Cable Drum Secured to a Modified Reverse Base Pallet

The cable drum presented several unique transport challenges. To prevent the high-voltage cable from drooping or becoming damaged, the drum had to remain in a fully upright position throughout the journey. No lashings, dunnage, or bracing could come into contact with the cable itself, meaning the entire 1,500 kg load had to be supported and restrained solely through the drum’s outer circular rim.

The transport solution also required the structural strength of a standard reverse base aircraft pallet to safely support the full weight of the drum. However, a standard reverse base pallet has a height of 250 mm, leaving only 155 mm of clearance between the drum’s overall height of 1,450 mm and the passenger aircraft’s maximum cargo height restriction of 1,600 mm. This left virtually no margin for error and required an innovative engineering solution that reduced the overall transport height while maintaining the pallet’s structural integrity and compliance with aviation handling requirements.

In addition, the pallet needed to withstand repeated lifting, handling, and aircraft loading operations while preventing any movement that could affect cargo stability during flight. Achieving the required strength, stability, and dimensional compliance without compromising the integrity of the cable drum demanded careful engineering and precision fabrication.