آموزش

Structural damage is part of aviation — but deciding how to fix it is where things get interesting.
As maintenance technicians or engineers, we don’t just repair things.
We make decisions that impact airworthiness, dispatch reliability, and sometimes the whole day’s operation.
Let’s break down the types of structural repairs — and why the classification really matters 
 

1. Minor repairs
These are repairs that don’t significantly affect the aircraft’s structure, flight characteristics, or airworthiness.
They follow standard procedures and typically require fewer resources — which makes them quicker and less costly to perform.
That said, “minor” doesn’t always mean simple.
Some still require OEM coordination to provide a temporary or customized solution, especially when there’s no standard repair in the manuals.

What defines a minor repair is that it can be done without altering certification data, requiring special inspections, or using non-standard methods.
 

 2. Major repairs
These repairs do affect airworthiness in a measurable way — for example:
• Structural strength or stiffness
• Weight and balance
• Flight controls or pressurization
• Fatigue life or damage tolerance
They often involve non-standard methods, require engineering approval, and may lead to changes in inspection programs or limitations.
 Major repairs must be performed in approved facilities — most commonly in hangars that have the tools, structures, and authorizations necessary to carry them out properly.
 

 3. Temporary repairs
When a full repair can’t be done immediately — due to time, parts, or manpower — a temporary solution may be approved to maintain dispatchability.
These repairs are always based on approved documentation and are valid for a limited time or number of flights.
 HST (High Speed Tape) is a typical example:
A certified, reinforced material used to temporarily cover minor external damage — commonly used in AOG situations to safely dispatch the aircraft until a permanent repair can be performed.

4. Permanent repairs
These restore the full strength and function of the structure, with no remaining restrictions.
They’re typically scheduled during heavy maintenance checks (like a C-check) — or during longer maintenance stops when sufficient time and access are available, even outside of a hangar, depending on the scope.
Why does it matter?
Because repair classification determines:
 Who can carry it out (technician, engineer, OEM)
✔️ What kind of facilities and tooling are needed
✔️ Whether the aircraft can be dispatched immediately
✔️ And how it’s documented to maintain continued airworthiness
 

Whether you're working on the ramp, inside MCC, or supporting from engineering, these decisions are part of everyday operations.