Appendix C APPENDIX C. DEFINITIONS RELATED TO AIR CARGO OPERATIONS C.1 Active Unit Load Devices (ULD). ULDs with active temperature control systems for transporting temperature-sensitive cargo. These systems consist of a highly insulated container with a battery-operated heating/cooling system integrated into the construction of the container.
Active ULDs are intended to be operating during flight. Active ULDs are battery-powered in flight and are only recharged while on the ground. The “active” component of these units typically consists of a vapor cycle refrigeration/heat pump type system that is powered by various types of large batteries, depending on the manufacturer.
C.2 Aircraft Loading Schedule. The loading schedule is used to document compliance with the certificated Weight and Balance (W&B) limitations contained in the manufacturer’s Aircraft Flight Manual (AFM) and W&B manual (WBM). The loading schedule is developed by the operator based on its specific loading calculation procedures and provides the operational limits for use with the operator’s W&B program accepted under this AC.
C.3 Approved Parts. Unless used with reference to another person, means parts approved by the Administrator.
C.4 Cargo. For the purpose of this AC, cargo refers to passenger-checked baggage, freight, Company Materials (COMAT), special cargo, and hazardous materials (hazmat). Cargo does not include passenger carry-on baggage.
C.5 Cargo Handling. An operator’s methods of accepting, weighing, securing, transporting cargo on the ground, and the loading and unloading of an aircraft.
C.6 Cargo Loading System (CLS). Equipment installed to the floor of an aircraft cargo compartment to restrain aircraft ULDs against the ground/flight loads. It usually consists of such items as rollers, side guides, and locks for securing ULDs to the aircraft structure. It does not include ULDs, barriers and tiedown straps.
NOTE: The CLS is certified as part of either the aircraft’s type certification (TC) or a Supplemental Type Certificate (STC).
C.7 Certified Restraint Straps. These devices should meet the requirements of TSO-C172, Cargo Restraint Strap Assemblies. In it, the FAA describes the minimum performance standards (MPS) by which cargo restraint strap assemblies are approved and identified with applicable TSO markings.
C.8 Certified Unit Load Device (ULD). A ULD meeting the requirements of TSO-C90, Cargo Pallets, Nets and Containers (Unit Load Devices), as amended; STC requirements, if applicable; or other FAA-approved certification standards.
C.9 Company Materials (COMAT). Company material, commonly called COMAT, is an industry term used by operators to describe nonrevenue materials and supplies owned by the operator that are shipped by the operator in support of its operations.
Appendix C
Page 2 C.10 Dunnage. Materials used to support and protect cargo in an aircraft cargo compartment or padding used in a shipping container to protect the container’s contents.
C.11 Dynamic Load. Loads imparted on the structure of the aircraft by loaded cargo during taxi, takeoff, cruise, and landing.
C.12 First Article Inspection. Inspection of the first of a manufactured component to ensure compliance with certification and airworthiness requirements.
C.13 Floating Pallet. ULD positioned over one or more pallet position and not fully restrained by the aircraft ULD restraint system, but restrained to the aircraft structure by means of strapping to tiedown fittings.
C.14 Frangible (Compressible) Cargo. Aircraft manufacturer’s W&B documents vary on this definition; therefore, you should reference their document.
C.15 Freight Staging. The holding of cargo awaiting transportation and the delivery of cargo to the aircraft in the right sequencing of cargo according to the load plan.
C.16 Hazardous Materials (hazmat). Materials or substances meeting the definition of hazardous material in Title 49 of the Code of Federal Regulations (49 CFR) part 171, § 171.8.
C.17 Interlining. Transfer from one operator to another, whether the same or different aircraft types are used. For example, a ULD transferred from a domestic operator to a foreign operator.
C.18 Load Supervisor. An operator-determined name, such as loadmaster or load lead, identifying the job function of the person with overall responsibility for supervising the loading of the aircraft. This person is responsible for signing the load manifest. Refer to Title 14 of the Code of Federal Regulations (14 CFR) part 121, § 121.665, Load Manifest.
C.19 Non-certified Unit Load Device (ULD). A ULD that is not certified by the ULD manufacturer, does not meet the TS-O C90 or Parts Manufacturer Authority (PMA) certification requirements, and/or is not listed in the OEM aircraft WBM (TC or STC).
C.20 Offset Cargo. Cargo positioned on the pallet in a manner that the cargo is shifted beyond the perimeter of the pallet resulting in either 1) the center of gravity (CG) limits of the pallet being exceeded, or 2) the restraint by the net to the pallet becoming ineffective in protecting the aircraft and preventing cargo shift.
C.21 Overweight Cargo. Cargo that exceeds the maximum allowable weight as defined by the aircraft WBM for aircraft ULD position.
C.22 Overhang Cargo. Cargo that extends beyond the perimeter of the pallet in at least one direction but still allows the net to perform its intended function. The pallet can still be restrained by the CLS and does not require additional straps to the aircraft structure.
Appendix C C.23 Outsized Cargo. Cargo that exceeds the maximum allowable contour of an aircraft ULD such that the ULD must be loaded on board an aircraft as a non-CLS restrained ULD.
C.24 Pallet (Air Cargo). A flat platform with flat under-surface of standard dimensions, on which cargo is assembled and secured and which interfaces directly with the aircraft handling and restraint system.
C.25 Piercing Cargo. Piece of cargo of a piercing or penetrating nature, such as rods, pipes, extrusions, beams, etc., that could become a projectile hazard under flight operational loads.
C.26 Pod. An external container attached to an aircraft for carrying cargo.
C.27 Primary Restraint. The restraint of the cargo payload to the aircraft structure for flight and other loads.
C.28 Rigid Cargo. Cargo with a density that is rigid in nature, as defined in the aircraft manufacturer’s W&B document.
C.29 Sharp Cargo. Cargo that has a piercing or penetrating nature, or cargo with sharp edges or corners.
C.30 Special Cargo. Cargo not contained in a ULD certified for the airplane CLS or not enclosed in a cargo compartment certified for bulk loading is special cargo. This type of cargo requires special handling and securing/restraining procedures.
C.31 Special Handling Procedures. Additional or unique procedures, as determined by the operator, which may be required for some cargo in order to protect the cargo or the aircraft during handling acceptance, loading, or in flight. Hazmat must be handled per regulatory requirements.
C.32 Supernumeraries. Persons that are not members of the crew, who are carried on board all-cargo aircraft that do not comply with all passenger-carrying requirements of part 121.
C.33 Supplemental Restraint. Restraint that is utilized in addition to primary restraint in order to stabilize cargo and prevent shifting.
C.34 Tall Rigid Cargo (TRC). Tall cargo is cargo greater than 98 inches tall. Certain sections of tall cargo can be frangible and certain sections can be rigid. If any part of the rigid section of tall cargo is above 98 inches, the tall cargo is TRC. TRC is only applies to the Boeing 747 aircraft.
C.35 Tare Weight. The weight of the empty ULD, including its normal complement of loading restraint devices. Also, the empty weight of other material handling equipment
(e.g., baggage carts and dollies) used to weigh cargo on a scale.
C.36 Temporary Restraint Device. Temporary net restraint fittings installed in place of damaged or missing fittings, or temporary net take-up hooks and net corner lashing lines.
Appendix C
Page 4 C.37 Unit Load Device (ULD). A device for grouping, transferring, and restraining cargo for transit. It may consist of a pallet with a net or it may be a container.
C.38 Unitized. Consolidated multiple packages or items loaded into or on a ULD.
C.39 Vendor. Any person or entity performing a service for the operator. This includes, but is not limited to, a freight forwarder, service providers, contractor, subcontractors, customs brokers, shipper, and another operator that performs cargo buildup, aircraft loading, and unloading for the operator. This also includes repair services provided by an FAA-certificated entity.
C.40 Zone Weight. Cumulative weight as loaded within a designated zone within the aircraft such as a specific area on the upper deck cargo area plus the cargo loaded on the lower deck directly beneath.
Appendix D Page 1 (and 2) APPENDIX D. ACRONYMS AND ABBREVIATIONS 14 CFR Title 14 of the Code of Federal Regulations AC Advisory Circular AD Airworthiness Directive AFM Airplane Flight Manual CASS Continuing Analysis and Surveillance System CFR Code of Federal Regulations CG Center of Gravity CLS Cargo Loading System CMM Component Maintenance Manual COMAT Company Material CRAF Civil Reserve Air Fleet DER Designated Engineering Representative FAA Federal Aviation Administration hazmat Hazardous Materials IATA International Air Transport Association ICA instructions for continued airworthiness ISO International Organization for Standardization MEL Minimum Equipment List MPS Minimum Performance Standard NAS National Aerospace Standard NIST National Institute of Standards and Technology NTSB National Transportation Safety Board OEM Original Equipment Manufacturer PC Production Certificate PMA Parts Manufacturer Approval SAE Society of Automotive Engineers SB Service Bulletin SCAF Special Cargo Analysis Function STC Supplemental Type Certificate TC Type Certificate TRC Tall Rigid Cargo TSO Technical Standard Order ULD Unit Load Device
Appendix E APPENDIX E. SUGGESTED STRUCTURAL DATA FOR PASSENGER-TO-CARGO
CONVERSION PROJECT An applicant should submit the following data to the Federal Aviation Administration (FAA) as structural substantiation in support of a passenger-to-cargo conversion project. This list is not all-inclusive, and each project should be individually evaluated to determine if additional data are necessary. The applicant and the approving authority representative should come to an agreement on the necessary data early in the program as part of the certification plan.
NOTE: Documents with an asterisk (*) are required by Title 14 of the Code of Federal Regulations (14 CFR).
E.1 Aircraft Flight Manual (AFM).* Identifies all operating limitations, including operating speeds and door operation, and contains allowable aircraft fuel and cargo loading directly or by reference. Any additional information necessary to safely operate the aircraft should also be provided.
E.2 Aircraft Loading Document.* Describes the types of cargo containers allowed, how the containers are restrained, and loading requirements when latches are missing or broken. This may be contained in the Weight and Balance (W&B) manual. Ensures compatibility of the cargo loading system (CLS) with the cargo conversion. These modifications have often been incorporated independent of each other. In addition, if the use of tiedown fittings is permitted, the tiedown strength and limitation data should be provided.
E.3 Assembly/Installation Drawings.* Details how all parts are assembled and identifies the number and types of fasteners used.
E.4 Cargo Restraint System. Designed for all critical ground, flight, and emergency landing loads. This includes seat tracks, pallet locks, side restraints, and roller trays. The 9G rigid barrier or cargo restraint net, if required, and its attachment, and the fuselage surrounding structure must be analyzed for critical payloads.
E.5 Certification Plan. Lists all steps necessary to complete FAA certification of the modification. At a minimum, the plan should discuss scope of the project, schedule, use of Designated Engineering Representatives (DER), data submittals, and conformity issues.
E.6 Compatibility Evaluation. The applicant evaluates each aircraft to be modified to ensure it is compatible with the Supplemental Type Certificate (STC) modification. The applicant also identifies and evaluates modifications, alterations, or the incorporation of other STCs that change the type design of the aircraft to be modified. The applicant notes and makes accommodations for differences and necessary drawing changes.
E.7 Compliance Checklist. Lists all applicable rules from the certification basis of the modification of the aircraft. Also identifies necessary compliance with outstanding Airworthiness Directives (AD) and the methods of compliance.
E.8 Configuration Deviations.* Lists all nonconformities with their engineering dispositions.
Appendix E
Page 2 E.9 Damage Tolerance Assessment (DTA).* Required for all 14 CFR part 25 post-Amendment-45-certified aircraft. The applicant should create a DTA for pre-Amendment-45 aircraft in support of a supplement to a standard that is required by an AD.
The DTA should evaluate whether an existing principal structural element has been changed or if one has been created by the modification. Fail-safe requirements should be addressed as necessary.
E.10 Decompression Analysis. The substantiation must show that the cargo compartment is designed to withstand the effects of a sudden release of pressure. Consider impact of solid 9G barrier in decompression scenarios (part 25, § 25.365(e); Civil Air Regulations (CAR) 4b.216(c)(4)).
E.11 Design Criteria. A list of design, analysis, and production methodologies, and requirements used in creating the modification.
E.12 Detail Drawings.* There should be a detail drawing for each part manufactured for use in the modification and some means of controlling the source of all vendor-supplied items.
E.13 Door Mechanical Systems. The applicant analyzes the door opening, latching, and locking mechanisms for most critical loads, which should include maximum hydraulic actuator output and possible jam conditions.
E.14 Door Surround Structure. The door surround structure must be analyzed for the redistributed loads resulting from the door cutout. This includes the fuselage skin, doublers, sills, headers, footers, surrounding frames, and longerons/stringers, latches, and their attachments. An analysis of the door and the door hinge should also be included.
E.15 External Loads Analysis.* Should include most critical aircraft weight distribution at both minimum and maximum weights and critical loading throughout the center of gravity (CG) range, including raised vertical CG, and must consider all points within the operating envelope (that is, gust and maneuver). External loads should also include the effects of loads on pallet locks, load impingement on main deck floors by lower deck, unrestrained cargo, and shift in unit load devices (ULD) or bulk load cargo CG locations consistent with pallet approvals and usage.
E.16 Final Documentation. Documentation showing that all structural margins are positive for the critical load case.
E.17 Floors. The floor beams, fuselage frames, and posts/struts should be analyzed for the most critical loading conditions.
E.18 Flutter Substantiation.* A cargo conversion can change the fuselage stiffness or change the mass distribution, which can have an effect on the aircraft’s flutter characteristics, particularly aft cargo doors.
E.19 Functional Check.* Performed to ensure proper operation of the main cargo door. The number of open-close cycles are to be decided upon with the aircraft certification office. The test
Appendix E could include determining the mean time between failure of components, validating the failure modes and effects analyses, and monitoring the wear of latches (§ 25.1301, CAR 4b.601).
E.20 Identification of Supplemental Type Certificate (STC) Team Members. Identify STC team members and DERs whose experience is commensurate with these kinds of projects (that is, external loads, systems safety assessment, finite element modeling, and validation).
E.21 Illustrated Parts Catalog. Catalog of all parts contained in the STC for procurement purposes.
E.22 Installation Instructions. Any installation instructions necessary other than what is listed in the installation drawings. Ensure that there are adequate instructions for the installation of cargo compartment liners and floor panels to minimize the use of a shop practice that may result in blind drilling of holes that could induce damage (double-drilled holes and short-edge margins) to floor beam caps and fuselage frames.
E.23 Instructions for Continuous Airworthiness (ICA). ICAs are a set of instructions as referenced in 14 CFR part 21, § 21.50, Instructions for continued airworthiness and manufacturer’s maintenance manuals having airworthiness limitations sections; and part 25, § 25.1529, Instructions for continued airworthiness, of the regulations that provide information on how to properly maintain a product in an Airworthy condition, including any inspections or other procedures, as necessary, to prevent catastrophic failure of the product. Without acceptable ICAs, a product cannot be maintained in an Airworthy condition. Order 8110.54 provides additional information on the scope of the ICA to be considered as a function of the original design and/or modifications to a transport aircraft.
E.24 Internal Loads Analysis.* Distribution of loads within the affected airframe structure.
Load distribution should be validated.
E.25 Maintenance Instructions.* Continued airworthiness requirements for the inspection program, which includes the frequency and extent of those inspections.
E.26 Maintenance Manual.* Instructions for continued airworthiness of the modifications.
E.27 Master Data List. Lists all process specifications and reports that substantiate the structural strength and damage tolerance of the modification, along with all test reports (that is, flutter, pressurization, finite element method (FEM) validation).
E.28 Master Drawing List.* Controls all drawings and process specifications that define design of the modification.
E.29 Methodology Description. Describes the methodology used to define (1) the barrier load distributions and intensities and distribute the barrier loads to the monocoque, and (2) the ULD load distributions and intensities and distribute the loads to the restraint system components and floor.
E.30 Pressure Test.* The structure must be designed to withstand (limit load) the maximum pressure relief valve setting combined with flight loads (§ 25.365(a), CAR 4b.216(c)(1)), and the
Appendix E
Page 4 maximum relief valve setting omitting other loads times a factor of 1.33 or 1.67, as appropriate (§ 25.365(d), CAR 4b.216(c)(3)). If the modification or conversion involves changes to the pressure barrier, such as a new door installation, it must be pressure tested per § 25.843 or CAR 4b.376.
E.31 Structural Repair Manual. Instructions for repair of the modifications.
E.32 Structural Substantiation.* Positive margins of safety should be shown for all modified structures. Assumptions used in any analysis or test must be consistent with how the loads are applied and the way the structure carries these loads. A margin of safety table should be published for each structural analysis.
E.33 Weight and Balance (W&B) Manual.* Describes aircraft fuel and payload distributions and CG restrictions. Defines applicable ULDs. Provides any other relevant information necessary for the safe operation of the aircraft.
Appendix F APPENDIX F. PASSENGER-TO-CARGO CONVERSIONS SUPPLEMENTAL TYPE
CERTIFICATE DATA PACKAGE FOR SYSTEMS AND EQUIPMENT F.1 An applicant should submit the following information to the Federal Aviation Administration (FAA).
F.1.1 Certification Plan. Helps determine the scope of the conversion project, that is, full passenger-to-cargo conversion, cargo door-only conversion, or smoke detection system-only conversion, and whether supernumeraries are included. A systems description document may have been included in the certification plan, system failure modes, and effects analyses. It is likely that safety analyses were not prepared; you may have to learn about the system based on drawings and diagrams.
F.1.2 Compliance Checklist. Helps determine methods to comply to all applicable Title 14 of the Code of Federal Regulations (14 CFR)/Civil Air Regulations (CAR).
F.1.3 Master Data List/Top Drawing List. Helps link the Supplemental Type Certificate (STC) drawings/reports down to detailed levels.
F.2 Based on, or lacking, the above data, the following areas should be reviewed for the conversions to determine that the modifications are safe:
F.2.1 Cargo Door. Should include:
F.2.1.1 Safety analyses (including any latch/lock/pin failures that could cause door to unlock);
F.2.1.2 Drawings;
F.2.1.3 Wiring qualification (flammability);
F.2.1.4 Wiring diagrams/schematics;
F.2.1.5 Electrical load analysis;
F.2.1.6 Hydraulic components qualification test;
F.2.1.7 System pressure proof/burst test;
F.2.1.8 Any conformity reports (parts, test article, installation);
F.2.1.9 Flammable fluid fire protection;
F.2.1.10 Aircraft Flight Manual (AFM) and limitations;
F.2.1.11 Cargo door opening, closing, and locking mechanisms, including vent door design with its associated power sources (electrical, hydraulics, mechanical), door opening retention system safety during cargo loading, and system isolation during flight; and