15. 1.

0 AIRFRAME STRUCTURES

15.1.1 Introduction
This module unit is designed to equip the trainee with the
knowledge, skills and attitude necessary to understand the aircraft
construction principles, materials and maintenance.

15.1.2 General Objectives

By the end of the module unit, the trainee should be able to:
a) understand the construction of various aircraft structures
b) select materials for aircraft construction
c) observe safety procedures at work pace
d) perform maintenance on aircraft structures
e) understand engineering principles related to aircraft structures

15.1.3 Module Unit Summary and Time Allocation

Code Sub-Module Content Time (Hrs)

Unit Theory Practice Total
15.1.01 Aircraft  classification 6 2 8
 components
 structural loads
15.1.02 Fuselage  Types of construction 6 2 8
 Materials
 Maintenance
 Safety precautions
15.1.03 Main planes  Types of construction 4 2 6
and tail unit  Attachment positions
 Materials
 Maintenance
 Safety precautions
15.1.04 Landing gear  Types 6 4 10
 Construction
 Functions
 materials
 Safety precautions
15.1.05 Control  Construction 6 2 8
surfaces  Classification
 Operation
 Safety precautions
15.1.06 Materials for  Properties 10 6 16
aircraft  classification
construction  Application
15.1.07 Flying  Construction 6 2 8
control  Operation
Code Sub-Module Content Time (Hrs)
Unit Theory Practice Total
system  Maintenance
 Safety precautions
15.1.08 Station  Definition 3 2 5
identification  types
 Purposes
15.1.09 Structural  Classification 4 4 8
damages  Repair
 Drawings
 Safety precautions
15.1.10 Manuals  Definition 2 2 4
 Classification
 Contents
15.1.11 Rotor crafts  Construction 8 0 8
 Rotor systems
 Control system
 maintenance
15.1.12 Aircraft fuel  Types of fuels 6 4 10
storage  Types of tanks
 Components
 Maintenance
 General safety
Total 0 0 23
 15.1.01 AIRCRAFT

15.1.01C Competence
The trainee should have the ability to inspect and maintain aircraft structures

Theory

15.1.01T0 Specific Objectives

By the end of the sub-module unit, the trainee should be able to:
a) classify types of aircraft
b) identify the main components
c) describe the structural loads

Content
15.1.01T1 Aircraft classification
i) lighter than air
ii) heavier than air
15.1.01T2 Aircraft components
i) fuselage
ii) tail unit
iii) stabilizers
iv) landing gear
v) control surfaces
15.1.01T3 Structural loads
i) tension
ii) compression
iii) bending
iv) torsion
v) shear

Practice

15.1.02P0 Specific Objectives

By the end of the sub-module unit, the trainee should be able to:
a) draw a chart showing classification of aircraft
b) identify aircraft parts

Content
15t.1.02P1 Drawing the
classification chart
15.1.02P2 Parts identification
i) fuselage
ii) tail unit
iii) stabilizers
iv) landing gear
v) control surfaces

Suggested Teaching/Learning Activities

- Taking notes
- Discussion
- Demonstration
 - Identifying aircraft
structures

Suggested Teaching/Learning Resources

- Aircraft
Structures(assorted
parts)
- Complete aircraft

Suggested Evaluation Methods

- Oral tests
- Timed written tests
- Timed tests

15.1.02 FUSELAGE

15.1.02C Competence
The trainee should have the ability to carry out inspections and repairs on fuselage

Theory

15.1.02T0 Specific Objectives

By the end of the sub-module unit, the trainee should be able to:
a) describe the construction of the fuselage
b) identify materials for fuselage construction
c) explain maintenance practices
d) State the safety precautions to be observed

Content
15.1.02T1 Fuselage construction
i) truss type
ii) monocoque type
iii) semi-monocoque type
iv) geodetic
15.1.02T2 Materials for fuselage
construction
i) wood
ii) fabric
vi) metal
v) composite
15.1.02T3 Maintenance
i) corrosion
ii) foreign object damage
vii) fatigue
vi) surface protection
15.1.02T4 Safety precautions
 Practice

15.1.02P0 Specific Objectives

By the end of the sub-module unit, the trainee should be able to:
a) construct a fuselage
b) identify fuselage materials

Content
15.1.02P1 Fuselage construction
i) riveting
ii) bending
iii) forming
iv) cutting
15.1.02P2 Identification of
materials
i) wood
ii) fabric
iii) metal
iv) composite

Suggested Teaching/Learning Activities

- Taking notes
- Discussion
- Demonstration

Suggested Teaching/Learning Resources

- Aircraft fuselage
- Charts
- Tools
- Sheet metal
- video

Suggested Evaluation Methods

- Oral tests
- Timed written tests
- Timed practical tests

15.1.03 MAIN PLANE AND

TAIL UNIT

15.1.03C Competence
The trainee should have the ability to carry out maintenance on aircraft wings and tail unit

Theory

15.1.03T0 Specific Objectives

By the end of the sub-module unit, the trainee should be able to:
a) describe types of wing construction
b) describe wing attachment positions
c) identify materials for construction
 d) explain maintenance of the wings
e) state the safety precautions to be observed when

Content
15.1.03T1 Wing construction
i) truss
ii) semi-monocoque
15.1.03T2 Wing attachment
positions
i) parasol
ii) high
iii) mid
iv) low
15.1.03T3 Materials for wing and
tail unit construction
i) wood
ii) metal
iii) composite
15.1.03T4 Maintenance
i) corrosion
ii) attachment
iii) surface protection
iv) cracks
15.1.03T5 Safety precautions

Practice

15.1.03P0 Specific Objectives

By the end of the sub-module unit, the trainee should be able to :
a) prepare a working drawing of a wing
b) identify materials for wing construction

Content
15.1.03P1 fabrication
15.1.03P2 identification of
materials
i) wood
ii) metal
iii) composite

Suggested Teaching/Learning Activities

- Taking notes
- Discussion
- Demonstration

Suggested Teaching/Learning Resources

- Aircraft wing
- Charts

Suggested Evaluation Methods

- Oral tests
 - Timed written tests
- Timed practical tests
- Assignments

15.1.04 LANDING GEAR

15.1.04C Competence
The trainee should have the ability to service and repair the landing gear

Theory

15.1.04T0 Specific Objectives

By the end of the sub module unit, the trainee should be able to:
a) explain the types of landing gear
b) describe the construction of the landing gear
c) identify the functions of the landing gear
d) identify materials for landing gear construction
e) state safety precautions to be observed during landing gear maintenance

Content
15.1.04T1 Types of landing gear
i) tri-cycle
ii) conventional
iii) fixed
iv) retractable
v) skids
vi) floats
vii) shock absorbing and non-shock absorbing
15.1.04T2 Construction
i) trunion
ii) strut
iii) axle
iv) side brace
v) drag brace
vi) torque links
15.1.04T3 Functions of a Landing
gear
viii) support aircraft on ground
ix) absorb the shock of landing
x) provide a provision for braking
xi) provide a provision for steering
xii) provide mobility on ground
xiii) dampen noise and vibration during taxiing
15.1.04T4 Materials used in
construction of landing
gear
i) steel
ii) magnesium
iii) aluminium alloy
15.1.04T5 Safety precautions
 Practice

15.1.04P0 Specific Objectives

By the end of the sub-module unit, the trainee should be able to :
a) wire lock landing gear fasteners
b) identify materials for landing gear construction
Content
15.1.04P1 Wire locking
15.1.03P2 Identification of
materials
i) steel
ii) aluminium alloys
iii) magnesium alloys

Suggested Teaching/Learning Activities

- Taking notes
- Discussion

Suggested Teaching/Learning Resources

- Aircraft landing gear
- Aircraft brakes
- Charts
- Aircraft model
- internet

Suggested Evaluation Methods

- Oral tests
- Timed written tests
- Timed practical tests
- Assignments

15.1.05 CONTROL
SURFACES

15.1.05C Competence
The trainee should have the ability to identify various controls and their use

Theory

15.1.05T0 Specific Objectives

By the end of the sub-module unit, the trainee should be able to:
a) explain the construction of control surfaces
b) categorize the flight control surfaces
c) describe the operation of the surfaces
d) state safety precautions

Content
15.1.05T1 Construction of Control surfaces
i) truss type
ii) semi-monocoque
15.1.05T2 Classification of control
surfaces
i) primary
ii) secondary
iii) auxiliary
iv) non-conventional
v) cannard
15.1.05T3 Operation of control
surfaces
i) cable operated
ii) push pull operated
15.1.05T4 Safety precautions

Practice

15.1.05P0 Specific Objectives

By the end of the sub-module unit, the trainee should be able to :
a) identify various control surfaces
b) operate controls
Content
15.1.05P1 Identifying control
surfaces
i) ailerons
ii) elevators
iii) rudder

Suggested Teaching/Learning Activities

- Taking notes
- Discussion
- Demonstration

Suggested Teaching/Learning Resources

- control surfaces
- Charts
- Aircraft model
- Tools
- Sheet metal

Suggested Evaluation Methods

- Oral tests
- Timed written tests
- Timed practical tests
- Assignments

15.1.06 MATERIALS FOR

AIRFRAME
CONSTRUCTION

15.1.06C Competence
 The trainee should have the ability to identify airframe construction materials and state
their properties

Theory

15.1.06T0 Specific Objectives

By the end of the sub-module unit, the trainee should be able to;
a) explain properties of airframe materials
b) classify airframe materials
c) identify airframe materials and their applications

Content
15.1.06T1 Properties of materials
i) mechanical
ii) chemical
iii) physical
15.1.06T2 Classification of
materials
i) non-metals
ii) metals
iii) composites
15.106T3 Application of airframe
materials
i) wood
ii) plastics
iii) aluminium alloys
iv) magnesium alloys
v) titanium alloys
vi) steel alloys
vii) composites
viii) ceramics
ix) fabrics

Practice

15.1.06P0 Specific Objectives

By the end of the sub-module unit, the trainee should be able to identify materials for
airframe construction

Content
15.1.06P1 Material identification
i) wood
ii) plastics
iii) aluminium alloys
iv) magnesium alloys
v) titanium alloys
vi) steel alloys
vii) composites
viii) ceramics
ix) fabrics
 Suggested Teaching/Learning Activities
- Taking notes
- Discussion
- Demonstration

Suggested Teaching/Learning Resources

- Text books
- Material samples
- internet

Suggested Evaluation Methods

- Oral tests
- Timed written tests
- Timed practical tests
- Assignments

15.1.07 FLYING CONTROL

SYSTEM

15.1.07C Competence
The trainee should have the ability carry out inspections and maintenance on the flight
control system

Theory

15.1.07T0 Specific Objectives

By the end of the sub-module unit, the trainee should be able to:
a) explain the construction of a mechanical flight control system
b) describe the operation of mechanical flight control system
c) explain the maintenance on the control
d) State the safety precautions to be observed during system maintenance

Content
15.1.07T1 Construction of flight control system
i) control cables
ii) control rods
iii) turn buckles
iv) chains and cables
v) temperature compensator, fair lead and pulley
vi) primary and secondary stops
vii) bellcranks
viii)control column
ix)rudder pedals
15.1.07T2 Operation of a flight
control system
i) manual operation
ii) power assisted
iii) fully powered
15.1.07T3 Maintenance
i) inspection
ii) operation
iii) security
iv) corrosion
v) cable tension
vi) syncronising of controls
vii) balancing the controls
viii) control surface travel
15.1.07T4 Safety precautions

Practice

15.1.07T0 Specific Objectives

By the end of the sub-module unit, the trainee should be able to :
a) test cable tension
b) measure control surface travel
c) inspect flight control system

Content
15.1.07P1 Cable tension test
15.1.07P2 Control surface travel
measurement
15.1.07P3 Control system
inspection
i) corrosion
ii) security
iii) operation

Suggested Teaching/Learning Activities

- Taking notes
- Discussion
- Demonstration
- Illustration

Suggested Teaching/Learning Resources

- text books
- internet
- rigging board
- inclinometer
- control cables
- tensiometer

Suggested Evaluation Methods

- Oral tests
- Timed written tests
- Timed practical tests
- Assignments
15.1.08 STATION
IDENTIFICATION

15.1.08C Competence
The trainee should have the ability to identify locations of different components on the
aircraft

Theory

15.1.08T0 Specific Objectives

By the end of the sub-module unit, the trainee should be
able to:
a) define aircraft station identification
b) identify aircraft zoning as specified in the ATA – 100 specification
c) explain the purpose of stations and zones

Content
15.1.08T1 Station identification
systems
i) fuselage stations
ii) wing stations
iii) buttline
iv) waterline
15.1.08T2 Zoning aircraft
structure
i) major zones
ii) major sub-zones
iii) zones
15.108T3 Purpose
i) locating components
Practice

15.1.08P0 Specific Objectives

By the end of the sub-module unit, the trainee should be able to interpret drawings in the
manuals to locate components

Content
15.1.08P1 Interpret the drawings
and locate components
on the aircraft

Suggested Teaching/Learning Activities

- Taking notes
- Discussion
- Demonstration
- illustration

Suggested Teaching/Learning Resources

- Text books
- Aircraft manual
- Model aircraft
 Suggested Evaluation Methods
- Oral tests
- Timed written tests
- Timed practical tests

15.1.09 STRUCTURAL
DAMAGES

15.1.09C Competence
The trainee should have the ability to carry out service, maintenance and repair on aircraft
structures

Theory

15.1.09T0 Specific Objectives

By the end of the sub-
module unit, the trainee should be able to:
a) classify structures and damages
b) describe types of repair to be carried out
c) observe safety precautions during the servicing

Content
15.1.09T1 Structure and damage
classification
i) structures
- primary
- secondary
- tertiary
ii) damage
- negligible damages
- minor damages
- major damages

15.1.10T2 Types of repair

i) negligible repair
ii) repair by patching
iii) repair by insertion
iv) repair by replacement
15.1.10T3 Observe safety precautions during repairs

Practice

15.1.10P0 Specific Objectives

By the end of the sub-module unit the trainee should be able to carry out minor repairs on
aircraft structures

Content
15.1.09P1 Repairs
i) overlap patches
ii) insert patches
 iii) riveting

Suggested Teaching/Learning Activities

- Taking notes
- Discussion
- Demonstration
- Illustration

Suggested Teaching/Learning Resources

- Text books
- Aircraft structural repair manual
- Aluminium sheet metal
- Riveting tools

Suggested Evaluation Methods

- Oral tests
- Timed written tests
- Timed practical tests

15.1.10 AIRCRAFT
MANUALS

15.1.10C Competence
The trainee should have the ability to use relevant aircraft manuals

Theory

15.1.10T0 Specific Objectives

By the end of the sub-
module unit, the trainee should be able to:
a) list aircraft manuals used in aircraft maintenance
b) explain the Contents and application of different types of manuals
Content
15.1.10T1 Manuals used in aircraft
maintenance
i) structural repair manual
ii) aircraft maintenance manual
iii) illustrated parts catalogue
iv) aircraft wiring diagram
v) overhaul manual
vi) other approved aircraft manuals
15.1.10T2 Contents and
Application of
i) aircraft
ii) maintenance
iii) manuals
iv) procedure to be used
v) ii) tools to be used
vi) iii)materials to be used
vii) drawings
 viii) component location
ix) support methods
x) material treatment

Practice

15.1.10P0 Specific Objective

By the end of the sub-module unit, the trainee should be able to identify aircraft manuals

Content
15.1.10P1 Identify different types
of manuals

Suggested Teaching/Learning Activities

- Taking notes
- Discussion
- Demonstration
- Illustration

Suggested Teaching/Learning Resources

- Text books
- Aircraft manuals

Suggested Evaluation Methods

- Oral tests
- Timed written tests
15.1.11 ROTOR CRAFTS

15.1.11C Competence
The trainee should have the ability to inspect and maintain rotor craft structures

Theory

15.1.11T0 Specific Objectives

By the end of the sub-
module unit, the trainee should be able to:
a) describe the construction of the rotor craft
b) explain the rotor systems
c) explain the rotor craft control systems

Content
15.1.11T1 Construction
i) fuselage
ii) tailboom
iii) rotor blades
15.1.11T2 Rotors systems
i) rigid
ii) semi-rigid
iii) fully articulated
15.1.11T3 Control systems
 i) cyclic pitch control
ii) collective pitch control
iii) tail rotor control
iv) power control
15.1.11T4 Inspection and
maintenance

Suggested Teaching/Learning Activities

- Taking notes
- Discussion
- Demonstration
- Illustration

Suggested Teaching/Learning Resources

- Text books
- Charts
- Model rotor craft

Suggested Evaluation Methods

- Oral tests
- written tests
- practical tests

15.1.12 FUEL STORAGE

15.1.12C Competence
The trainee should have the ability to carry out maintenance on aircraft fuel tanks

Theory

15.1.12T0 Specific Objectives

By the end of the sub-module unit, the trainee should be able to :
a) identify types of aviation fuels
b) describe the construction of different types of aircraft fuel tanks
c) carry out maintenance on fuel tanks
d) observe precautions during maintenance of aircraft fuel tanks

Content
15.1.12T1 Types of aviation fuels
i) aviation gasoline
ii) aviation turbine
15.1.12T2 Types of fuel tanks
i) rigid removable fuel tanks
ii) flexible fuel tanks (bladder type)
iii) integral fuel tanks
15.1.12T3 Maintenance of aircraft
fuel tanks
15.1.12T4 General safety
precautions
i) working in and on fuel tanks
 ii) refuelling and defueling
Practice

15.1.13P0 Specific Objectives

By the end of the sub-module unit, the trainee should be able to identify aircraft fuels and
tanks

Content
15.1.13P1 Identify types of fuel
tanks

Suggested Teaching/Learning Activities

- Taking notes
- Discussion
- Demonstration
- Illustration

Suggested Teaching/Learning Resources

- Text books
- Aircraft tanks

Suggested Evaluation Methods

- Oral tests
- Timed written tests
- Timed practical tests