In a significant stride towards enhancing aerospace maintenance capabilities, Northrop Grumman has introduced a state-of-the-art mobile docking system at the Royal Australian Air Force (RAAF) Base Amberley. After a detailed assessment by SafeSmart Access of the operational needs and challenges, the necessity for mobile stands to facilitate engine and wing maintenance tasks including flight controls, for the C-27J Aircraft was identified.
C-27J Aircraft’s Requirements
The C-27J Spartan is a valuable asset for the Australian Defence Force, bridging the gap between the larger C-130J Hercules and smaller rotary-wing aircraft and enhancing the overall operational flexibility and reach of the RAAF. Operated by No. 35 Squadron, the C-27J facilitates:
- Transportation of up to 60 troops, 46 paratroopers, or cargo, including vehicles and pallets.
- The delivery aid and evacuate casualties from short, unpaved airstrips.
- Configurations for transporting injured personnel with onboard medical support.
- Supporting rescue missions with its range and ability to operate in rugged conditions.
- And, conducts airborne operations, airdropping paratroopers and cargo efficiently.
The aircraft’s versatile and demanding operational profile requires frequent and thorough maintenance to ensure peak performance and safety. The conventional fixed docking structures were inadequate to support the increased maintenance demands triggered by the aircraft’s full operational capability status. A modular and fully mobile docking system was designed and tailored specifically for the C-27J aircraft to address these requirements.
Reconnaissance
The initial phase involved thoroughly assessing the operational needs and challenges at RAAF Base Amberley. The core requirement was mobile stands that could facilitate engine and wing maintenance without necessitating the full-scale setup of the existing fixed docking structure. This need was driven by the aircraft reaching Final Operational Capability, necessitating additional checks and maintenance activities that could not be efficiently accommodated within the current schedule given the setup and downtime associated with full-fixed docking. This assessment of the operational needs was completed onsite, by SafeSmart Access personnel, in an effort to gain a thorough understanding of the challenges and intricacies the maintenance tasks.
No. 35 Squadron’s Solution
A modular and mobile docking stand system was developed in response to these requirements. Tailored specifically for the C-27J aircraft, this solution comprised Engine & Flap Service Stands, Flight Control Stands, and Stair Access Stands. The modularity of this docking system is its defining feature, allowing for flexible positioning and adaptation to the aircraft’s maintenance needs, whether on or off jacks and independent of fuel load variations. Each module interlocks with its counterparts, creating a cohesive and secure workspace.
Product & Commercial Proposal
The proposed product included three work stands: height-adjustable stands, mobile stairs, and mobile aluminium wing docks to facilitate access to flight controls at the rear of the wing. The designs emphasised ease of mobility, quick assembly, and sturdiness. Constructed from box-section aluminium, the design ensured solid yet lightweight structures, minimising on-ground impact while maximising stability and safety. The Inbound and Outbound Rear Access Platform featured flap storage on large 8800mm x 2400mm decks, allowing crews unmitigated access to the wings, preventing any damage of the flight controls in taking the flight controls to/from the aircraft and reducing the turnaround time of the task.
Manufacturing to Airdrop
The custom platforms were manufactured to AS1657:2018 standards in our major manufacturing facility in New Zealand. . With engineering experience from other docking systems, modifications to suit the C-27J Spartans were straightforward and implemented with approval from Northrop Grumman. The docking system’s delivery and installation were marked by its modular build and quick connection features, facilitating rapid setup and takedown. This adaptability was complemented by the system’s towability, ensuring it could be easily relocated in line with operational needs.
Through Life Support
Ensuring the longevity and relevance of our solution through life support was a critical component of the project. This entailed comprehensive safety, assembly, and operation documents for the docking system, providing comprehensive training for the personnel. By utilising standardised extrusion and parts across the design and manufacturing process, SafeSmart Access ensures the availability of replacement parts for the system should any maintenance be required for the platform over its lifetime.
Mission Support
As the C-27J continues its Final Operation Capability assessments, No. 35 Squadron is heavily utilised throughout the Pacific and domestically for disaster response. The fleet of 10 can now undergo maintenance from their fixed docking systems and new mobile stands as they adapt to various operational demands. These new maintenance solutions ensure that the fleet remains in optimal condition and is ready for rapid deployment in both domestic disaster response and international missions.
The combination of fixed and mobile docking systems enhances the flexibility and efficiency of maintenance operations, allowing No. 35 Squadron to maximise the C-27J’s capabilities. This dual approach underscores a commitment to maintaining high readiness levels and operational effectiveness, ultimately supporting the diverse mission requirements of the Australian Defence Force.