I've been checking about this Airboot issue with "empty USB drives" as well, as I'm also encountering this which prevented the system from booting using Airboot.
I'm using the 1.1.4 release version. With legacy USB enabled and the card reader (that comes with my chassis) picked up by BIOS, it'll halt with a "Scanning...LOAD ERROR!". I'm able to work it around by configuring the card reader (which is a mass storage device) as a CDROM device in the BIOS of my motherboard (ASUS Crosshair V Formula-Z), so Airboot would not pick it up and would not halt there.
From what I know, card readers may present themselves in two ways: Mass storage device, or card reader device. The former is more common on desktops while the latter is more common on laptops.
Card readers that present themselves as mass storage devices can be booted from BIOS, and would be "empty" if no cards are installed (which causes the LOAD ERROR).
Card readers that present themselves simply as card reader devices cannot be recognized by or booted from BIOS, thus they would not cause the LOAD ERROR.
On the other hand, I don't think there's a straightforward way in BIOS to "remove" empty USB devices from boot list, as long as the USB controller the devices in question reside can be picked up by BIOS. The ways I know are:
1. Physically detach the card readers from the system.
2. Disable legacy USB support (which you can't if you use USB keyboard and mouse, as doing so disables them as well).
3. Attach the card reader to a PCI or PCIe USB expansion card (which the BIOS may not immediately pick up) instead of onboard headers.
Airboot needs to be able to properly ignore "empty USB drives" (card readers) instead of halting the system. This was never a problem for BIOSes themselves: The presence of empty card readers that present themselves as mass storage devices hardly ever caused boot issues from my experience.
EDIT: After some detailed testing, setting Mass Storage Device to CDROM is not a panacea. For my motherboard, the configuration is stored by the logical order of the USB devices, so if I plug a USB stick and that stick is placed logically ahead of the card reader, it'll become the one to be treated as CDROM instead of the card reader, which breaks its ability to boot as well as triggering the LOAD ERROR again. In the end, if I want to boot from USB I'll always need to make sure things are correct in BIOS, and clean up afterwards to avoid any boot issue that I might not immediately be able to figure out why.
EDIT 2: The issue might be board-specific. I replaced the previous motherboard as it's reported to have issues and with the new board the issue started to go away by itself (although sometimes it can still happen). It's possible that some BIOSes handled INT13h better that it might be able to avoid causing LOAD ERROR for some reasons.