Hangar Cards — one printed page per course

CertiFlyers · Hangar CardDocumentation, Records & Parts

Aircraft Maintenance Documentation

14 CFR 43.9, 43.11, 91.417 and Part 39

A signature on an incomplete entry equals work not done.

Numbers to remember

4required elements in every 14 CFR 43.9 record entry

43.11inspection entries add the airworthy or unairworthy statement

91.417the Part 91 AD-status rule — AD number, revision date, method, next due (air carriers: 121.380)

60 dayscertificate suspension for one non-compliant avionics entry

$10.2 MSouthwest 2008, proposed penalty — 46 aircraft, 59,791 flights on overdue ADs

47 screwsleft out after a verbal handover — Continental Express 2574, 14 lives

Unlocks when you pass this course

Sums up the course. It does not replace the approved technical data or the maintenance manual.Print on Letter or A4

Take the course: Aircraft Maintenance Documentation →

CertiFlyers · Hangar CardHazardous Materials & Chemical Safety

Global Hazard Communication

OSHA Hazard Communication Standard (HCS) 29 CFR 1910.1200

Read the label and Section 8 before you open the container.

Numbers to remember

1910.1200OSHA Hazard Communication Standard — (f) labels, (g) safety data sheets

16SDS sections — 1–8 for workers and responders, 9–16 technical data

4 · 5 · 6first aid · firefighting · accidental release — the emergency sections

7 · 8handling and storage · exposure limits and PPE — before routine use

< 23 °Cflash point of Category 1 and 2 flammable liquids, such as acetone

≤ 60 °Cflash point ceiling for Category 3 — diesel fuel, turpentine

Unlocks when you pass this course

Sums up the course. It does not replace the approved technical data or the maintenance manual.Print on Letter or A4

Take the course: Global Hazard Communication →

CertiFlyers · Hangar CardHuman Factors & Professional Skills

Human Factors Primer

FAA-H-8083-30, Chapter 14 and AC 120-72A

Distracted, go back three steps; handing over, walk to the work site.

Numbers to remember

80 percentapproximate share of all aviation maintenance errors driven by human factors

20 percentof general aviation maintenance accidents cite installation errors — the deadliest category

15 percentof maintenance-related errors are estimated to come from distraction

three stepsback in the written procedure when you return from a distraction

SA-022NTSB Safety Alert — Mechanics: Manage Risks to Ensure Safety

14 peoplekilled on Continental Express 2574 — screws omitted after a poor handover

Unlocks when you pass this course

Sums up the course. It does not replace the approved technical data or the maintenance manual.Print on Letter or A4

Take the course: Human Factors Primer →

CertiFlyers · Hangar CardHuman Factors & Professional Skills

The Dirty Dozen Human Factors

FAA Human Factors in Aviation Maintenance

After a distraction, go back 3 steps — never resume from memory.

Numbers to remember

Over 80%of aviation accidents are attributable to human error — Dirty Dozen preconditions

30%of verbal communication is received and understood — write the handover down

15%of maintenance errors — distraction, the number one cause of skipped steps

3 stepsback in the manual checklist before restarting after any distraction

12-hourshift extended under pressure — junior tech stayed silent, unairworthy aircraft released

TP 12863ETransport Canada — Human Factors for Aviation, Basic Handbook

Before the task: check

Current manual or approved data for this task in hand
All parts, approved tools and documentation physically present
Fatigue and stress self-check done — mind fully on the job
Fatigued but cleared to work? Secondary inspector arranged
Team briefed on job scope, responsibilities and tooling
Handover taken with a physical checklist — critical airworthiness items first

Sums up the course. It does not replace the approved technical data or the maintenance manual.Print on Letter or A4

Download the PDF Take the course: The Dirty Dozen Human Factors →

CertiFlyers · Hangar CardMaintenance & Repair Practices

Aircraft Fastener Identification and Selection

14 CFR §43.13(a) and FAA AC 43.13-1B w/CHG 1

Same diameter is not the same bolt: match the full part number.

Numbers to remember

250 °Fceiling for fiber or nylon self-locking nuts, AC 43.13-1B 7-64.f

10–20 mincommonly the window to drive DD or D rivets after refrigeration

1.5×shank diameters the unset rivet must project beyond the joint

1/8 inchmaximum combined washer height used to make up grip (para 7-37)

10-32smallest steel bolt for primary structure — aluminum: 1/4-inch (para 7-41)

160 ksiNAS6204 close-tolerance bolt — the look-alike AN4 is 125 ksi

Unlocks when you pass this course

Sums up the course. It does not replace the approved technical data or the maintenance manual.Print on Letter or A4

Take the course: Aircraft Fastener Identification and Selection →

CertiFlyers · Hangar CardMaintenance & Repair Practices

Integral Fuel Tank Maintenance and Leak Detection

TO 1-1-3, 14 CFR § 25.981 and SFAR No. 88

Final torque within the sealant's application life — or start over.

Numbers to remember

600 PPMmaximum VOC for standard entry — 10% LEL

> 1200 PPMIDLH — above this, or oxygen outside 19.5–23.5%, nobody enters

30 minminimum purge before entry; also adhesion promoter drying time

6 minafter wiping dry — read the wetted area to classify the leak

TO 1-1-3the USAF technical order for tank entry limits, sealing and leak classes

≤ 1/4 inslow seep wetted area; 3/4 to 8 inches (depending on fuel type) is a heavy seep

Unlocks when you pass this course

Sums up the course. It does not replace the approved technical data or the maintenance manual.Print on Letter or A4

Take the course: Integral Fuel Tank Maintenance and Leak Detection →

CertiFlyers · Hangar CardSafety Management & Quality

Corrective and Preventive Action

14 CFR §145.211(c)(1)(ix); EASA Part-145 point 145.A.95

Close a finding only when independent evidence shows the fix worked.

Numbers to remember

96 hoursService difficulty report limit after discovery, 14 CFR §145.221(a)

24 hoursLatest voluntary disclosure notice after detection, Advisory Circular 00-58C

72 hoursOccurrence report limit, organization outside a European Member State

three monthsInitial maximum period for a European level 2 finding

145.A.95European Part-145 point: root causes, plan, demonstrated implementation

§145.21114 CFR section requiring the written corrective action procedure

Sums up the course. It does not replace the approved technical data or the maintenance manual.Print on Letter or A4

Download the PDF Take the course: Corrective and Preventive Action →

CertiFlyers · Hangar CardSafety Management & Quality

Foreign Object Debris (FOD)

SAE AS9146 and FAA AC 150/5210-24A

Anything you can't account for is FOD until proven otherwise.

Numbers to remember

AS9146aerospace FOD prevention standard — tool and material accountability, Clean As You Go housekeeping

150/5210-24AFAA AC (2024): advisory guidance for airport FOD programs — prevention, detection, removal, evaluation

100%accountability of tools, hardware and consumables before any panel is sealed

3 zonesCritical, Sensitive, Non-Critical — match the inspection method to the zone

2017Metroliner — mechanic called away, screwdriver left in the wiper area

109 + 4Concorde 2000 — perished aboard and on the ground; runway metal strip

Before closing up: check

All tools, hardware and consumables brought in accounted for — 100%
Safety wire clippings, packaging and rags removed from the zone
Tools returned to their designated locations — shadow board complete
Zone classified — Critical, Sensitive or Non-Critical — matching check done
Critical zone? Borescope exam, torque seal audit, fastener checklist complete
Self-check: did familiarity with the task make you overlook a detail?

Sums up the course. It does not replace the approved technical data or the maintenance manual.Print on Letter or A4

Download the PDF Take the course: Foreign Object Debris (FOD) →

CertiFlyers · Hangar CardShop & Hangar Safety

Aircraft Confined Space & Fuel Tank Entry Procedures

OSHA 29 CFR 1910.146

The Attendant stays outside — even when the entrant goes down.

Numbers to remember

19.5–23.5%acceptable oxygen, tested first

< 10% LELflammable gas, tested second

< 25 ppmcarbon monoxide, tested third; some programs use NIOSH's 35 ppm exposure limit

15 minventilation off before atmospheric testing, so the monitor reads raw air

1 ohmmaximum DC resistance for a bonding jumper on in-tank metal

> 60%of confined space deaths are would-be rescuers, not the entrant (NIOSH)

Unlocks when you pass this course

Sums up the course. It does not replace the approved technical data or the maintenance manual.Print on Letter or A4

Take the course: Aircraft Confined Space & Fuel Tank Entry Procedures →

CertiFlyers · Hangar CardShop & Hangar Safety

Eye and Face Protection

29 CFR 1910.133 and ANSI/ISEA Z87.1

If you can't read Z87 on it, it isn't eye protection.

Numbers to remember

Z87+high-impact rating for grinding, chipping and machining

10 smaximum travel to an eyewash station — about 55 feet

15–20 mincontinuous flushing after a chemical splash — even if it feels better

60–100 °Ftepid eyewash water, 16–38 °C, for a 15-minute flush

D3 · D4 · D5splash · dust · fine-dust markings on the eyewear

10–15 sthe most critical window after a corrosive splash: get to the eyewash

Unlocks when you pass this course

Sums up the course. It does not replace the approved technical data or the maintenance manual.Print on Letter or A4

Take the course: Eye and Face Protection →

CertiFlyers · Hangar CardShop & Hangar Safety

Fall Prevention

OSHA 29 CFR 1910 Subpart D and 1910.140

4 feet and an open edge: guardrails first, PFAS last, or disengage.

Numbers to remember

4 feetor more, unprotected edge — fall protection is mandatory

6 feetmaximum free fall — tie off at or above the dorsal D-ring

5,000 lbsanchorage strength per attached worker — or designed, installed and used under a qualified person's supervision, safety factor at least 2

70%lanyard strength lost over a sharp edge without an abrasion-pad adapter

1:4ladder base: 1 foot out for every 4 feet of vertical height

36 inchesof side rail above the landing on a straight ladder

Before you climb: check

Working height verified — unprotected edge 4 feet or more? Protection required
Ground-based tooling ruled out; guardrails on all open sides of the stand
Harness, lanyard and snaphooks inspected today — labels and certifications legible
Anchorage approved, 5,000 lbs per worker, at or above the D-ring
Ladder: no loose rungs or cracked rails, no grease, set at 1:4
Stand: platform clear, fully planked, casters locked, no lateral flex

Sums up the course. It does not replace the approved technical data or the maintenance manual.Print on Letter or A4

Download the PDF Take the course: Fall Prevention →

CertiFlyers · Hangar CardShop & Hangar Safety

Personal Protective Equipment

29 CFR 1910.132–1910.135, 1910.138, 1910.140 and 1910.95

Walk the zone first — the hazard you find picks the PPE.

Numbers to remember

1 to 1¼ inchsuspension clearance, shell to head (OSHA guidance), maintained at all times

90 dBhearing protection mandatory above this for an 8-hour shift

115 dBmandatory above this for 15 minutes — engine runs routinely exceed it

5,000 poundsminimum PFAS anchor rating per attached employee (29 CFR 1910.140)

four feetunprotected side or edge this high or more above a lower level — fall protection required (29 CFR 1910.28(b)(1))

14 feetDFW 2015 — a 30-year mechanic died closing a 767 door

Unlocks when you pass this course

Sums up the course. It does not replace the approved technical data or the maintenance manual.Print on Letter or A4

Take the course: Personal Protective Equipment →

CertiFlyers · Hangar CardShop & Hangar Safety

Respiratory Protection

OSHA Respiratory Protection Standard 29 CFR 1910.134

Below 19.5% oxygen it's IDLH — no air-purifying respirator of any kind.

Numbers to remember

19.5–23.5%oxygen monitoring must prove — with contaminant levels known — before a fuel tank is no longer treated as IDLH

10 secondshold the negative pressure check; the facepiece must stay collapsed

P100pink particulate filter for composite dust; organic vapor cartridge for solvents

43 °Cmaximum wash water (110 °F), mild detergent, no organic solvents

50 ppmhypochlorite: immerse components two minutes, then rinse thoroughly

17.1%fuel tank oxygen reading: the technician refused a half-mask and used full-facepiece pressure-demand air (SCBA, or SAR with auxiliary escape bottle)

Unlocks when you pass this course

Sums up the course. It does not replace the approved technical data or the maintenance manual.Print on Letter or A4

Take the course: Respiratory Protection →

One page per course, for the workstand

Aircraft Maintenance Documentation

Global Hazard Communication

Human Factors Primer

The Dirty Dozen Human Factors

Aircraft Fastener Identification and Selection

Integral Fuel Tank Maintenance and Leak Detection

Corrective and Preventive Action

Foreign Object Debris (FOD)

Aircraft Confined Space & Fuel Tank Entry Procedures

Eye and Face Protection

Fall Prevention

Personal Protective Equipment

Respiratory Protection

Where a card does its job

The card is the summary. The course is the why.