Robins team gives fast assist to special ops warfighters

  • Published
  • By Damian Housman
  • Warner Robins Air Logistics Center Public Affairs
ROBINS AIR FORCE BASE, Ga. (AFPN) --  When MH-53 Pave Low crews discovered they were more vulnerable to small-arms fire than they thought, they put out a call for help. A team from the 330th Special Operations Support Group, now called the 580th Aircraft Sustainment Group, answered the call.

What had alarmed one crew was finding that a rifle bullet had penetrated their helicopter from below and made it into the crew compartment. Ballistic blankets are used on the floor of the aircraft to stop such penetrations, but a combination of age and contamination by fuel and hydraulic fluid made the blanket less useful.

Special operations crews wanted something done fast since their work frequently exposes them to the risk of small-arms fire and all MH-53 Pave Lows use the same blankets.
 
A requirement for new, lightweight armor for six aircraft, plus three sets of spares, was included in a combat mission needs statement written in July. Installation was to be done in Iraq. Special Operations Command officials followed with a requirements definition for what the new armor was supposed to protect against, and a statement of work was placed under contract. The time from requirement to contract was just nine days.

“By the end of September, we had selected a prime contractor, and two armor manufacturers supplied samples,” said Larry Layfield, supervisor for the 573rd Aircraft Sustainment Squadron/Pave Low Flight. “By mid-October we briefed United States Special Operations Command in Tampa, and production was approved. We were on a very fast track indeed.”

By mid-December the first test kit was installed in a helicopter at Hurlburt Field, Fla., and an aircrew started testing it the next day. The replacement ballistic set was built in segments, as hard shells inside the helicopter. The whole set was slightly heavier than a new ballistic blanket, but lighter than a ballistic blanket after years of soaking up fuel and hydraulics. It also protected the crew far better. Each set had brackets and 16 armor plates, and cost about $180,000.

“The aircrew was favorably impressed,” Mr. Layfield said. “The install went smoothly and there were few problems to fix. They especially liked the fact that there was less vibration, especially in the rear gunner position. That was unexpected.”

Once flight testing was completed, full-scale production was approved in mid-February. Soon several sets of ballistic armor were ready for the fleet. Tech. Sgt. James Hardy, equipment specialist and modification manager for Pave Low aircraft, was sent to Iraq to train maintenance personnel to install the kits, and to supervise installation.

“Installing the retaining brackets took five hours for the first helicopter,” Sergeant Hardy said. “Putting in the actual armor plates took little more than half an hour.” 

After the first set was installed, brackets became easier and quicker to place in each helicopter. Sergeant Hardy supervised four installations in Iraq, then went to Hurlburt for the remaining two installs. All six installations were complete before the end of March -- eight months from start to finish.

“What our team did in record time was noticed throughout the community,” Mr. Layfield said. “Everyone was amazed at the speed we were able to bring a needed item into the fleet. They are looking at using our contracting methods for other systems as well.”

The special operations community is looking at the armor system for use in other helicopters, and the Army also is considering it.

“The Army is looking at this system for Humvees, since it is lighter (than) and at least as effective as what they have now,” Mr. Layfield said.

“Compared with other airframes, we are light-years ahead. This is a system we can actually take into battle,” Sergeant Hardy said. 

“Most important, the warfighter is very happy with the result,” he said.