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CASA Part 141 / 142 / 145 documentation · instructor-signed · SMS-mandate-ready

The CASA paperwork that used to take a year. Fixed-fee. Delivered in two weeks.

Operations Manuals. SMS template library. Maintenance Control Manuals. Internal audit registers. The documentation pack that every Part 141, Part 142, and Part 145 operator owes CASA — productised, AI-accelerated, signed by a commercial pilot and Grade 2 flight instructor. Aligned with the December 2026 Safety Management Systems mandate from day one.

Built for AU operators under CASR Part 141, Part 142, Part 145, and Part 42 CAMOs — flight training organisations, approved maintenance organisations, and continuing airworthiness management organisations. Sits inside the broader OTGM Compliance Practice; companion offer to the Audit-Defensible CBTA Pack.

What's in the pack

  • · MAAT-populated training manual templates
  • · Safety Management System (SMS) template library — Dec 2026 mandate-aligned
  • · Operations Manual templates (Part 141 / 142 / 145 variants)
  • · Maintenance Control Manual templates (Part 145)
  • · Internal audit + non-conformance register templates
  • · 30-day amendment cover on CASA-published changes
  • · Instructor-signed defensibility declaration on every artefact
  • · Monthly retainer for ongoing amendments + audit-prep support

Quick answer

What is the CASA Documentation Pack?

A fixed-fee consulting engagement producing a complete CASA documentation pack — Operations Manuals, SMS templates aligned with the December 2026 mandate, Maintenance Control Manuals for Part 145, internal audit registers, and MAAT-populated training manuals — for Part 141 / Part 142 / Part 145 operators in Australia. Delivered in 7-15 business days, instructor-signed, audit-ready for the next CASA Surveillance inspection.

The pain

More administrative staff. More paperwork. More reporting. Less time in the air.

If you operate under CASR Part 141, 142, or 145, you already know the shape of this pain. A Part 141 to Part 142 transition runs around $250,000 in lived cost across legal, consulting, and lost flying time. The 2 December 2026 SMS transition under Parts 119 / 121 / 133 / 135 / 138 adds another documentation layer — and the documentation submission deadline for air transport operators is 1 September 2026, not December.

Most operators run their documentation on Word + Excel + a shared drive. It works until CASA Surveillance arrives. Then the gaps surface — outdated Operations Manual sections, missing SMS hazard register entries, internal audit log that hasn't been touched in nine months, Maintenance Control Manual that doesn't match what the engineers actually do on the floor.

Bespoke aviation consultants charge $20-100K to fix this on phone-quote engagements that take months. CASA gives you the Manual Authoring and Assessment Tool (MAAT) and sample manuals for free — but the labour to populate them with operator-specific, defensible content is the real constraint. That's what this pack productises. Every deliverable is MAAT-compatible: drafts load straight into the tool without conversion.

What you get

A pack the inspector can read in five minutes. A system you can maintain in fifteen minutes a week.

Operations Manual

Full Operations Manual following CASA's sample structure, populated with your operator-specific procedures, normal and abnormal operations, training and checking processes, and quality assurance framework. Per-part variants (Part 141, Part 142, Part 145).

Safety Management System (SMS) library

Safety policy, accountabilities, hazard identification register, risk assessment matrix, change management framework, safety assurance, safety promotion, Human Factors and Non-Technical Skills (HFNTS) program templates. Aligned to the 2 December 2026 SMS transition under Parts 119 / 121 / 133 / 135 / 138 — documentation submission deadline 1 September 2026.

Maintenance Control Manual (Part 145)

Quality system, approved maintenance data control, maintenance personnel competency framework, tool and equipment control, parts and consumables traceability, certifying staff authorisation register.

Internal audit + non-conformance registers

Recurring internal audit framework + non-conformance log + corrective action tracking + root-cause analysis templates. The artefacts CASA looks at first to assess whether your system is actually being used.

MAAT-populated training manuals

Training manual + checking manual produced in MAAT (Manual Authoring and Assessment Tool) format that CASA accepts directly. No conversion friction at submission.

30-day amendment cover + retainer

30 days of CASA-amendment cover included in the initial pack. After that, the $300/month retainer covers ongoing amendments + SMS log maintenance + audit-prep support.

Naming matters · Operations Manual ≠ Exposition

We ship the correct artefact for your CASR Part. Not a generic “manual”.

CASA uses different deliverable names for different Parts, and a Head of Operations will notice immediately if you submit the wrong one. We map the right MAAT-compatible artefact to the Part you operate under.

Your CASR PartCASA-required deliverableMAAT moduleCompanion artefacts
Part 141Non-integrated flight trainingOperations ManualPart 141 Operations Manual (MAAT)Training and Checking Manual · Quality / Safety system · CFI / HOO key personnel files
Part 142Integrated · MPL · contracted recurrent T&CExpositionPart 142 Exposition (MAAT)Training and Checking Manual · HOTC key personnel file · SMS Manual · HFNTS program
Part 145Approved Maintenance Organisations (AMO)Exposition (AMO)Part 145 Exposition (MAAT)Maintenance procedures · Approved Maintenance Data control · CRS authorisation register · Certifying staff list
Part 42Continuing Airworthiness Management Organisations (CAMO)Exposition (CAMO) · also called the Maintenance Control Manual (MCM)Part 42 Exposition (MAAT)Maintenance program · Reliability program · Airworthiness review process · Defect reporting framework
Part 119 / 121 / 133 / 135 / 138Air transport operators (AOC holders)Operations Manual + Training and Checking Manual + SMS ManualPer-Part MAAT modulesHFNTS program · Hazard / Risk Register · ERP · Flight Data Analysis Program (where required)

Honest note: in everyday operator conversation people use “manual” for both. On the page you submit to CASA, the distinction matters. Every Documentation Pack we ship comes labelled correctly and built in the right MAAT module.

Packages + pricing

Fixed fee. Public pricing. Tier scales with regulatory scope.

Productised CASA Part 141 / Part 142 / Part 145 documentation pack — MAAT-populated training manuals, SMS template library, Ops Manual templates, and 30-day amendment cover. Companion to the Audit-Defensible CBTA Pack. Instructor-signed. $3,500 to $8,000 USD one-time + $300 USD/month (~$5,300 to $12,200 AUD + ~$460 AUD/month).

Tier 1

Single regulatory part

Part 141 OR Part 142 OR Part 145, single licence/rating scope.

From $3,500 USD

~$5,300 AUD one-time

+ $300 USD/mo retainer (~$460 AUD/mo)

  • Operations Manual (one part)
  • SMS template library
  • Internal audit register
  • 30-day amendment cover
  • 7-10 business day delivery

Tier 2 · most popular

Multi-part pack

Two or more regulatory parts (e.g. Part 141 + Part 142).

From $5,500 USD

~$8,400 AUD one-time

+ $300 USD/mo retainer (~$460 AUD/mo)

  • Everything in Tier 1, multi-part
  • Cross-part procedure alignment
  • Maintenance Control Manual if Part 145 included
  • 10-15 business day delivery

Tier 3 · enterprise

School-wide + CBTA bundle

Documentation Pack + Audit-Defensible CBTA Pack bundled.

From $8,000 USD

~$12,200 AUD one-time

+ $300 USD/mo retainer (~$460 AUD/mo)

Rush turnaround (5 business days inclusive of intake for Tier 1) is +25%. Bundle discount of 10% if combined with the Audit-Defensible CBTA Pack or any active marketing retainer from the OTGM marketing practice.

Frequently asked

Questions that come up before you enquire.

The CBTA Pack handles the competency mapping side — lesson-to-MOS mapping, per-student rubrics, course rollups. This pack handles the documentation side — Operations Manuals, Safety Management System templates, Maintenance Control Manuals (for Part 145), internal audit registers. Most operators need both. Bundle pricing is available.

Yes. Every SMS template in the pack is aligned with the Safety Management System transition under CASR Parts 119, 121, 133, 135, and 138 (Part 91 also has general operating rules). The 2 December 2026 deadline is the end of the CASA EX73/24 SMS exemptions; the documentation submission deadline for affected air transport operators is 1 September 2026. There is no separate "CASR Part 100" — SMS requirements live inside those operator-class Parts. We track CASA-published amendments and fold any changes into your pack at no extra cost for the first 30 days post-delivery; ongoing amendments are covered by the monthly retainer.

You get 30 days of amendment cover with every initial pack. CASA-published changes inside that window are folded in at no extra cost. Outside the window, the $300/month retainer covers ongoing amendments + SMS log maintenance + audit-prep support. If the rules change materially mid-cycle, we re-scope and credit any unused retainer.

AI does the data-assembly work — parsing MOS units, populating MAAT templates against your operation, drafting first-pass SMS hazard registers, generating Operations Manual section structure. An instructor (commercial pilot + Grade 2 CFI) reviews every artefact, calibrates the rubric, resolves operator-specific edge cases, and signs the defensibility declaration. AI on the inside; instructor signature on the outside.

Yes. Part 145 operators get the Maintenance Control Manual templates + internal audit register + non-conformance log + Approved Maintenance Data control framework. The pack is scoped per regulatory part — Part 141, Part 142, Part 145, or combined for operators running multiple certificates.

Tier 1 (single regulatory part, single licence or rating): 7-10 business days from intake call. Tier 2 (multiple parts, multiple licences or ratings): 10-15 business days. Rush turnaround (5 business days for Tier 1) is +25%.

Send it across at intake. We audit what you have, identify gaps against current CASA guidance, and produce a delta-pack that updates the outdated sections without rewriting what already works. Often this is cheaper than the full pack — quoted per scope.

Bespoke aviation consultants typically work on phone-quote, multi-month engagements without public pricing. We work fixed-fee with public pricing and 7-15 business day delivery. The deliverables are similar; the speed, transparency, and cost profile are not. Joey has been on the receiving end of bespoke consulting engagements — the productised path exists because the bespoke one was expensive and slow.

Yes. Reply on the enquiry form with "sample request" and we will send a sanitised excerpt — a single Operations Manual section + an SMS hazard register page + a Planning Matrix row. Enough to evaluate the quality without exposing other operators' material.

Get a fixed-fee quote

Send the operator details. Reply within one business day.

Tier recommendation, fixed-fee scope, and a 30-minute intake call slot. Or use the longer /contact form if you want to chat first.

We only work with aviation businesses. Your details stay with us. Replies within one business day.

About

Built by the instructor who carried this work by hand for months at a previous employer.

Joey Pehrson is a commercial helicopter pilot and Grade 2 flight instructor based in Brisbane. The documentation pack started as a manual rebuild job at a previous Part 141 operator that took months — Operations Manual, SMS, training manuals, internal audit register, all of it. The AI workflow that compresses that work into 7-15 business days is the wedge. The instructor signature on every artefact is the moat.

See the full OTGM Compliance Practice — the Documentation Pack sits alongside the Audit-Defensible CBTA Pack and the RTO Overlay, all instructor-signed. See the CBTA Pack if competency mapping is the bigger pain. See all services for the full OTGM picture.