Date: 201409
Local time of day: 0601-1200
Location: ZZZ.Airport, US
Light: Daylight
Aircraft: B777-200
Operator: Air Carrier
Operating under: Part 121
Flight phase: Parked
Aircraft component: Reverser Translating Sleeve
Reporter organization: Air Carrier
Reporter function: Technician
Reporter qualification: Maintenance Powerplant; Maintenance Airframe
Human factors: Confusion; Communication Breakdown
Second reporter function: Other / Unknown
Anomaly: Aircraft Equipment Problem Less Severe; Deviation / Discrepancy - Procedural Hazardous Material Violation; Deviation / Discrepancy - Procedural Published Material / Policy
Detector: Person Maintenance
When detected: Routine Inspection
Result: General Maintenance Action
Contributing factors: Human Factors; Staffing
Primary problem: Human Factors

Narrative: I was assigned a Hotbond Repair to a thrust reverser inner wall here at ZZZ. I told supervisor we need an adhesive we don't store here at ZZZ. An order was placed to get adhesive from ZZZ1. The next day; the adhesive arrived at about late morning. It had shipping paperwork with it that had all the info I needed; Company Part Number (CPN); Manufacturer's number; type and class; batch number and hours out of storage. The adhesive sent is a small piece cut from a roll from a storage freezer at ZZZ1. It did not have our Air Carrier's Raw Material Control Form; that form stays with the roll next to the freezer. I had no reason to question the integrity of the material sent; it was dry; clean and well packaged. I can understand why the Raw Material Control Form was not sent; that Form needs to be near the main roll. I used the adhesive in the repair; the repair went well; finished repair and signed off [repair] that same day. The material came into question the following day; when Shop mechanics discovered the improper handling from the day before. The supervisor from ZZZ1 did not follow material handling procedures. [Recommend] Qualified personnel to handle composite material. Send our Raw Material Control Form with the piece; or a copy of it. Technical data not on correct form. Aircraft Out of Service (OTS).

Callback: Reporter stated the fan reverser for their Rolls Royce Trent RB-211 engine was punctured on the inner wall and needed to be repaired. A special sheet of adhesive was needed to perform a hotbond repair of the damaged inner acoustic composite material. The problem was the cold storage adhesive material was shipped by a Supervisor at their Maintenance Overhaul Base who was not qualified to sign-off the Raw Material Control Form or ship the hazardous adhesive material. An Inspector and Mechanic at their Overhaul Base noticed the unqualified signature on the Control Form and raised the issue of hazardous material being shipped by unqualified personnel. The adhesive can be left out of the freezer for 100-hours and still be in serviceable condition. The hotbond repair he accomplished was never an issue.

Second narrative: It has been brought to my attention that a supervisor in Composite Repair shipped composite repair adhesive to ZZZ for a repair on a B777-200 Engine Fan Reverser. The adhesive was not properly handled and never received the proper certification form per our Procedures Manual. Dayshift.


Synopsis: Two Aircraft Maintenance Technicians (AMTs) report about a sheet of hazardous adhesive material that was shipped by a Supervisor not qualified to sign-off their Raw Material Control Forms. The adhesive material was required to repair a punctured fan reverser inner acoustic liner for a B777-200 aircraft.