Aircraft Ground Damage Prevention

June 2002June 2002

NBAA AIRCRAFT NBAA AIRCRAFT GROUND DAMAGE GROUND DAMAGE PREVENTIONPREVENTION

Best practices for preventing Best practices for preventing business aircraft ground business aircraft ground

damage eventsdamage events

NBAA Safety Committee NBAA Safety Committee

IntroductionIntroduction• Purpose of program - reduce aircraft ground damage risk by Purpose of program - reduce aircraft ground damage risk by

providing “best practices” interventions providing “best practices” interventions

• Focused audience - corporate flight and maintenance crewsFocused audience - corporate flight and maintenance crews

• Intended use - training and awareness tool Intended use - training and awareness tool

• Self-audit tool - gap analysis, how do we manage these risks? Self-audit tool - gap analysis, how do we manage these risks? (tbd)(tbd)

• Incident analysis flow chart -tool to look at human factors issuesIncident analysis flow chart -tool to look at human factors issues

• What this is not - a tool to manage FBO’s What this is not - a tool to manage FBO’s

• Size of the problem ? Many costs uninsured, estimated at over Size of the problem ? Many costs uninsured, estimated at over $100 million/year in direct costs$100 million/year in direct costs


Most significant risk factors for Most significant risk factors for ground damagesground damages

1. Towing 2. Ramp movements3. Ground service equipment4. Hangar movements

0 10 20 30 40 50

Hangar

GSE

Ramp

towing

Frequency of events%


Most significant human factors Most significant human factors issues for ground damagesissues for ground damages

1. Time pressures - task saturation2. Skill based errors - over/under skilled3. Customer satisfaction4. Direct rule based violations5. Environmental i.e. illumination, visual obstructions, noise levels

6. Communications breakdowns7. Loss of situational awareness


Maintenance Related ExposuresMaintenance Related Exposures


Risk Exposure - Area: Maintenance Related Exposures

• Mobile ladders/equip near Mobile ladders/equip near aircraft control surfacesaircraft control surfaces

• Walk paths near aircraft Walk paths near aircraft storage positionsstorage positions

• Use of non-rubber chocks Use of non-rubber chocks while in hangarswhile in hangars

• Static wick protection Static wick protection warning deviceswarning devices

• Complete a Job hazard Complete a Job hazard analysis for specific aircraft analysis for specific aircraft maintenance exposures maintenance exposures related to unique situationsrelated to unique situations

Situation/ExposureSituation/Exposure


• Fire Protection - urea foam Fire Protection - urea foam deluge systems should deluge systems should receive periodic inspectionreceive periodic inspection

• Equipment that can move Equipment that can move due to vibration or jet blast due to vibration or jet blast should be chocked or should be chocked or securedsecured

• Aircraft log books should be Aircraft log books should be stored in a secure storage stored in a secure storage system when not in usesystem when not in use

• Clothing - Belt buckles Clothing - Belt buckles covered and shoe covered and shoe protectors used if required.protectors used if required.


Risk Exposure - Area: Maintenance Related Exposures


Aircraft MovementAircraft Movement


• Use of at least 2 Use of at least 2 wingwalkers while wingwalkers while moving aircraft from or moving aircraft from or into hangars along with into hangars along with tug operatortug operator

• Team completes an area Team completes an area risk assessment before risk assessment before moving aircraftmoving aircraft

• Perimeter floor marking Perimeter floor marking that delineates limits of that delineates limits of aircraft placement near aircraft placement near hangar wallshangar walls


Risk Exposure - Area: Aircraft Movement In/Out of Hangars/Storage



• Hangar doors - securing Hangar doors - securing methods to prevent methods to prevent inadvertent closure due to inadvertent closure due to jet blast or high windsjet blast or high winds

• Aircraft wings should not Aircraft wings should not overlap other aircraft due overlap other aircraft due to settling hazardto settling hazard

• Hangar doors should be Hangar doors should be fully opened before aircraft fully opened before aircraft movementmovement

• Aircraft should not be Aircraft should not be moved through propeller moved through propeller arcsarcs




• Floor/ramp markings Floor/ramp markings delineate best aircraft delineate best aircraft positions for entry or exit positions for entry or exit from hangarsfrom hangars

• Suggested hangar Suggested hangar staking diagrams should staking diagrams should be provided as visual be provided as visual aidsaids

• Overhead doors systems Overhead doors systems should have a periodic should have a periodic inspection processinspection process




• A Job hazard analysis should be A Job hazard analysis should be completed for aircraft completed for aircraft movement exposures in hangar movement exposures in hangar areas related to unique areas related to unique situationssituations

• Written procedures for aircraft Written procedures for aircraft movement should be available movement should be available in both the flight and in both the flight and maintenance operations maintenance operations manualsmanuals

• Employees who move aircraft Employees who move aircraft receive should receive training receive should receive training on company procedures on company procedures




• A visual inspection of the A visual inspection of the aircraft should be completed aircraft should be completed before any tow initiatesbefore any tow initiates

• The team should complete an The team should complete an area risk assessment briefing area risk assessment briefing before moving aircraft - all before moving aircraft - all sides of aircraft perimeter sides of aircraft perimeter visually inspected for hazardsvisually inspected for hazards

• Towing equipment - Towing equipment - tugs/lektro tugs visually tugs/lektro tugs visually inspected, brakes checked, inspected, brakes checked, correct tow bar verifiedcorrect tow bar verified




• Towbars should be labeled as Towbars should be labeled as to aircraft typeto aircraft type

• Tugs are marked as to rated Tugs are marked as to rated maximum loadsmaximum loads

• A post tow inspection should A post tow inspection should completed of aircraftcompleted of aircraft

• For aircraft pushes, the rear For aircraft pushes, the rear area must be inspected area must be inspected before movementbefore movement

• A written job hazard analysis A written job hazard analysis should be completed for should be completed for aircraft towing exposuresaircraft towing exposures


15,000lb


Aircraft TowingAircraft Towing


Risk Exposure - Area: Aircraft Towing - Ramp Areas

• Verification that aircraft Verification that aircraft brakes are off is brakes are off is completed before the completed before the tow or push is initiated tow or push is initiated

• Employees who move Employees who move aircraft should receive aircraft should receive training on procedurestraining on procedures

• Aircraft are towed at a Aircraft are towed at a safe walking speedsafe walking speed

• Towing safety rules Towing safety rules marked on tugsmarked on tugs




• Large/heavy aircraft Large/heavy aircraft should require a should require a person acting as a person acting as a brake monitor during brake monitor during movement - in cockpitmovement - in cockpit

• If the tow operator If the tow operator loses sight of wing loses sight of wing walker, an immediate walker, an immediate STOP STOP should occur should occur

• If there is any doubt as If there is any doubt as to having adequate to having adequate space/clearance,an space/clearance,an immediate immediate STOPSTOP should occurshould occur




• Aircraft should only be Aircraft should only be moved by approved moved by approved vehiclesvehicles



Aircraft TaxiAircraft TaxiFlight Crew Procedures Flight Crew Procedures


Risk Exposure - Area:Risk Exposure - Area:Initial Aircraft Taxi Approach to Ramp AreaInitial Aircraft Taxi Approach to Ramp Area

• Pilots should visually scan the Pilots should visually scan the ramp for risks while taxing in ramp for risks while taxing in

• Ground marshaller’s should Ground marshaller’s should provide the correct hand signals provide the correct hand signals - if in doubt, stop- if in doubt, stop

• While taxiing, the area should While taxiing, the area should continually be scanned for continually be scanned for threats such as: drain grates, threats such as: drain grates, narrow rows of positioned narrow rows of positioned aircraft, ramp slope, blind aircraft, ramp slope, blind spots,jet blast hazards, wind spots,jet blast hazards, wind direction, loose chocks,direction, loose chocks,vehicle movementsvehicle movements



Risk Exposure - Area:Risk Exposure - Area:Initial Aircraft Taxi Approach to Ramp AreaInitial Aircraft Taxi Approach to Ramp Area

• Pilots should Pilots should communicate (radio) with communicate (radio) with unicom or for taxi in unicom or for taxi in assistance from FBO, etc.assistance from FBO, etc.

• Pilots should observe any Pilots should observe any hazards related to hazards related to ground service ground service equipment movements or equipment movements or positioning hazards - plan positioning hazards - plan ahead for departure ahead for departure routesroutes



Flight Crew PrecautionsFlight Crew Precautions (departure) (departure)• Flight crew should Flight crew should

complete a visual complete a visual inspection of the aircraft inspection of the aircraft prior to departureprior to departure

• Pilots should ensure that Pilots should ensure that wing walkers are used in wing walkers are used in confined areas or areas confined areas or areas where marshalling person where marshalling person cannot see all positions of cannot see all positions of the aircraft.the aircraft.

• Pilots should visually Pilots should visually survey the ramp area for survey the ramp area for risks during pre-start and risks during pre-start and taxitaxi


Aircraft ParkingAircraft Parking

Flight Crew PrecautionsFlight Crew Precautions


Risk Exposure - Area:Risk Exposure - Area:Aircraft Parking/Tie Down - Ramp AreasAircraft Parking/Tie Down - Ramp Areas

• Warning cones should be Warning cones should be placed at wing tips and tailplaced at wing tips and tail

• Potential jet exhaust blast Potential jet exhaust blast hazards should be planned hazards should be planned forfor

• Aircraft should be Aircraft should be positioned to avoid wing positioned to avoid wing overlap hazardsoverlap hazards

• Triple chocks should be Triple chocks should be placed at mains and nose placed at mains and nose gear for overnight parkinggear for overnight parking



Risk Exposure - Area:Risk Exposure - Area:Aircraft Parking/Tie Down - Ramp AreasAircraft Parking/Tie Down - Ramp Areas

• The main gear should be The main gear should be chocked at all ramp chocked at all ramp parking situationsparking situations

• A ground marshler A ground marshler should be used to aid for should be used to aid for taxi in and departure taxi in and departure from parking spotsfrom parking spots

• Ground air stair mats Ground air stair mats should be removed should be removed before engine startbefore engine start



Ground Service EquipmentGround Service Equipment


Risk Exposure - Area:Risk Exposure - Area:Ground Service EquipmentGround Service Equipment

• Fuel Trucks should be chocked Fuel Trucks should be chocked when servicing aircraftwhen servicing aircraft

• All mobile equipment should be All mobile equipment should be positioned to not face aircraftpositioned to not face aircraft

• Ground power units should not be Ground power units should not be positioned under tail sections and positioned under tail sections and must be chockedmust be chocked

• Special precautions should be Special precautions should be followed to insure the removal of followed to insure the removal of GPU plugs before the unit is movedGPU plugs before the unit is moved

• Tugs and other types of GSE such Tugs and other types of GSE such as golf carts should be shut-off, as golf carts should be shut-off, parking brakes set, and chocked parking brakes set, and chocked when left unattendedwhen left unattended


Flight crew communicationsFlight crew communications

with ground crews with ground crews

Pilot

Ground crew

Hey, do you have crew cars? Fuel her

up and I will seeyou in the AM


FFlliigghhtt CCrreewwQQuueessttiioonnss

GGrrnndd CCrreewwRReessppoonnssee

AAccttiioonnss

““WWiillll yyoouu bbeettoowwiinngg oouurraaiirrccrraafftt ttooddaayy??””

NNoo

YYeess

PPrreesseenntt tthhee ccoommppaannyy’’ss wwrriitttteennssuuggggeesstteedd pprroocceedduurreess tthhaatt oouuttlliinneessggrroouunndd cchhoocckkiinngg pprroocceedduurreess aannddpprrootteeccttiioonn -- ccoonneess,, eettcc..

IInnffoorrmm ggrroouunndd ccrreeww -- ““bbee aaddvviisseedd,, tthheebbrraakkeess aarree ooffff aanndd hheerree iiss aa ccooppyy ooff oouurrccoommppaanniieess pprreeffeerrrreedd mmeetthhooddss ffoorrttoowwiinngg aanndd sseeccuurreeiinngg oouurr aaiirrccrraafftt””..

““AArree yyoouuffaammiilliiaarr wwiitthhtthhiiss ttyyppee ooffaaiirrccrraafftt??””

YYeess

NNoo oorr sshhoowwssuunncceerrttaaiinnttyy

IIff ttiimmee ppeerrmmiittss,, aassssiisstt aass aa ssppootttteerr

AAsskk tthhaatt tthhee aaiirrccrraafftt rreemmaaiinn wwhheerree iitt iissoorr tthhaatt aann eemmppllooyyeeee wwhhoo iiss ffaammiilliiaarrwwiitthh ttoowwiinngg tthhee ttyyppee ooff aaiirrccrraafftt bbeellooccaatteedd bbeeffoorree iitt iiss ttoowweedd

Crew Communications Crew Communications Flight and Ground - TowingFlight and Ground - Towing




AAccttiioonnss

““HHaavvee yyoouu bbeeeennttrraaiinneedd ttoo ttooww tthhiissttyyppee ooff aaiirrccrraafftt??””

NNoo AAsskk tthhaatt tthhee aaiirrccrraafftt rreemmaaiinn wwhheerree iitt iissoorr tthhaatt aann eemmppllooyyeeee wwhhoo iiss ffaammiilliiaarrwwiitthh ttoowwiinngg tthhee ttyyppee ooff aaiirrccrraafftt bbeellooccaatteedd bbeeffoorree iitt iiss ttoowweedd

““WWiillll tthhee aaiirrccrraaffttbbee ttoowweedd dduurriinnggttiimmeess tthhee fflliigghhttccrreeww iiss nnoottaavvaaiillaabbllee??””

YYeess RReeqquueesstt tthhaatt aa wwiinngg wwaallkkeerr bbee pprreesseennttaanndd tthhaatt tthhee ppeerriimmeetteerr ooff tthhee aaiirrccrraaffttbbee cclleeaarreedd bbeeffoorree mmoovveemmeenntt.. TThhee uusseeooff aa bbrraakkee mmoonniittoorr mmaayybbee rreeqquuiirreedd oonnhheeaavvyy aaiirrccrraafftt..

Crew Communications Crew Communications Flight and Ground - TowingFlight and Ground - Towing




AAccttiioonnss

““DDoo yyoouu hhaavveerroooomm ffoorr oouurraaiirrccrraafftt iinn aahhaannggaarr??””

YYeess PPrreesseenntt tthhee ccoommppaannyy’’ss wwrriitttteennssuuggggeesstteedd pprroocceedduurreess ffoorr hhaannggaarrmmoovveemmeennttss,, ii..ee..,, rreeqquuiirreedd wwiinnggwwaallkkeerrss,, cchhoocckkss,, mmoovveemmeenntt ssppeeeedd,, eettcc..

Crew Communications Crew Communications Flight and Ground - Hangar Flight and Ground - Hangar operationsoperations




AAccttiioonnss

““AArree yyoouu ffaammiilliiaarrwwiitthh tthhee ffuueelliinnggpprroocceedduurreess ffoorr tthhiissaaiirrccrraafftt??””

NNoo

YYeess

PPrreesseenntt tthhee ccoommppaannyy’’ss wwrriitttteennssuuggggeesstteedd pprroocceedduurreess tthhaatt oouuttlliinneessffuueelliinngg mmeetthhooddss..

IIff ttiimmee ppeerrmmiittss aassssiiggnn aa ppiilloott ttoooobbsseerrvvee ffuueelliinngg..

AAss mmuucchh aass pprraaccttiiccaall,, ffuueelliinngg sshhoouullddbbee ccoonndduucctteedd oonnllyy wwhheenn aa fflliigghhttccrreewwmmeemmbbeerr oorr eemmppllooyyeeee ooff tthheeaaiirrccrraafftt’’ss oowwnneerr iiss pprreesseenntt..

Crew Communications Between Crew Communications Between Flight and Ground Crews - FuelingFlight and Ground Crews - Fueling


Case studies of what can go wrongCase studies of what can go wrong

Aircraft Towing (Hangar)

Event:

Two ground crew employees were positioning a Falcon 50 into a hangar when the left wing tip struck a golf cart. One employee was operating the Lektro tug and the other employee was acting as the wing walker. The aircraft was being nosed into the hangar. There was a golf cart being charged on the left side of the hangar and a car was parked on the right side of the hangar. As the aircraft was being pulled in, the wing walker was at the rear of the aircraft going between the right wing and left wing to monitor clearance. As the right wing cleared the car the wing walker started to move back to the left wing when the left wing tip struck the golf car` `

Lear–60 Ground Power Unit

Event:

A Lear-60 requested a GPU start assist. Upon completion of both engine starts, and proper shut down procedures of the GPU, the line service technician noticed the GPU cable plug head felt very hot to the touch during disconnect from the aircraft GPU receptacle. The crew was notified, shut down the engines, and requested a maintenance inspection of the GPU receptacle and related components. The aircraft maintenance representative discovered a lose wire on the internal bracket of the GPU receptacle located within the fuselage.

.



Aircraft Towing and Hangar Storage

Event:

Two line service employees with the additional assistance of two aircraft crewmembers were preparing to pull an aircraft from a hangar. The tractor operator misjudged the gear pattern noted on the transmission stick selector, and upon release of the clutch pedal the tractor lurched forward several inches pushing the aircraft into another aircraft positioned directly behind. The intended tow aircraft suffered a dent to the right outboard flap, and the other aircraft suffered a scratch to the nose cone.

Use of Approved Tow Bars

Event:

The owner of a Mitsubishi MU-2 recently requested his aircraft to be towed from a hangar utilizing the customer owned tow bar. Upon the initial tow bar inspection, it was noticed the tow bar was not equipped with manufacturer identification tags and the tow bar was bent.

The line crew notified their supervisor of their findings, and the supervisor instructed the crew not to use the tow bar. The supervisor notified the pilot of the issue and requested the manufacturer labeled tow bar, designed for the aircraft be used. The pilot understood the concern and had no issue with utilizing the approved tow bar. The approved tow bar was used with no further incident.



Crew miscommunication

Event:

The ground crew was informed by the flight crew that the aircraft ( King Air 200 ) brakes were set in the off position. A tow was initiated which resulted in damage to the brake and wheel assembly.

Aircraft Towing - lektro tug

Event

An employee used the Lektro 8750 to tow a Cessna 425 Corsair to a hangar. After the employee captured the C-425 he installed the front gate guard on the bucket of the Lektro. The aircraft was towed to and placed in the common hangar. The operator of the Lektro unit lowered the bucket and released the winch strap prior to chocking the aircraft. The C-425 rolled backwards into the front gate guard crushing the nose wheel fender. The nose wheel fender, which covers the rear of the nose wheel, was crushed against the tire and the fender brackets were broken.



The result of unauthorizedvehicle operation on rampareas



The result of no chocks on a sloping ramp


Self-audit tool:Gap AnalysisSelf-audit tool:Gap Analysis• We have written standard operating procedures Y NWe have written standard operating procedures Y N

• Employees trained on procedures Y NEmployees trained on procedures Y N

• Employees provided risk awareness training Y NEmployees provided risk awareness training Y N

• Incident investigations conducted Y NIncident investigations conducted Y N

• We have completed a risk assessment Y NWe have completed a risk assessment Y N

• Compliance evaluations completed Y NCompliance evaluations completed Y N

• We have the correct ground equipment Y NWe have the correct ground equipment Y N

• We monitor FBO actions Y NWe monitor FBO actions Y N

• We have an accountability system in place Y NWe have an accountability system in place Y N

• Access to ramp areas is controlled Access to ramp areas is controlled

• Flight crews provided ground damage awareness trainingFlight crews provided ground damage awareness training


For Each

At-Risk Behavior

Did Condition Result from a

Behavior?

Unforced Behavior Was the Behavior Simply an Error by

the Individual?

Forced Behavior Was the Behavior Out of Control of the

individual?

Explore “Hard” System Issues•Workstation Design

•Tool/Equipment Design•Tool/Equipment Availability

Influenced Behavior Was there a Risk/Reward Influence on

the Behavior?

Conduct an Analysis to Determine What Drives the

At-Risk Behavior

•Redesign Workstation•Redesign Tool/Equipment

•Purchase Necessary Tool/Equipment

Incident

Explore “Soft” System Issues•Procedures

•Training•Human Factors

Identify and Implement Antecedents and Consequences that Support Desired

Behaviors and Reduce At-Risk Behaviors

Yes No

Yes Yes Yes

No No

Ground damage incident review process

Ground damage incident review process

Make Improvements to:•Procedures

•Training•Human Factors

For Each UnSafe Condition


Special Thanks to:Special Thanks to:• Home Depot FTYHome Depot FTY

• Hill Aircraft FTYHill Aircraft FTY

• Signature Flight Support Signature Flight Support

• Purdue UniversityPurdue University

Documents

Aircraft Ground Damage Prevention