Archives

Project Details

Fabric 1

10 oz High Abrasion Resistant MIL-SPEC Vinyl Coated Cloth
Producer/Manufacturer: Flexfirm Products Inc.
Primary Use: Main Fabric

Fabric 2

3/16" Multi-layer Open Cell Microcellular Polyurethane/1/2" Closed Cell Irradiation Cross-Linked Polyethylene Foam Padding
Producer/Manufacturer: Ehmke Manufacturing COmpany, Inc.
Primary Use: Main Fabric

Fabric 3

70 Denier MIL-SPEC RipStop
Producer/Manufacturer: MMI Textiles
Primary Use: Additional Fabric

Fabric 4

2" COBRA Buckles
Producer/Manufacturer: Gerald Schwartz Inc.
Primary Use: Hardware/Findings

Fabric 5

Webbing & Fastener Tapes
Producer/Manufacturer: MMI Textiels
Primary Use: Webbing/Narrow Fabric

Engineer Name 1
Steven Aust

Engineer Company 1
Ehmke Manufacturing Company, Inc.

Design Name
Steven Aust

Design Company
Ehmke Manufacturing Company, Inc.

Architect Name
Glenn Aust

Architect Company
Ehmke Manufacturing Company, Inc.

Fabrication Name
Bob Rosania

Fabrication Company
Ehmke Manufacturing Company, Inc.

Project Manager Name
Greg Nichols

Project Manager Company
Ehmke Manufacturing Company, Inc.

Please describe the project specifications

Project Description:

Peterson Space Force Base (Colorado Springs, CO) provides continuous, world-class infrastructure and base support in order to enable global Space Force mission Deltas and other space and homeland defense mission partners to conduct combat operations. It is America's epicenter of space power; providing agile and uninterrupted service to our warfighters. The Air Force (USAF) Reserve Command’s 302d Airlift Wing operates & maintains C-130 aircraft for personnel and equipment transportation, reconnaissance and Search & Rescue missions. The fleet of aircraft must maintain and high rate of readiness to react to any emergent mission under the Space Force platform.

To ensure the C-130 aircraft availability, the 302d Airlift Wing must ensure its aircraft is protected from all environmental conditions that may affect its readiness. With many previously deployed aircraft now stationed at US bases, hanger capacity is very limited. Often aircraft are left on the flightline risking damage from hailstorms and foreign object debris. The cost of unplanned hail damage can be extraordinary and loss of operational readiness is disastrous. For example, in 2021, the USAF spent $134 Million to repair thirty-nine (39) T-1 Jet Trainers stationed at Laughlin AFB alone (see relevant articles below) The unique weather conditions in Colorodo Springs, CO. subject the aircraft to unanticipated torrential hailstorms. Peterson Space Force Base (PSFB) called on our company as a sole-source solution to provide the design, engineering, fabrication and installation of an original protection system to cover all horizontal surfaces from impact of the C-130 aircraft. The requirement set forth by PSFB required an engineered solution that was design with tight tolerances with materials that needed to perform under extreme temperatures, be highly abrasion proof, and be constructed to deflect 2” diameter hail stones. Performance specifications included deployment of the protection system with 4 individuals in 2 hours or less without the use of overhead cranes or the access to walk on top of the aircraft. Please note that our company was tasked with the development of a solution that was never fielded before that needed to protect over 5,600 square feet of valuable USAF assests.

Project Complexity:

The protective hail covers must be deployable, extreme temperature resistant, portable, easily storable, and consistently withstand the impact force of a 2” hail stone traveling at terminal velocity. The criteria required resistant fabric, strike face, cushioning, webbing, fastener tape and hardware that is resilient to extreme cold conditions. The fabric could not tear on the airframe or scratch the aircraft skin. All hardware needed to be recessed and protected so not to contact the aircraft skin. Universal cutouts and contours are required to accommodate the numerous antennas, access doors, engine nacelles and complex angles of an aircraft surface and flight control components The robust solution needed to meet our customer’s aggressive mission cadance profile and defeat the local environmental conditions. The proprietary multi-layer solution required extensive environmental testing.

Project Results:

Our Company delivered a successful solution on-time and under budget. Our “Away Team” of five people (project manager, design engineer, installation specialist, sewing machine operator and quality control manager) spent two (2) weeks on site tailoring and custom fitting multi-layer panels to contour to the unique external features (i.e antennas, emergency hatches, radars) of the aircraft. Peterson Space FOrce Base calculated that our company's solution saved them approximately $1,000,000 in lifecycle repairs. The successful completion of the project has led to add-on business at USAF bases in the hail threat zones throughout the country.

Relevant Articles:
• https://www.dvidshub.net/news/226645/recovering-july-hailstorm-peterson-aero-club-returns-first-six-damaged-airplanes-fleet
• https://www.twz.com/39945/the-air-force-spent-134m-to-repair-39-hail-damaged-t-1-jet-trainers-its-about-to-retire
• https://www.laughlin.af.mil/News/News/Article/674596/hail-storm-rips-through-laughlin/
• https://www.bbc.com/news/uk-30832747
• https://www.airforcetimes.com/news/your-air-force/2023/07/27/thunderstorm-damage-to-vances-t-6-fleet-will-slow-pilot-training/
• https://gazette.com/military/itll-take-more-than-a-bit-of-bondo-to-fix-damaged-air-force-planes-hit/article_a7c26a00-ef71-5e86-8108-4c935091764c.html

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