Setback in the Sand-Mishap Aircraft Returns to Service

The H-60 Strategic Business Team (SBT) at Fleet Readiness Center Southeast (FRCSE) knows they are a critical component of a global Navy that is forward deployed to protect and preserve national security.

The team is responsible for repairing and maintaining the H-60 Seahawk Helicopter.

Last month, an HH-60H helicopter completed its first flight in ten months after suffering damage in Balad, Iraq, in October 2008. The aircraft was flown from FRCSE to Helicopter Sea Combat Squadron 84 (HSC-84) in Norfolk, Va., and has since returned to full duty.

The accident involved two HH-60H aircraft engaged in night operations supporting the Global War on Terror. One aircraft was on the ground turning when a second aircraft came in too close and clipped the tail pylon of the first aircraft with its main rotors.

Night operations, especially those which are airborne, are among the most difficult activities performed by the military. Although darkness increases the effectiveness of surprise for our forces and reduces the enemy’s ability to effectively aim his fire, there are many factors which contribute to this being a very dangerous environment.

These factors include limited visibility or the absence of a horizon, the affect in darkness where objects sometimes appear larger and distances seem greater, and the physical ability of the eye to adjust to varying light conditions. Even the simplest of operations can become a dangerous evolution.

Once the dust settled and only after the morning sun had risen could an accurate assessment of the damage be established. The stationary aircraft sustained extensive tail pylon damage and would require a total replacement of the tail pylon and accessories.

The taxiing aircraft sustained excessive right-side damage after it came to rest on its right side. The right landing gear and associated support structure either snapped off or collapsed into the lower fuselage of the aircraft. The aft weapons pylon, as well as the right hand horizontal stabilizer of the tail pylon was also damaged when the aircraft stopped on its right side. A comprehensive and in-depth inspection of the aircraft would be required to determine if the aircraft would be salvageable or not.

FRCSE was contacted and the H-60 SBT team stepped in to do what they do best. In January, both aircraft were airlifted from Balad, and delivered to FRCSE. The stationary aircraft was examined and a thorough evaluation of the damage it sustained was documented. Sudden Stoppage / Collision Damage Inspections and nondestructive inspections of all bulkheads and support structures were performed, as well as extensive examinations and evaluations of the drive train.

Over the course of four months, the donor tail was installed and a drive-shaft alignment check was performed to ensure proper structural integration. Structural repairs were completed along with the reassembly of the drive train and main rotor head assembly, and several new components were installed. Additionally, an extensive examination of the aircraft’s electrical and avionics equipment was performed and crash damage repairs were completed.

Before the final release with a clean bill of health, FRCSE performed an Operational Level special inspection to the aircraft. By July, HSC-84 personnel completed their pre-flight checks, records review, ground turns, and successful first flight. Two days later, the squadron returned the aircraft to Norfolk, Va.

HSC-84, better known as the “Red Wolves,” is the only squadron in the Navy dedicated to Naval Special Warfare support and Strike Rescue. The squadron operates eight Sikorsky HH-60H Seahawk helicopters and is tasked with maintaining readiness to deploy anywhere in the world within 72-hours notice.

By Edmond Galluccio - Deputy Director, FRCSE H-60 Seahawk Strategic Business Team