The semi-finished aircraft floor panel – and its pros and cons

An increasingly popular option for floor panels is the semi-finished product. These floor panels are boards of a standard measurement (such as Airbus’ 1.9m x 2.95m boards) which are supplied to the airline in a pre-cut condition. Two or three floor panels can be cut from just one board, depending on the supplier and application area. A single Airbus semi-finished board will yield up to three panels.

Inserts and hardpoints for fitting the panel to the floor structure are also provided or purchased separately. Airbus offers improved Torlon inserts, completely reducing the risk of micro corrosion on the floor structure. It has also implemented new and improved potting processes.

As an alternative to finished panels, semi-finished panels can boast the following features.

5 important factors about semi-finished aircraft floor panels

Increased robustness: Some semi-finished panels on the market are more robust – and longer-lasting – because a smaller honeycomb composition is used, providing greater compression and higher impact resistance.
Cross-solution: An important advantage of Airbus’ semi-finished panels is that they are a cross-solution for a number of aircraft in the Airbus family. A semi-finished floor panel bought for an A320 can also be used for an A350, A380 and an A330, for example. Instead of requiring a dedicated finished panel for one ‘head of version’ aircraft, the semi-finished panel is a single repair solution for multiple aircraft, positively impacting the administration and handling of panels. They can even support aircraft now out of production, such as the A380.
100 percent availability: Another significant benefit of this option is that it provides 100 percent availability, enabling operational flexibility. By having one board in stock, up to three panels are immediately available for repair or retrofit as soon as they are cut. This means there are no lead time issues for the airline and maintenance duration can be considerably reduced.
Complete aircraft coverage: Airbus’ semi-finished solutions cover the complete aircraft layout and are 100 percent installable. They will be repairable to the same standards as finished floor panels and follow existing repair procedures.
Affordability: Semi-finished floor panels are often a more affordable option, being competitively priced and less expensive than their finished-panel counterparts. They can be a cost-savings option given their higher usability, particularly those from which three panels can be cut.

Disadvantages of the semi-finished aircraft floor products

One disadvantage of the semi-floor panel is that it needs to be cut to size. It is not ready for installation, so will involve time and resources. And today, it is not a replacement solution but a pure repair solution, in that a semi-finished panel will only be used when a normal panel is damaged. However, this may change in the future.

In addition, the strength and robustness of the semi-finished floor panel mean that they are heavier than finished panels. Within the semi-finished panel market, however, some products are lighter than others and the increased weight of Airbus’ semi-finished panel is not significant and can be balanced by carrying less fuel. Moreover, there are cargo panels for both the container area and the bulk area currently under development for the A320 Family, A330, A340, A350, A380. Additionally, a passenger light variant (seat, aisle and galley) will be developed for the A320 family.

The grey market in aircraft flooring

While these options are available from qualified suppliers, such as the panels that receive the Airbus stamp, a grey market for the production of both finished and semi-finished floor panels also operates.

Highly customised floor panel derivatives, similar to Airbus floor panels, for example, are available on the market.

Floor panels made by holders of Parts Manufacturer Approvals (PMA) can be sourced. But while PMA holders have received, for example, FAA approval for both design and production of the floor panels, they do not bear the Airbus stamp of quality and performance.

Similarly, Supplementary Type Certificates (STC) may be granted by local authorities for floor panels that are based on the Airbus qualified product, but also do not carry the Airbus stamp of quality and performance. As such, the use of these uncertified panels by an airline carries a risk.

The Satair Takeaway

Floor panels are important supporting structures that must be strong enough to withstand use over time. The finished floor panel is a good option, particularly for those with contractual, guarantee or insurance obligations.

The semi-finished option is a very robust, less expensive option that has the added benefit of being usable for multiple aircraft types and covering the complete aircraft layout. Importantly, it is immediately available, reducing maintenance downtime. Those semi-floor panels that are produced with the Airbus stamp guarantee that they meet or exceed all current standards, quality and performance.

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Flooring it: What options are available for aircraft floor panels?