How Regulatory Changes in the Aviation industry Affect Container Design

Q&A with Americase’s Steve Arnold, Industrial Sales Engineer & Mike Pagel, Sr. HazMat Safety Consultant

Question #1: What regulatory changes in the aviation industry have driven the need for redesigning cargo containers?

The ATA 300, which has been published in 1960, has three categories.

Category 1 allows for a minimum of 100 round trips. Category 2 permits a minimum of 10 trips. Category 3 is designed for single-use and only needs to survive one trip. The category you qualify for depends on the construction of the case.

Within the ATA 300 regulation, there’s also a drop test requirement. For a container to maintain Category 1 status, it must endure 280 drops from a height of 30 to 36 inches. These drops are done on the case’s face, sides, and edges. After the test, the container must still be lockable and functional. For Category 2, the requirement is reduced to 80 drops, while Category 3 may not have a drop test at all, as it’s designed for single-use.

Question #2: How do safety and compliance standards impact the materials and structural integrity of aviation containers?
One significant regulatory change stems from the tragic ValueJet incident in the mid-1990s. A fire on an aircraft, caused by improperly stored oxygen generators, led to new regulations. These regulations required oxygen generator containers to pass flame and heat resistance tests. That event, although decades ago, still influences industry standards today.

More recently, there’s been an ongoing regulatory initiative related to lithium battery packaging. The SAE G27 committee is working on a standard that will likely require packages shipping lithium batteries by aircraft to contain hazards associated with thermal runaway. Although this standard hasn’t been adopted yet, it’s expected to be implemented in the next two to six years. It will necessitate packages capable of containing fire, projectiles, and flammable off-gases during a thermal runaway. These are performance standards, meaning the material used for the package—whether metal, plastic, or fiberboard—must pass the required containment tests.

Lithium battery thermal runaway is highly volatile, producing extremely high temperatures and flames. While fiberboard packaging might technically qualify, it’s unlikely to meet these performance criteria. We anticipate a shift toward more robust materials like aluminum cases, which are better suited for containing such hazards. Aluminum containers, often paired with advanced fire-resistant foams, are likely to become the norm.

Additionally, certain industries, such as defense contractors, impose specific testing requirements like vibration tests, drop tests, and rain tests to prevent water intrusion. These requirements align with military specifications, many of which date back to the 1950s. While those older specifications often cite wood construction, our aluminum cases meet and exceed those standards, making them more reliable and durable.

Question #3: In what ways do regulatory shifts related to carbon emissions and sustainability influence the design and functionality of aviation containers?
Aluminum cases offer numerous advantages over wood or fiberboard. They are lighter, reducing aircraft fuel consumption, and are recyclable without losing material properties. This contributes to environmental benefits alongside their reusability. For example, while fiberboard boxes are typically single-use, aluminum cases can handle over 100 trips, dramatically reducing waste.

The helicopter industry provides a prime example of this. Historically, wooden cases were used to transport $250,000–$1,000,000 blades. However, forklifts frequently caused damage, prompting a shift to aluminum cases, which are far more durable. As a result, our aluminum containers are often described as the ‘tanks’ or ‘Rolls Royce’ of packaging—sometimes over-engineered but consistently exceeding expectations.

In conclusion, while regulatory changes are relatively infrequent, significant updates—like those involving lithium batteries—are on the horizon. At Americase, we remain proactive, ensuring our products are not only compliant but also lead the industry in safety, durability, and sustainability.