1_BW_2024_12StF Memo ABAV_SML Approved (1).pdf

DEPARTMENT OF THE AIR FORCE

AIR FORCE LIFE CYCLE MANAGEMENT CENTER

WRIGHT-PATTERSON AIR FORCE BASE OHIO

MEMORANDUM FOR DISTRIBUTION

FROM: AFLCMC/ROU

Human Systems Division 1981 Monahan Way Wright-Patterson AFB OH 45433

SUBJECT: Safe-to-Fly (StF) Recommendation for the Aviation Body Armor Vest (ABAV)

(StF Package Identifier: BW-2024-12).

References: (a) AFLCMC/WNU OI, Operating Instruction for Safe-to-Fly Recommendation

(b) AFMAN 11-301V1 Aircrew Flight Equipment

(c) USAF, ABAV, Inspection Manual

1. The Human Systems Division (HSD) (AFLCMC/ROU) recommends the Aviation Body

Armor Vest (ABAV), manufactured by FirstSpear, as StF for the following USAF aircraft:

AC-130, C-130, MC-130, HC-130, EC-130, U-28, MC-12, PC-12, C-208, C-146, C-145, C-17, C-5, KC-46, KC-10, KC-135, C-21, C-32, C-40, C-37 A/B, UH-1, MH-139, HH-60, and CV-22.

2. An evaluation was accomplished by HSD (AFLCMC/ROU) to assess the ABAV for use on military aircraft as a body armor plate carrier with restraint harness and flotation capabilities in accordance with references (a), and (b). The ABAV with integrable restraint harness and flotation aid consists of the following equipment:

Item Size Part Number

ABAV Front Panel Small PN 300-12-00376-5179F-02

ABAV Back Panel Small PN 300-12-00377-5179F-02

ABAV Front Panel Medium PN 300-12-00376-5179F-03

ABAV Back Panel Medium PN 300-12-00377-5179F-03

ABAV Front Panel Large PN 300-12-00376-5179F-04

ABAV Back Panel Large PN 300-12-00377-5179F-04

ABAV Front Panel X-Large PN 300-12-00376-5179F-05

ABAV Back Panel X-Large PN 300-12-00377-5179F-05

ABAV Shoulder Strap Small PN 300-15-00206-9179-02

ABAV Shoulder Strap Medium/Large PN 300-15-00206-9179-52

ABAV Shoulder Strap X-Large PN 300-15-00206-9179-05

ABAV Shoulder Sleeve Small PN 300-15-01032-5179F-02

ABAV Shoulder Sleeve Medium/Large PN 300-15-01032-5179F-52

ABAV Shoulder Sleeve X-Large PN 300-15-01032-5179F-05

ABAV Adaptive Cummerbund Small PN 300-15-01171-5179F-02

ABAV Adaptive Cummerbund Med PN 300-15-01171-5179F-03

ABAV Adaptive Cummerbund Large PN 300-15-01171-5179F-04

ABAV Adaptive Cummerbund X-Large PN 300-15-01171-5179F-05

Advanced Crew Tether System N/A PN R44100-3

LPU-10/P MK II N/A 4220-01-705-8648/S-4570-1

3. The evaluation results indicated that the equipment does not adversely affect the aircraft listed in paragraph one with the following limitations:

a. Vest material burns, melts, and drips when exposed to flash fire. Burn injury risk from melt and drip exists for the operator and rescue personnel. Hampered rescue of personnel, loss of armor plates, life preserving unit, and/or essential equipment could result in injury as severe as permanent total disability and death.

b. The ABAV Cummerbund Tactical Aid to Flotation (CTAF) does not provide unconscious or conscious auto-righting, ambidextrous one-handed activation, and positive freeboard of 4 inches following egress from an aircraft into water which could lead to drowning resulting in injuries up to total permanent disability and death. The land cummerbund should be used in place of the CTAF with LPU-10/P substituted for flotation aid.

c. Ditching of hard armor may be impossible during emergency egress, escape and evasion, and water survival scenarios.

d. The ACTS R41150-3 harness may inadvertently release under high force creating a risk for aircrew to fall from the aircraft resulting in death. The ACTS R44100-3 should be used for restraint harness capability.

e. The mobility range allowed by the ACTS restraint system tether from approved attachment points are inadequate, limiting movement throughout the aircraft, operation of the gun, and visual scan.

f. The BA-22/30 parachute harness leg straps obstruct inflation of the ABAV Cummerbund

Tactical Aid to Flotation which creates a drowning risk.

g. The ACTS harness leg straps interfere with securement of leg drop and hip holsters.

h. The ABAV with hard armor may restrict or impede personnel from performing routine and emergency procedures, such as exiting from the aircraft and navigating small hatches, tight areas/openings-snagging. Larger aircrew had difficulty traversing up and down the KC-46 hatch ladder due to the armor plates causing the vest to snag in the entryway.

i. Blowing dust, blowing sand, and salt fog impacted the functionality of the ACTS Cobra Buckles and Quick Release Tether (QRT) snaphook. Inability to actuate the QRT during emergency such as a cabin fire could result in injury.

j. The electrically insulative properties of the ABAV’s material allows for the accumulation of static charge which could result in an electrostatic discharge in conducive conditions.

Electrostatic discharge may cause an explosion in an environment with combustible materials that leads to injury.

k. No repository exists for technical data and maintenance of safety data. Current documentation lacks relevant safety warnings, and no process has been established to continuously update manuals with discovered safety risks. The use of incompatible armor, restraints, or life preserving units creates the risk for injury.

l. ACTS harness Cobra Buckles, carabiner, and QRT snaphook failed below specificized strength loads. Under extreme loads the restraint harness may fail causing aircrew to fall from the aircraft resulting in injury.

m. Insufficient data was obtained to assess the system accommodates the 5 th to 95 th percentile chest size.

n. Processes to support maintenance of safety matters specific to Air Force platforms have not been established. Without processes in place to implement safety changes to manuals, users will not be able to react to changes in system design or manufacturing mistakes.

4. Any MAJCOM adopting use of the system assumes responsibility for life cycle management of the ABAV, including the creation and maintenance of user manuals detailing the risks and limitations identified in paragraph 3.

5. Configuration Management responsibility resides with any MAJCOM adopting use of the

ABAV. The use of AFLCMC/ROU endorsement on this memorandum for authorization to employ the referenced equipment operationally is contingent upon MAJCOM Functional

Managers and Unit Commanders incorporating the identified risk mitigations into documentation. Any changes to the configuration that was evaluated by HSD

(AFLCMC/ROU) invalidates this StF recommendation and the resulting approvals by the

Program Offices for the aircraft identified in paragraph 1.

6. Final approval for use of the ABAV is contingent upon final Airworthiness approval by the listed Aircraft Program Offices identified in paragraph 1.

7. RECOMMENDATION: Based on the HSD (AFLCMC/ROU) evaluation of the ABAV, I recommend that the Program Offices listed in paragraph 1 proceed with reviewing the data provided by HSD (AFLCMC/ROU) in order to approve the ABAV for use on aircraft. This StF recommendation is specific to the ABAV with ACTS R44100-3 and LPU-10/P configuration that was evaluated by HSD (AFLCMC/ROU).

a. StF Type: Final

b. StF Expiration Date: None

c. Applicable Aircraft: AC-130, C-130, MC-130, HC-130, EC-130, U-28, MC-12, PC-12, C-208, C-146, C-145, C-17, C-5, KC-46, KC-10, KC-135, C-21, C-32, C-40, C-37 A/B, UH-1, MH-139, HH-60, and CV-22

d. Applicable Aircrew Positions: all applicable positions

e. Applicable Operational Procedures: USAF, ABAV, Inspection Manual, USAF ABAV

Commercial Guide Manual

8. Approval and StF Recommendation: I recommend that the ABAV is StF for the listed aircraft. I request that the respective Program Offices evaluate the risks with respect to the applicable aircraft. If the applicable Program Office concurs with the risks and is willing to accept the risks, then I request that Program Office to accept the risks at the appropriate level.

Upon risk acceptance, I request that the Program Office provide HSD (AFLCMC/ROU) with the documentation it issues authorizing use on aircraft.

9. My point of contact for this StF recommendation is lead engineer for Aviation Body Armor, Andrew Montgomery at andrew.montgomery.18@us.af.mil.

1st Ind, AFLCMC/ROU

I Concur.

NICHOLE TAYLOR, NH-04, DAF

Chief Engineer, Human Systems Division AFPEO Combat Readiness

2nd Ind, AFLCMC/ROU

I Approve.

DAVID McCAIN, NH-04, DAF Senior Materiel Leader Chief, Human Systems Division AFPEO Combat Readiness

16 Attachment(s):

1. Aviation Body Armor StF Briefing, 02 DEC 2024

2. Technical Assessment ACE, 02 DEC 2024

3. ABAV SSRA 1 – Heat and Flame Protection

4. ABAV SSRA 2 – Flotation

5. ABAV SSRA 3 – Hard Armor Release

6. ABAV SSRA 4 – Restraint Tether Safety

7. ABAV SSRA 5 – Restraint Tether Functionality

8. ABAV SSRA 6 – Parachute Harness Integration

9. ABAV SSRA 7 – Leg and Hip Holster Integration

10. ABAV SSRA 8 – Aircraft Integration

11. ABAV SSRA 9 – Environmental Conditions

12. ABAV SSRA 10 – Electrostatic Discharge

13. ABAV SSRA 11 – Technical Documentation

14. ABAV SSRA 12 – Restraint System Hardware Strength

15. ABAV SSRA 13 – Anthropometric Accommodation

16. ABAV SSRA 14 – Maintenance of Safety

DISTRIBUTION:

AFLCMC/ROU

AFLCMC/WI

AFLCMC/WL

AFLCMC/WNDI

AFLCMC/WVV

AFMC 645 AESG/WIJE

ACC/A3TO

AFGSC/A3OL

AFGSC/A5BS

AFSOC/A3OZ

AMC/A3TL

Record of Changes

Version Effective Date Summary

1.0 12/11/2024 Original