Class Code 3830
Aircraft/Spacecraft Mfg; Unmanned Aircraft System Mfg – 55 Pounds Or Heavier
Class Code 3830 applies to manufacturers and integrators of aircraft, spacecraft components and unmanned aircraft systems (UAS) weighing 55 pounds or heavier. The California pure premium rate approved for Sept 1, 2026 is $1.900 per $100 of payroll. Accurate classification matters because it drives baseline workers' comp cost and determines applicable safety and regulatory requirements for shop floor, assembly, and flight-test operations.
What Class Code 3830 Covers
This classification covers production and assembly of manned and unmanned aircraft and spacecraft components, plus system-level integration and final assembly for UAS that weigh 55 pounds or more. Operations include structural fabrication (metal and composite layup), avionics and wiring harness installation, propulsion and motor installation and bench testing, battery and energy system assembly, payload integration, CNC machining, welding and fastening, non‑destructive testing, and ground/limited flight test activities performed by manufacturing personnel. It applies to on-site hangars, factory floors, dedicated test benches, and tethered or controlled flight-test ranges operated by the manufacturer. Routine maintenance performed as part of manufacturing, prototype assembly and system integration tied to production, and direct quality inspection by production employees are typically included here; full commercial flight operations or field maintenance by a separate flight operations group may be classified differently.
Who It Applies To
- Unmanned aircraft system (UAS) OEMs producing platforms 55+ lbs
- Manned aircraft and spacecraft component manufacturers
- Aerospace subcontractors doing composite layup, machining, or riveting
- Avionics integrators and electrical harness assembly shops
- Propulsion and battery system manufacturers and test teams
Common Job Duties
- Composite layup, curing and trimming of airframe structures
- Riveting, bolting and structural assembly of fuselage/frames
- CNC machining, metal fabrication and precision finishing
- Avionics installation, harness routing and soldering
- Installation and testing of propulsion systems and motors
- Handling, assembly and testing of lithium battery packs
- Ground and tethered flight-test setup, instrumentation and data collection
Common Injury Risks
Understanding the $1.900 Rate
The pure premium rate of $1.900 per $100 of payroll is the baseline amount assigned to losses for this classification — it means $1.90 for every $100 of classified payroll before company-specific adjustments. Final premiums an employer pays are adjusted by experience modification (E-Mod), policy forms, carrier expense constants, credits or debits, classification splits and any deductible or retrospective programs. Factors that materially affect your premium include your loss history, payroll allocation accuracy, safety controls, return‑to‑work practices and whether you participate in pooled or alternative risk programs.
Cal/OSHA Compliance Requirements
Manufacturers in this classification must maintain a written Injury and Illness Prevention Program (IIPP) per Cal/OSHA (Title 8) and comply with General Industry Safety Orders for hazard communication, electrical safety and lockout/tagout (control of hazardous energy). Specific requirements often apply for fall protection on elevated assemblies, confined-space rules for fuel tanks or large enclosures, respirators and ventilation for composite/chemical work, and procedures for safe storage, handling and charging of lithium battery systems. Flight-test activities require coordination with FAA and range safety, but Cal/OSHA still governs employee safety during test operations.
How Key HR Helps Employers Under Class Code 3830
A PEO like Key HR helps manufacturers in this high‑risk class by ensuring accurate payroll classification, deploying aerospace‑specific safety programs and training (composite handling, battery safety, electrical safety and fall protection), and managing claims and return‑to‑work to limit experience‑mod impacts. We also assist with OSHA-compliant documentation, regulatory audits, and access to alternative risk or pooled programs that can lower overall workers' comp expense.
Get a QuoteFrequently Asked Questions
Does class code 3830 include prototype and R&D flight testing?
Prototype assembly and flight testing performed by production or integration staff are commonly included under 3830 when directly tied to manufacturing. Separate flight operations, commercial flight crews or contracted field maintenance may be classified differently — an auditor will evaluate payroll and operational boundaries.
What specific loss control measures reduce comp costs for heavy UAS manufacturing?
Effective measures include engineered lifting fixtures and hoists, blade/propeller safety protocols, confined-space and fall protection programs, formal battery handling and charging procedures, PPE and respirator programs for composite work, and a documented restricted-duty/return-to-work plan to shorten claim durations and improve your experience modification.
Are there special insurance concerns for lithium-ion battery assembly and testing?
Yes. Lithium‑ion cells present fire and thermal-runaway hazards that insurers review closely. You should have specialized storage, fire suppression, segregated charging/test areas, written emergency procedures and employee training; these controls reduce both safety risk and underwriting penalties.
Quick Facts
- Class Code
- 3830
- Classification
- Aircraft/Spacecraft Mfg; Unmanned Aircraft System Mfg – 55 Pounds Or Heavier
- Pure Premium Rate
- $1.900 / $100 payroll
- Effective Date
- September 1, 2026
- Source
- WCIRB Approved Filing
Manage Workers' Comp Through a PEO
Key HR provides pay-as-you-go workers' comp for California employers — no large deposits, no audits, better rates.
Get a Quoteor call (800) 922-4133Ready to Simplify Workers' Comp for Class Code 3830?
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