Presented to: FAA Southern Region By: Light Sport Aviation Branch AFS 610 Date: March 18,19,20, 2008 Federal Aviation Administration CONSENUS STANDARDS

Presented to: FAA Southern Region

By: Light Sport Aviation Branch AFS 610

Date: March 18,19,20, 2008

Federal AviationAdministrationCONSENUS

STANDARDS

Federal AviationAdministration

2ASTM Consensus Standards March 18,19,20, 2008

Consensus Standards

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Regulatory Requirement

• 21.190 (c)– Is the requirement for the manufacturers to list,

state conformance with and for the aircraft to meet the applicable consensus standards.

• 91.327(b)(5)– Is the requirement for all alterations to be in

compliance with the applicable and current consensus standard and authorized by the manufacturer.

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ASTM Standards General

• FAA requires that various subject areas are covered by consensus standards.

• The FAA accepts, not approves, the standards:– Reference Public Law 104-113 (1995)

• The FAA does not require a specific number of standards.

• The FAA does not have veto authority of the standards content or requirements.

• The Industry can and has voluntarily imposed additional standards on themselves: – Engine Standard– Ballistic Parachutes



INDUSTRY & ASTM

• Industry proposed the use of consensus standards and self certification to the FAA during the development of the US Light Sport Aircraft regulation

• Industry explored many systems and concluded that ASTM international provided the best framework and support for our needs and EAA proposed the selection of ASTM to the US community.



About ASTM International• 109 years of developing standards• Developing Voluntary, Full-Consensus Standards for

Materials, Products, Systems & Services World-Wide through Direct-Member participation.

• ASTM International Has Approximately 12,000 Standards Used Internationally.

• ASTM International Standards Reflect the Most Current Technology Because they are Living Documents that are Continually Revised.

• Over 31,000 Members from 130 Countries Participate on ASTM International Committees; users from 175 countries.



140 Technical Committees

EXAMPLES• A01 on Steel, Stainless Steel and Related Alloys• B07 on Light Metals and Alloys• C16 on Thermal Insulation• D01 on Paint• D02 on Petroleum Products and Lubricants

– D02.J0 on Aviation Fuels / D910 Standard Specification for Aviation Gasolines• D20 on Plastics• E28 on Mechanical Testing• F04 on Medical and Surgical Materials and Devices• F24 on Amusement Rides and Devices• F37 on Light Sport Aircraft• F38 on Unmanned Aircraft Systems• F39 on General and Utility Category Aircraft Electrical Wiring Systems• G01 on Corrosion of Metals



Committee F37 StructureCommittee F37 Structure& Product& Product

F37.30Pwd Parachute

F37.20Fixed Wing

F37.40Weight Shift

F37.50Gyroplane

F37.60Lighter than Air

F37.10Sailplane

F37.70Cross Cutting

Issues assigned to each sub-committee

-Design/Performance (D&P)

-Production Acceptance (PA)

-Continued Airworthiness (CA)

-Quality Assurance (QA)



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FAA Notice of Availability

Consensus Standard Topics [See Note 1] Airplanes Gliders

Gyroplanes [See Note 2]

Lighter Than Air

Powered Parachutes

Weight Shift Control

1 Design and Performance F2245-06 F2564-06 F2352-05 F2355-05a F2244-05 F2317/F2317M-05

2 Required Equipment F2245-06 F2564-06 F2352-05 F2427-05a F2243-05 F2457-05

3 Quality Assurance F2279-06 F2279-06 F2449-05 F2353-05 F2240-05 F2448-04

4 Production Acceptance Tests F2279-06 F2279-06 F2449-05 F2356-05a F2242-05 F2447-05

5 Aircraft Operating Instructions F2245-06 F2564-06 F2352-05 F2427-05a F2243-05 F2457-05

6 Maintenance and Inspection Procedures F2483-05 F2483-05 F2483-05 F2483-05 F2483-05 F2483-05

7Identification and Recording of Major Repairs and Major Alterations

F2483-05 F2483-05 F2483-05 F2483-05 F2483-05 F2483-05

8 Continued Airworthiness F2295-06 F2295-06 F2415-06 F2354-05b F2241-05a F2425-05a

9Manufacturers Assembly Instructions [Kit builders only]

F2563-06 F2563-06 F2563-06 F2563-06 F2563-06 F2563-06

Wing Interface Documentation N/A N/A N/A N/A F2426-05a N/A

NOTE 1: Numbered topics are specified by the rule.NOTE 2: Gyroplanes are not eligible for a special light-sport airworthiness certificate.

Accepted ASTM Consensus Standards



Use of NOAs

Use of F37 Standards / Regulatory Framework



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Minimum Equipment

• The minimum equipment requirements are set by the Consensus standards, the manufacturer, and the operating limitations issued with the airworthiness certificate.

• SLSA aircraft are not required to meet 91.205• FAA policy 8130.2 operating limitations states

that 91.205 equipment is required for night and or IFR operations. (This is in addition to ASTM requirements)

• Other part 91 equipage requirements apply, for example:– Transponders (optional equipment)– ELT’s (Mandatory for Airplanes only)



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Maintenance Manuals

• The standard for maintenance and maintenance manuals is the ONE standard that applies to all classes. ASTM F2483

• 21.190(b) requires each aircraft to have “maintenance and inspection procedures.”

• 21.190(c)(4) requires the maintenance and inspection procedures to meet the applicable consensus standard.

• 91.327(c)(1) Requires inspections to be done in accordance with the procedures developed by the aircraft manufacturer.



Maintenance Manuals

• The ASTM standard requires that the manufacture provide among other things the following information in the maintenance and inspection procedures:

• 5.2 Inspection, Repair, and Alterations—Each of the inspections, repairs, and alterations outlined in the maintenance manual shall specifically list:

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Maintenance Manual Cont’

• (1) Recommended special tools to accomplish the task,

• (2) The parts needed to perform the task,

• (3) Type of maintenance, for example, line, heavy, or overhaul,

• (4) The level of certification needed to accomplish the task, for example, owner, A&P, repairman (light sport aircraft) inspection, and repair station,

• (5) Detailed instructions and diagrams as needed to perform the task, and

• (6) Method to test/inspect to verify the task was accomplished properly.

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Maintenance Manual Cont:

• The maintenance manual shall have the following sections:

– General: Listings of general specifications, capacities and instructions on ground handling, servicing and lubrication such as:

• Equipment list• Sources to purchase parts• List of disposable replacement parts; e.g. air filters, fuel filters, oil filters, and

tires• Engine specifications• Weight and Balance information• Tire inflation pressures• Approved oils and capacities• Recommended fastener torque values• General safety information• Instructions for reporting possible safety of flight concerns found during

inspection /maintenance



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Maintenance Manual Cont:

• Inspections • Structures • Engine • Fuel System • Propeller • Utility Systems

• Instruments and avionics

• Electrical system • Structural repair • Painting and coatings • Revisions • Feedback Form



Identification and Recording of Major Repairs and Alterations

• FAA required Consensus standards to address this topic.

• ASTM F2483 is the standard that addresses this for all classes of SLSA aircraft

• 91.327(b)(5)(6)&(7) Requires alterations to authorized by manufacturer, meet the applicable ASTM standard in effect at the time of the modification and document the alteration per the manufacturers instructions.

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ASTM Definitions

• 3.1.10 major repair, alteration, or maintenance—any repair, alteration, or maintenance for which instructions to complete the task is excluded from the maintenance manual(s) supplied to the consumer are considered major.

• 3.1.12 minor repair, alteration, or maintenance—any repair, alteration, or maintenance for which instructions provided for in the maintenance manual(s) supplied to the consumer of the product are considered minor.

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Manufacturers Requirements• 9.1 All major repairs or alterations made to aircraft

subsequent to its initial design and production acceptance testing to applicable ASTM standards and sale to a consumer must be evaluated relative to the requirements of the applicable ASTM design and production acceptance specification(s).

• 9.2 The manufacturer or other entity that performs the evaluation of an alteration or repair shall provide a written affidavit that the aircraft being altered will still meet the requirements of the applicable ASTM design and performance specification subsequent to the alteration.

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Requirements Cont’

• 9.3 The manufacturer or other entity that performs the evaluation shall provide written instructions and diagrams on how, who, and the level of certification needed to perform the alteration or repair.

• 9.3.1 The instructions must include ground and flight testing that complies with the original ASTM production acceptance testing standard, as appropriate, to verify the alteration was performed correctly and the aircraft is in a condition for safe operation.

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Requirements Cont’

• 9.4 The manufacturer or other entity that performs the evaluation shall provide information to the owner of the aircraft for the documentation of the alteration in the aircraft’s records.

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Pilot Operating Instructions

• Standards vary for each class of aircraft, however, each aircraft must have a manual. (Ref. 21.190)

• Many different titles for manual, content is the requirement not the title.




• Airplanes must have the following sections:– General Information

– Airplane and System Descriptions

– Operating Limitations

– Weight and Balance Information

– Performance

– Emergency Procedures

– Aircraft Ground Handling and Servicing

– Required Placards and Markings

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• Powered Parachutes must have the

following sections:– General– Limitations– Emergency Procedures– Normal Procedures– Performance– Weight and Balance– Description of Systems– Handling, Servicing, and Maintenance– Warning Statement “Operator’s Responsibilities”



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Airplanes

• Airplanes must comply with ASTM F2245

• Minimum Equipment Day VFR: – Airspeed indicator (with required markings)– Altimeter– Fuel Quantity Indicator– Tachometer– Engine “Kill” Switch– Engine Instruments Required by Engine

Manufacturer



Airplanes Cont:

• Minimum Equipment night VFR– Everything as required for day and

additional equipment as described in Annex 2 of the ASTM standard

– Attitude Indicator*– Instrument Lights *

– Separate switches for cabin, position, anti-

collision, landing lights and taxi lights.*– *note: these are not required by 91.205

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Airplane Cont:

• Passenger warning placard: “This aircraft was manufactured in accordance with Light Sport Aircraft airworthiness standards and does not conform to standard category airworthiness requirements.”

• “No Intentional Spins” placard, if applicable,

reference POH to see if airplane is approved for

spins.• Each seat must have shoulder harness.• Emergency parachute, if installed, marked per

ASTM 2316-03 (triangular warning signs)



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Airplanes Cont:

• Engines must meet ASTM F2339 or shall be type and

production certificated under FAR-33, JAR-E or JAR-22

Subpart H. Engine data plate should indicate this.

• No self-locking nuts shall be used on any bolt subject to

rotation in operation unless a nonfriction locking device

is used in addition to the self locking device.

• Control system must be shown by functional tests that

it is free from interference, jamming and excessive

friction.



Airplanes Cont:

• Each airplane must meet and maintain throughout its life as a SLSA a minimum useful load requirement:

• In general the requirement is 190 lbs. per seat plus ½ the horsepower in pounds.– Typically this is a minimum useful load of 430

pounds– No alteration may reduce this minimum (Ref

91.327(b)(5)&(6) (note: exception if placed in the Experimental LSA category)

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Powered Parachute

•New class of aircraft and pilot certificate

•Many exist in the field



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Powered Parachutes

• Powered Parachutes must comply

with ASTM 2244

• Minimum Equipment: – Fuel Gauge– Engine Kill Switch– Engine Instruments as Required by

Engine Manufacturer



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Powered Parachute Cont:

• Safety belt and harness; e.g. must have shoulder

restraint

• There must be at least one fuel strainer or filter;

a replaceable filter, accessible for drainage and

cleaning (or both) shall be included in the system.

• Control Systems must be free from jamming,

excessive friction, or excessive deflection when

the maximum pilot forces are applied from the

cockpit.

• Engine does not need to meet a ASTM, JAA or FAA

standard.



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Weight-Shift-Control (Trikes)

Like PPC, weight-shift

control is a new class

of aircraft and pilot

certificate, with many

existing aircraft in the

field as unregistered

(ultralight) aircraft.



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Weight-Shift-Control (Trikes)



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Weight Shift

• Weight Shift aircraft must comply with ASTM 2317

• The standard have the following requirements:

– An Airspeed Indicator.

– Fuel indicator or means to view fuel quantity from the pilot

seat.

– Engine instruments as required by the engine

manufacturer.

– Lap Safety Belts and Shoulder Harnesses.

– If installed, an electrical system shall include a master

switch and overload protection devices.



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Weight Shift-Control Cont:

• Engine, transmission, and propeller must comply

with:

– F 2339, JAR-22 parts H and J, JAR-E, JAR-P, FAR-33,

FAR-35, or;

– For aircraft having a wing loading no greater than 5.12 lb/ft2

(25 kg/m2) or a stall speed (VS0) no greater than 35 kts

(40.3 mph) for wing loadings greater than 5.12 lb/ ft2 (25

kg/m2) a manufacturer, may;

• Elect to use an engine meeting its own design standard that

has been demonstrated by flight test for a minimum of 100

hours on the make and model of aircraft it is being used on.



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Weight Shift-Control Cont:

• The fuel filler must be located outside of the passenger compartment.

Spilled fuel must be prevented from entering or accumulating in any

enclosed part of the aircraft.

• Each fuel tank must be vented.

• A fuel filter accessible for drainage and cleaning or replacement must be

included in the system.

• Fuel lines located in any area subject to high heat must be fire resistant or

protected with a fire-resistant covering.

• There must be a control accessible to the pilot while wearing a seat belt by

which the pilot can effectively shut off the flow of fuel.



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Weight Shift Cont:

• No self-locking nut shall be used on any bolt subject to differential angular motion between the contact surface on the bolt and the contact surface on the nut during taxi, takeoff, flight, and landing unless a non-friction locking device is used in addition to the self-locking device.

• In aircraft with dual controls, it must be possible to operate the throttle and the ignition kill switch from each pilot’s seat.



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Gliders



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Gliders Cont:• Gliders must comply with ASTM F2564

• Minimum Equipment: – Flight and Navigation Instruments:

• Airspeed indicator, and

• Altimeter.

– For a Powered Glider, the Following Powerplant

Instruments:

• Fuel quantity indicator,

• Tachometer (RPM),

• Engine “kill” switch, and

• Engine instruments as required by the engine

manufacturer.



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Gliders Cont:

• Required Placards and Markings:– Airspeed indicator range markings,– Operating limitations on instrument panel, if applicable,– Passenger Warning—“This aircraft was manufactured in

accordance with Light Sport Aircraft airworthiness standards and does not conform to standard category airworthiness requirements,”

– “NO INTENTIONAL SPINS,” if applicable,– Empty weight,– Maximum takeoff weight,– Maximum and minimum weight of crew,– Allowable weight of the load in any luggage area, and– Seat for solo operations of two seated gliders.



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Gliders Cont:

• Engines must meet ASTM F2339 or shall be type and production certificated. Engine data plate should indicate this.

• There must be at least one drain to allow safe drainage. A drainable sediment bowl located at the lowest point in the fuel system may be used instead of the drainable sump in the fuel tank.



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Gliders Cont:

• No self-locking nuts shall be used on any bolt subject to rotation in operation unless a nonfriction locking device is used in addition to the self locking device.

• Control System—Each control must operate easily, smoothly, and positively enough to allow proper performance of its functions. Each control system must have stops that positively limit the range of motion of each movable aerodynamic surface controlled by the system.



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Rotorcraft

•Gyroplane



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Gyroplanes



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Gyroplane Standards

• Although the FAA did not include Gyroplanes in the final rule as eligible for a special airworthiness certificate, the industry did develop standards for these aircraft.

• The standards are not mandatory.• The standards do cover all aspects of

design, manufacturing and continued airworthiness.



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Gyroplane

• May Comply with ASTM F2352• Minimum Equipment:

– Air Speed Indicator– Altimeter– Compass– Engine Instruments as Required by Engine Manufacturer– Fuel Quantity Indicator (can be sight gauge)

• Engine controls must be marked in RED• Occupant Warning Placard stating “This aircraft

was manufactured in accordance with light sport aircraft airworthiness standards and does not conform to standard category airworthiness requirements.”



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Gyroplane Cont:

• Each fuel tank must have a drainable sump and

the fuel system must have a sediment bowl or

chamber.

• Unusable fuel quantity must be identified on

the fuel level indicator.

• Controls must be free from jamming or binding,

excessive friction and excessive deformation

under control load forces specified in the

design specification.



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Pre-rotator



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Lighter Than Air



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Lighter Than Air

• Must meet ASTM standard F 2355• Required Instruments (ASTM F

2427):– Fuel Quantity indicator– Engine Kill Switch– Engine Instruments Required by Engine

Manufacturer

• Two Point Restraint System



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Questions?