ROBINS AIR FORCE BASE, Ga. -- When Special Operations MH-53 Pave Low helicopter crews discovered they were even more vulnerable to small arms fire than they thought, they put out a call for help. That call was answered by a team from the 330th Special Operations Support Group, now called the 580th Aircraft Sustainment Group.
What had alarmed the Pave Low crews was finding that a rifle bullet had penetrated their chopper from below, and made it into the crew compartment. They use ballistic blankets on the floor of the aircraft which are supposed to stop such penetrations, but a combination of age and contamination by fuel and hydraulic fluid rendered the blanket less useful in ballistic protection. Since all MH-53 Pave Lows used the same blankets, and since their work frequently exposes them to the risk of small arms fire, the special operators wanted something done fast.
A combat mission needs statement was written in July 2005, with a requirement for new lightweight armor for six aircraft, plus three sets of spares. Installation was to be accomplished in Iraq. Headquarters, Special Operations Command quickly followed with a requirements definition for what the new armor was supposed to protect against, and a statement of work was placed under an umbrella contract. 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 580th ASG’s 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 Air Force Base, 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," said Mr. Layfield. "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."
Lessons were learned from the test article, flight testing was completed, and full scale production was approved in mid-February 2006. 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 dispatched by the 580th 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," said Sergeant Hardy. "Putting in the actual armor plates took little more than half an hour," he added. 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, a spectacular eight months from start to finish.
"What our team did in record time was noticed throughout the community," said Mr. Layfield. "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 entire special operations community is looking at the armor system for future use in other helicopters, and the Army is looking at it for helicopters and other uses.
"The Army is looking at this system for HUMVEEs, since it is lighter and at least as effective as what they have now," said Mr. Layfield.
"Compared with other airframes, we are light years ahead. This is a system we can actually take into battle," said Sergeant Hardy.
The team has been nominated for several command, Air Force, and Department of Defense awards. And, while they would be proud of any recognition, one thing is far more vital to the team. "Most important, the warfighter is very happy with the result," said Sergeant Hardy.