity Assessment Applicable Only for ABS 5429F008A in FAR §
25.856(b) Affected Areas ......................................................................................... 16
6 Reference Documents ....................................................................................................... 17
7 Glossary ............................................................................................................................ 17
Record of Revisions ........................................................................................................................ 18
Printed Copies are not controlled. Confirm this is the latest issue available through the Portal.
Page 2 of 18
LIST OF FIGURES
Figure 1: Tear in Insulation Blanket Covering Foil ............................................................................ 8
Figure 2: Tear in Insulation Blanket Covering Film Burn Through Resistant .................................... 9
Figure 3: Glass Wool Crack inside Field Insulation Blanket ............................................................ 10
Figure 4: Traces of Felt-Tip Pen on Covering Foil .......................................................................... 12
Figure 5: Spots of Varnish for Electrical & Mass Bonding Installation on Blanket Covering Foil .... 13
Figure 6: Fall down of Glass wool; cabin window area ................................................................... 15
Figure 7: Adherence of insulation blankets on primary structure .................................................... 16
Page 3 of 18
1 About this Document
1.1 Background
The purpose of this Manual is to provide decision rules for acceptance of Thermal and
Acoustical Insulation Blankets non-conformities at Airbus and its subcontractors.
This Manual is part of the Concession Support Decision Manual (CSDM), Ref. AM2205.0.
The specific use of the CSDM within this procedure is detailed in AP2655.0, Managing
Nonconforming Items.
1.2 Detailed Purpose

This Manual defines acceptance limits of non-conformities on insulation cover foil and glass
wool during final installation.
 it classifies non-conformities which might be found during installation,
 it provides requirements, acceptance criteria and instructions for handling of
Insulation Blankets non-conformities in terms of documentation needs and
disposition.
1.3 Organisation of the Document

This Manual is divided into 5 paragraphs:
 the firsts paragraph covers background and purpose of the Manual,
 the second paragraph covers decision frame,
 the third paragraph covers an evaluation scheme,
 the fourth paragraph covers applicability and limitations,
 the fifth paragraph defines the non-conformities covered by this procedure, states the
limits and requirements for non-conformities related to insulation blankets.
Page 4 of 18
2 Decision Frame
There are systematically three decision classes based on authority to decide.
Class 1: Quality decides without reporting to Engineering
The characteristic dimension of the assumed non-conformity is below the Limit For
Documentation (LFD) and all class 1 requirements are fulfilled (if defined).
The assumed non-conformity is not regarded as non-conformity as defined in AP1006.
No rework is requested and documentation is not mandatory.
Class 2: Quality decides on behalf of Engineering (delegation)
The Blanket is below the Limit For Concession (LFC).
The non-conformance is judged as insignificant non-conformity as per AP1006 and AP2655.0

definition.
Internal documentation is mandatory.
Class 3: Engineering decides
The Insulation Blankets non-conformity is above the Limit For Concession (LFC) and class 2
installation criteria are not fulfilled.
Quality submits the non-conformity to Engineering based on the internal documentation of the
case.
The non-conformance is judged as a significant non-conformity as per AP1006 definition.
Page 5 of 18
3 Evaluation Scheme for Insulation Blankets Non-Conformities

Type of
Non-conformity
Within LFD
and Class 1 Class 1 No further action
Requirement
No
Within LFC Yes Repair solution in

and Class 2 Class 2 accordance to
Requirement referenced documents
No
Replace the part or

Class 3 raise a request for
concession
Page 6 of 18
4 Applicability and Limitations

The evaluation criteria presented below are applicable for ATA 258 Fuselage Primary
Insulation Blankets and is applicable for all Airbus aircrafts with the following maximum
acceptable number of reworked insulation blankets per A/C Zone:
 Cargo area at section delivery to the FAL
 Maximum 10% of reworked blankets per A/C section are acceptable when
sections are delivered to FAL
 Maximum 5 consecutive reworked blankets are acceptable
 Cargo area at final installation

 Maximum 20% of reworked blankets per A/C section are acceptable
 Cabin area at section delivery to FAL

 Cabin area at final installation

Note: The above mentioned limitations do not apply for FLEX CONCEPT areas!
.
Page 7 of 18
5 Types of Non-Conformities on Primary Insulation Blankets
5.1 Tear in Insulation Blanket Covering Foil

Definition:
A tear is a complete break in the insulation covering foil, leaving an opening in the blanket.
5.1.1 Non-Conformity Assessment (Not Applicable for ABS 5429F008A in

FAR § 25.856(b) Affected Areas)
Max 200 mm
Figure 1: Tear in Insulation Blanket Covering Foil
5.1.1.1 Class 1
N/A
5.1.1.2 Class 2
The following requirements shall be fulfilled:
 Maximum one (1) allowable rework of cover foil per blanket.
 Maximum allowed covering foil rework length, 200 mm per blanket.
 Rework in accordance to AIPS 03-07-004.
5.1.1.3 Class 3
Criteria for Class1 or Class 2 are not fulfilled.
Page 8 of 18
5.1.2 Non-Conformity Assessment (Applicable only for ABS 5429F008A in

FAR § 25.856(b) Affected Areas)
MAX. 50 mm
Figure 2: Tear in Insulation Blanket Covering Film Burn Through Resistant
5.1.2.1 Class 1
N/A
5.1.2.2 Class 2
 Maximum one (1) allowable rework of cover foil per blanket
 Maximum allowed covering foil rework length, 50 mm per blanket
 Rework in accordance with AIPS 03-07-004
5.1.2.3 Class 3
Criteria for Class 1 and Class 2 are not fulfilled.
Page 9 of 18
5.2 Glass Wool Crack Inside Insulation Blanket

Definition:
One of the main reasons for blanket replacements is due to cracks on the glass wool inside
the field blanket, see Figure 3.
A glass wool crack is a damage of the insulation blanket filling material. These types of
damages are caused by several removals, re-installations of the system and insulation blanket
mishandlings.
Figure 3: Glass Wool Crack inside Field Insulation Blanket
5.2.1 Non-Conformity Assessment (Not Applicable in FAR § 25.856(b) Affected

Areas)
5.2.1.1 Class 1
N/A
5.2.1.2 Class 2

 Maximum one (1) allowable rework of glass wool per blanket
 Maximum allowed crack rework length, 400 mm per blanket
 Rework solution in accordance AIPS 03-07-004
Page 10 of 18
5.2.1.3 Class 3
5.2.2 Non-Conformity Assessment (Applicable Only for FAR § 25.856(b)

Affected Areas)
5.2.2.1 Class 1
N/A
5.2.2.2 Class 2

 Maximum one (1) allowable rework per blanket
 Maximum allowed crack rework length, 400 mm per blanket
 Rework in accordance with AIPS 03-07-004
Maximum acceptable numbers of reworked insulation blankets per A/C Zones:

 See chapter 4.
5.2.2.3 Class 3
Page 11 of 18
5.3 Traces of Felt-Tip Pen on Covering Foil

Based on the primary insulation blanket production it might happen that some blankets will be
found with traces of felt-tip pen on top of insulation blanket covering foil.
Figure 4: Traces of Felt-Tip Pen on Covering Foil
5.3.1 Non-Conformity Assessment
5.3.1.1 Class 1
 The ink is in line with AIPS 08-03-002
 There are no damages or scratches visible caused by the marking process
5.3.1.2 Class 2

 If there is a scratch/damage found below the ink the blanket damage can be
assessed as defined in chapter 5.1 (tear in insulation blanket covering foil).
5.3.1.3 Class 3
Page 12 of 18
5.4 Spots of Varnish for Electrical & Mass Bonding Installation on Blanket
Covering Foil
After electrical installations it can occur that spots of varnish for electrical mass bonding
installation (blue color varnish acc. to DAN1174) can be found on top of primary insulation
blankets.
Blue colour
varnish
MAX = 10 mm
Figure 5: Spots of Varnish for Electrical & Mass Bonding Installation on Blanket Covering
Foil
5.4.1 Non-Conformity Assessment (Only Applicable for ABS 5429A004A and

ABS 5429B005A)
5.4.1.1 Class 1
N/A
5.4.1.2 Class 2

 Contamination shall be removed in accordance to AIPS 08-03-002.
5.4.1.3 Class 3
Page 13 of 18
5.5 Spots of Structure Water Repellent Product on Covering Foil

To ensure a proper behaviour of the insulation blankets regarding FAR 25.856(a)
requirements for flammability and flame propagation in cases where those are contaminated
with water repellent product (DINITROL & Socopac 65H) following technical position was
defined acc. the test results from the Radiant panel and Vertical burner tests for thermal and
acoustical materials.
5.5.1.1 Evaluation Matrix for Non-Conformities

Water repellent: Dinitrol Water repellent: Socopac 65H
Terul 18 ABS 5429A004A Limit of contamination: Limit of contamination:

Class 1: < 40000 mm² and < 200 mm length of edge Class 1: < 40000 mm² and < 200 mm length of edge
Class 2: > 40000 mm² or > 200 mm length of edge; Cleaning procedure Class 2: > 40000 mm² or > 200 mm length of edge; Cleaning procedure
AIPI 09-01-002 AIPI 09-01-002
AIPI 09-01-002 AIPI 09-01-002 not possible
Terul 19 ABS 5429B005A Limit of contamination: Limit of contamination:
AIPI 09-01-002 AIPI 09-01-002
AIPI 09-01-002 not possible AIPI 09-01-002 not possible
Terimide 7 ABS 5429C006B Limit of contamination: Limit of contamination:
AIPI 09-01-002 AIPI 09-01-002
Terimide 8 ABS 5429C006A Limit of contamination: Limit of contamination:
AIPI 09-01-002 AIPI 09-01-002
Glass Wool ABS 5630 Class 3 Class 3
Terflame 29 ABS 4529F008A Limit of contamination: Limit of contamination:
AIPI 09-01-002 AIPI 09-01-002
Class 3: > 2500 mm² or > 50 mm length of edge, Cleaning procedure Class 3: > 2500 mm² or > 50 mm length of edge; Cleaning procedure
AIPI 09-01-002 not possible AIPI 09-01-002not possible
Note: All other blanket contaminations not mentioned in this document result in class 3.
Page 14 of 18
5.6 Fall Down of Glass Wool Inside the Cover Foil Cabin Window Blanket
The fall down of glass wool can have negative effects on the thermal and acoustic quality of
the insulation.
Figure 6: Fall down of Glass wool; cabin window area
5.6.1.1 Class 1
The following requirement shall be fulfilled:

 The sliding glass wool distance is below 5 mm.
5.6.1.2 Class 2
N/A
5.6.1.3 Class 3
Page 15 of 18
5.7 Adherence of Insulation Blankets on Primary Structure

After application of water repellents on primary structure the case may occur that insulation
blankets with burnthrough resistant covering foil Terflame 29 (ABS 5429F008A) adhere on
primary structure. This could be caused by manufacturing processes as too short drying times
before installation or installation methods.
This non-conformity could cause damages of the insulation blanket covering foil.
Figure 7: Adherence of insulation blankets on primary structure
5.7.1 Non-Conformity Assessment Applicable Only for ABS 5429F008A in

FAR § 25.856(b) Affected Areas
5.7.1.1 Class 1
No damage of the covering foil.
5.7.1.2 Class 2
N/A
5.7.1.3 Class 3
In case of damaged covering foil.
Page 16 of 18
6 Reference Documents
Doc Reference Title
AIPI 09-01-002 Cleaning with Liquid Non Aqueos Agents

AIPS 03-07-004 Manufacturing of Insulation Blankets
AIPS 08-03-002 Permanent Marking with Ink
AM2205 Concession Decision Support Manual
AP1006 Control of Non Conforming Items
AP2080 Airbus Reference Language Main
AP2655.0 Managing Non Conforming Items
7 Glossary
Always refer to AP2080 - LEXINET
Page 17 of 18
Record of Revisions
Issue Date Reasons for Revision
A Jan 2005 Initial issue.

B Jan 2010 Implementation of non-conformities to FAR § 25.856(b).
C Apr 2010 Revision of referenced documents due to AIPI 03-007-004
release.
If you have a query concerning the implementation or updating of this document, please
contact the Owner on page 1
For general queries or information contact:

airbus.documentation-office@airbus.com
This document and all information contained herein is the sole property of AIRBUS S.A.S. No intellectual property
rights are granted by the delivery of this document or the disclosure of its content. This document shall not be
reproduced or disclosed to a third party without the express written consent of AIRBUS S.A.S. This document and
its content shall not be used for any purpose other than that for which it is supplied. The statements made herein do
not constitute an offer. They are based on the mentioned assumptions and are expressed in good faith. Where the
supporting grounds for these statements are not shown, AIRBUS S.A.S. will be pleased to explain the basis
thereof.
Page 18 of 18
REFERENCE AM2205.8
Validation Report
ISSUE C DATE 26 Apr 2010
Handling of Non-Conformities on Primary Insulation Blankets ATA 25-80

Validation Report
APPROVAL
Name [Siglum] Date
Mueller Rainer [EDYVVS] 26 Avr 2010 Electronically validated
SMART COLIN [SEERM] 03 Mai 2010 Electronically validated
AUTHORIZATION
Name [Siglum] Date
Klein Bernd [EDYVC] 03 Mai 2010 Electronically validated
AUTHORIZATION FOR APPLICATION

Name [Siglum] Date
Schawaller Bernd [QYA] 10 Mai 2010 Electronically validated

Non-Conformities of Insulation Blankets - Airbus Manual

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Non-Conformities of Insulation Blankets - Airbus Manual

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AM2205.

Handling of Non-Conformities on Primary

This Airbus Manual is applicable for all AC types and models.

Owner’s Approval: Authorization:

Name: KLEIN Bernd Name: SCHAWALLER Bernd

1 About this Document

1.2 Detailed Purpose

1.3 Organisation of the Document

Class 1: Quality decides without reporting to Engineering

The assumed non-conformity is not regarded as non-conformity as defined in AP1006.

No rework is requested and documentation is not mandatory.

Class 2: Quality decides on behalf of Engineering (delegation)

The Blanket is below the Limit For Concession (LFC).

The non-conformance is judged as insignificant non-conformity as per AP1006 and AP2655.0

Internal documentation is mandatory.

Class 3: Engineering decides

The non-conformance is judged as a significant non-conformity as per AP1006 definition.

3 Evaluation Scheme for Insulation Blankets Non-Conformities

Within LFC Yes Repair solution in

Replace the part or

4 Applicability and Limitations

 Cargo area at final installation

 Cabin area at section delivery to FAL

 Cabin area at final installation

5 Types of Non-Conformities on Primary Insulation Blankets

5.1 Tear in Insulation Blanket Covering Foil

5.1.1 Non-Conformity Assessment (Not Applicable for ABS 5429F008A in

Figure 1: Tear in Insulation Blanket Covering Foil

Criteria for Class1 or Class 2 are not fulfilled.

5.1.2 Non-Conformity Assessment (Applicable only for ABS 5429F008A in

Figure 2: Tear in Insulation Blanket Covering Film Burn Through Resistant

Criteria for Class 1 and Class 2 are not fulfilled.

5.2 Glass Wool Crack Inside Insulation Blanket

Figure 3: Glass Wool Crack inside Field Insulation Blanket

5.2.1 Non-Conformity Assessment (Not Applicable in FAR § 25.856(b) Affected

The following requirements shall be fulfilled:

Criteria for Class 1 and Class 2 are not fulfilled.

5.2.2 Non-Conformity Assessment (Applicable Only for FAR § 25.856(b)

The following requirements shall be fulfilled:

Maximum acceptable numbers of reworked insulation blankets per A/C Zones:

Criteria for Class 1 and Class 2 are not fulfilled.

5.3 Traces of Felt-Tip Pen on Covering Foil

Figure 4: Traces of Felt-Tip Pen on Covering Foil

5.3.1 Non-Conformity Assessment

The following requirements shall be fulfilled:

Criteria for Class 1 and Class 2 are not fulfilled.

5.4.1 Non-Conformity Assessment (Only Applicable for ABS 5429A004A and

The following requirements shall be fulfilled:

Criteria for Class 1 and Class 2 are not fulfilled.

5.5 Spots of Structure Water Repellent Product on Covering Foil

5.5.1 Non-Conformity Assessment

5.5.1.1 Evaluation Matrix for Non-Conformities

Terul 18 ABS 5429A004A Limit of contamination: Limit of contamination:

Figure 6: Fall down of Glass wool; cabin window area

5.6.1 Non-Conformity Assessment

The following requirement shall be fulfilled:

Criteria for Class 1 and Class 2 are not fulfilled.

5.7 Adherence of Insulation Blankets on Primary Structure

Figure 7: Adherence of insulation blankets on primary structure

5.7.1 Non-Conformity Assessment Applicable Only for ABS 5429F008A in

No damage of the covering foil.

In case of damaged covering foil.

AIPI 09-01-002 Cleaning with Liquid Non Aqueos Agents