Pave Hawks – New Combat Rescue Helicopter

Aging HH-60G Pave Hawks

A solution to replace the USAF’s aging HH-60G Pave Hawk combat search and rescue helicopters becomes more pressing as SAR(Search And Rescue) and MEDEVAC(MEDical EVACuation) flight hours keep piling in. These helos are derived from early-model UH-60 Black Hawks, and were fielded starting in 1982 with an estimated operational life of 7,000 flight hours. Of the initial 112 airframes, the inventory was down to 99 as of late 2010. Only 93 of them were assessed as flyable as of March 2012, with signs of structural fatigue (i.e. cracks) on a majority of them. They are all expected to have reached the 7,000-hour milestone by 2019. In September 2011 two of them were already exceeding 10,000 flight hours.

The shortfall in the fleet has been addressed with an Operational Loss Replacement (OLR) program that funded 20 replacement H-60 family airframes over FY 2011-12. That’s just a short-term stopgap, as maintaining older helos becomes increasingly expensive and dangerous.

Development funding for a new program was featured in the FY 2013 President Budget, but Congressional dithering took its toll. A couple of months into FY 2014, the Air Force sounded ready to both award the contract, and deprive it of any funding in its FY 2015 budget request. By March 2014, however, funds had been found.

Savvy observers will recall that years ago, CSAR-X Initial Operational Capability (IOC) was scheduled for 2012, at 10 operational aircraft. In order to defend its lead on this all-service mission, the USAF is putting an emphasis on affordability and fast production. Even so, it will be several more years before meaningful replacements begin to arrive in the field. IOC for the CRH-60M isn’t expected until 2020.

CRH: Contracts & Key Events

January 18/23: From HH-60 To HH-60W The US Air Force has started phasing out one of its oldest and most reliable assets, the HH-60G Pave Hawk helicopter. This move comes as the Air Force’s 55th RQS (Rescue Squadron) has just returned from a successful deployment, during which the Pave Hawk fleet played a crucial role in a variety of missions, including personnel recovery, casualty evacuation and on-call support to joint and coalition forces. The 55th RQS, based at Davis-Monthan Air Force Base in Arizona, is now preparing to fully integrate the new HH-60W Jolly Green II helicopter into its fleet. This newer helicopter model is expected to bring increased aircraft availability and newer technologies to the table, which will be leveraged by 55th RQS aircrews to continue the vital mission of combat search and rescue operations.

October 19/22: GAU-18 The GAU-18 .50 caliber machine gun was recently unmounted from an HH-60 helicopter and mounted on the ground to be tested as a defensive weapon. The test took place at Avon Park Air Force Range, Florida on October 14. It was organized by the 920th Rescue Wing.

May 24/21: Repair Sikorsky won a $25.8 million deal for the repair/overhaul of the refueling probes on the HH-60G helicopter. The HH-60G Pave Hawk is the US Air Force’s primary combat search and rescue helicopter used by Air Force special tactics teams and pararescuemen. The Pave Hawk is a highly modified version of the Army Black Hawk helicopter which features an upgraded communications and navigation suite that includes integrated inertial navigation/global positioning/Doppler navigation systems, satellite communications, secure voice, and Have Quick communications. Work will take place in Connecticut. Expected completion is in May 2026.

February 15/21: Upgrade The US Air Force is to contract Sikorsky to upgrade its HH-60W Jolly Green II combat search and rescue (CSAR) helicopter to improve on the 2012 requirements baseline. According to the service, the manufacturer is to bring the capabilities of the Combat Rescue Helicopter (CRH) up to today’s specifications, ahead of the commencement of full rate production in fiscal year 2022. Under the potential five-year deal for rolling capability upgrades to both the helicopter’s hardware and software systems, Sikorsky stands to receive up to $980 million.

November 10/20: Jolly Green II The first two HH-60W “Jolly Green II” helicopters arrived at Moody Air Force Base in Georgia on November 5, 2020. The USAF expects the arrival of 112 of these helicopters. The first two aircraft arrived from Lockheed Martin’s Sikorsky Training Academy in Stuart, Florida. Moody’s 41st Rescue Squadron and the 413th Flight Test Squadron and 88th Test and Evaluation Squadron flew the “Jolly Greens II“, The HH-60W is an improved variant of the combat-proven UH-60M Black Hawk helicopter, and will eventually replace the HH-60G Pave Hawk medium-lift, combat search-and-rescue helicopter, which entered service in 1982. The new helicopter is designed for deployment in casualty evacuation, medical evacuation, non-combatant evacuation missions, civil search-and-rescue, humanitarian aid, disaster relief, and insertion or extraction of combat forces. The USAF ordered the choppers in 2014.

October 15/19: Replacement Sikorsky showcased its next generation Combat Rescue Helicopter during a ceremony at its Development Flight Center in West Palm Beach, Florida last week. The HH-60W is manufactured by Sikorsky, a unit of Lockheed Martin, and is designed to replace Air Force’s aging fleet of HH-60G Pave Hawks. During the event, United States Air Force General James M. Holmes, Commander, Air Combat Command, Joint Base Langley-Eustis, Virginia described the HH-60W helicopter as a critical tool for the warfighter. The US Air Force program of record calls for 113 helicopters to replace the HH-60G Pave Hawk, which perform critical combat search and rescue and personnel recovery operations for all US military services.

September 12/18: Next milestone The new US Air Force’s combat rescue workhorse will soon make its first test flight. The HH-60W, or Pave Hawk II will soon replace the ageing HH-60G Pave Hawks. The Whiskey boasts longer range, and a specially-developed tactical mission kit that will give pilots and para-rescue crew information from an array of sensors. The HH-60W can be deployed in casualty evacuation, medical evacuation, non-combatant evacuation missions, civil search-and-rescue, humanitarian aid, disaster relief, and insertion or extraction of combat forces. The first two HH-60Ws are currently undergoing several months of instrumentation checks at Sikorsky’s West Palm Beach, Florida facility. The Pave Hawk II program calls for the delivery of 112 helicopters at a cost of $7.9 billion. The Air Force expects to fly its first helicopter by March 2020, and says that deliveries will likely run through 2029.

February 22/18: Pave Hawk W enters final assembly Lockheed Martin said Tuesday, that its helicopter subsidiary Sikorsky is beginning final assembly of the first HH-60W Combat Rescue Helicopter, the latest variant of the long-serving Pave Hawk. The assembly will include the installation of a Tactical Mission Kit (TMK) delivered from Lockheed Martin’s Owego, New York, facility, which integrates sensors, radar and multiple defense systems and other sources of intelligence information for use by combat rescue aircrews. A new fuel system will also be installed which features duel internal fuel tanks totaling 660-gallons, nearly doubling the capacity of the internal tank on a UH-60M Black Hawk. A total of nine aircraft will be built by Sikorsky in Connecticut during the Engineering Manufacturing Development (EMD) phase of the program—four EMD aircraft and five System Demonstration Test Articles (SDTA)—and the USAF is calling for 112 helicopters to replace its aging HH-60G Pave Hawk helicopters. For more on the USAF’s ageing G-model Pave Hawks, check out this recent article from Defense News

August 18/17: The US Air Force has awarded Lockheed Martin’s AN/APR-52 radar warning receiver Technical level 6 status after a round of successful testing by the US Air Force Integrated Demonstrations and Applications Laboratory at Wright Patterson Air Force Base in Dayton, Ohio. News of the milestone comes over a year before the HH-60W combat rescue helicopter—which will use the receiver—makes its first flight. During the test, the receiver was evaluated in simulated threat environments. Sikorsky’s HH-60W will replace the Air Force’s aging HH-60G Pave Hawk search-and-rescue helicopters.

June 2/17: Lockheed Martin has successfully completed an Air Vehicle Critical Design Review for the USAF’s Combat Rescue Helicopter program, allowing the firm to continue with the manufacture and testing of the HH-60W helicopter. The milestone moves forward the $1.28 billion development program, which will see Lockheed produce at least 112 HH-60Ws in order to replace the service’s existing fleet of HH-60G Pave Hawk helicopters. The June 2014 contract includes test aircraft, maintenance, training and simulation suites, and a $203 million modification in January 2017 brought the total number of test helicopters to nine.

July 1/16: The first of 21 US Army UH-60L Black Hawks, converted and remissionized into HH-60G Pave Hawks, has been introduced as part of the service’s Operational Loss Replacement (OLR) program. Works on the UH-60s is being carried out by Science and Engineering Services LLC which involves adding a comprehensive kit of modifications to the utility helicopter, along with additional equipment to convert it into a combat search and rescue HH-60G. The OLR program aims to replace aircraft lost in nearly 15 years of deployed combat operations since the commencement of the “War on Terror.”

May 24/16: Sikorsky’s HH-60W Combat Rescue Helicopter is to move into the detailed design phase after successfully passing an air vehicle preliminary design review by the US government. The UH-60 Black Hawk variant will now enter a 75-month engineering and development phase which will see nine aircraft produced, including five “system demonstration test articles” to support operational testing. The design includes air force and mission-specific avionics, equipment and defensive countermeasures, plus a larger internal fuel capability and cabin area when compared to its UH-60 cousin and is unique enough to warrant its own development phase and even a separate assembly line.

Nov 29/14: Designation. The CRH is officially designated by the Air Force as HH-60W – or 60-Whiskey more informally – as the HH-60G’s successor. A name will be picked up later. The systems requirement review is scheduled later this fiscal year, with initial deliveries expected in FY19. For one this will depend on how the FY15 budget is actually wrapped up, as well as whether sequestration affects FY16 spending. The W in HH-60W could very well mean “wait”, as this project is clearly not among the Air Force’s top acquisition priorities.

Dec 13/13: Politics. Secretary of Defense Hagel gets a letter from 74 of 528 Congressional representatives, who don’t want the USAF to leave new combat rescue helicopters out of USAF’s budget. They cite Gen. Moseley’s (correct) characterization of CSAR as a moral imperative for USAF pilots.

The USAF is cagey about committing to anything in response. It’s also worth asking, and answering: if a CRH-60M is really the only choice left, could the US military just choose to equip planned HH-60M buys with a fitting for an aerial refueling probe, then handle the job using a combination of Army (HH-60M) and USMC (MV-22) assets? By all accounts, this is a question being asked in the Pentagon. Using other services’ platforms could meet the moral imperative objection. If the answer is “no, that won’t do,” an effective case requires a precise explanation of why not. Sources: Defense News, “Congress to Hagel: Keep funding search-and-rescue helos.

Nov 22/13: The Air Force posts on its CRH solicitation page that:

“In response to the CRH solicitation, the USAF received one proposal. That offer, from Sikorsky Aircraft Corporation has provided an acceptable technical solution and the USAF intends to award a contract based upon budget availability. The USAF is laying the groundwork to award the CRH contract in the second quarter of fiscal year 2014. The award is contingent on the outcome of the President’s budget review process where CRH would need to be funded across the future year’s defense program.”

Earlier in the week Defense News had reported that a CRH start was not funded in the FY 2015 – 2018 budget plans, which were put together by the Air Force under the assumption that sequestration will remain in place over the entire period. Acting Air Force Secretary Eric Fanning explained that new program starts were caught between a rock – the biggest priorities being F-35, KC-46 and the future strategic bomber – and a hard place called sequestration. Maybe this public messaging that the Air Force may have to curtail its combat search and rescue mission will succeed in what looks like a deliberate effort to shame Congress into disarming at least part of the sequester.

Aug 2/13: Delay. USAF spokesman Ed Gulick says that the CRH award will be delayed past Oct 1/13, instead of being awarded before Sept 30/13. The 1-year delay is attributed to “time required to complete an independent cost estimate and the impact of government furloughs.”

It’s hard to avoid the conclusion that the USAF is either more focused on other spending priorities and likely to drop CRH in coming reviews, or taking the extra time in order to help ensure that the award will be as difficult as possible to challenge. With Sikorsky’s “CRH-60M” as the only contender, a challenge is likely anyway if the award goes through. Reuters.

Jan 4/13: Only 1. Reuters reports that the USAF wouldn’t confirm that it had received only 1 CRH bid, but USAF spokesman Ed Gulick said that they had “acquisition procedures in place to proceed with this important acquisition regardless of the number of bidders.”

That may not stop GAO protests, however, which doomed the USAF’s CSAR-X predecessor. Ominously, EADS North America Chief Executive Sean O’Keefe is quoted as saying that as written, CRH’s terms didn’t call for an evaluation of full life cycle costs. The Defense Department’s emphasis on affordability, and a new federal law which required such an evaluation, could be enough to sustain a protest.

Dec 12/12: Why 112? James Hasik wonders about the math behind 112 CRH helicopters. Why that number?

“I have watched at least two NATO air wars now in which the US Marine Corps seems to have had the hammer for CSAR. It’s important to note that the Marines don’t actually have specialized CSAR units or aircraft… What they do have is long-range rotorcraft and guys who train hard… In Bosnia in 1995, that was a CH-53 and some escorts from the Kearsarge, pulling out an USAF F-16 pilot. In Libya in 2011, it was an MV-22 from (coincidentally) the Kearsarge, pulling out an USAF F-15 crew.”

“…Without seeing the missions needs statement, it’s hard to know what led to the number 112, but the quantity is easy to criticize, and on the numbers… [set of assumptions made]… The point is that even under these unrealistically generous assumptions, the USAF would only want a fleet of 112 dedicated CSAR aircraft if it was figuring on losing lots of planes in a massive bloody war. The only plausible opponent that could give it that much trouble is China, and in that case, the H-60 hasn’t anywhere close to the range needed to recover the aircrews.”

He doesn’t think that math augurs well for budgetary survival.

Dec 11/12: Sikorsky alone. After studying the RFP’s structure and terms, most bidders decide that it’s impossible to win. Once minimum requirements are met, it’s a straight cost battle, with no credit for additional capacity or capabilities, and terms that will disqualify any bid over $6.84 billion. That’s a legitimate contracting approach, especially with the USAF’s top priorities leaving very little room for anything else. The KC-46A tankers are urgent, the F-35 program is set to spend huge amounts of money, and the vastness of the Pacific has made the next-generation bomber a priority. As contracting consultant Jim McAleese notes, everything else is going to be pushed to bare minimums to pay for them.

For CRH, this means that Sikorsky and Lockheed Martin are the lone team willing to bid. Their 2010 teaming agreement for the HH-60 Recap was issued long before the current RFP, and they won’t say which helicopter they’re bidding. All they could tell us is that: “Sikorsky intends to continue with its proposal to offer the Air Force a proven, affordable combat rescue helicopter system to perform the critical mission of saving warfighters’ lives.”

The HH-60M is certainly proven in this role, but the S-92 could also be touted as “proven” given its coast guard service, so the statement means nothing. As for the others:

• AgustaWestland and Northrop Grumman have decided not to bid the AW101/ “HH-71”.
  
• Boeing won’t bid the HH-47 that won the cancelled CSAR-X competition.
  
• Nor will the Boeing-Bell team bid the V-22 Osprey tilt-rotor.
  
• Eurocopter has decided not to submit a bid, either, which presumably would have involved the special forces/ SAR variant of its EC725 Cougar, or a modified NH90 FAME with the MEDEVAC/SAR kit.

The question now is whether the USAF will simply barrel ahead with a late FY 2013 contract and say “these were our terms, whomever bids, bids” – or withdraw and revise the RFP. Reuters | Aviation Week | Defense News.

September 2012: Industry Day and 3rd draft. Details emerge as contractors seek clarification on terms and schedules. The “affordability gate” has been set at $6.848B, a number the Air Force does not seem keen to elaborate on. It is going to be a Best Value award with expected discussions past initial proposals, as the sums at stake lead the contracting officers to think an award without discussions would not be realistic. A 1% schedule incentive is built in, to be paid after (timely) delivery.

The draft Statement of Work shows how production of 112 helicopters is expected to be scheduled between EMD over FY 2013-16, followed by LRIP in FY 2017-18, and FRP in FY 2019-24. That would exactly replace the initial HH-60 fleet, but would be below the canceled 141 helicopter CSAR-X buy. CRH’s 2018 date for Initial Operational Capability would come 6 years later than CSAR-X had been aiming for.

One contractor made a salient comment that the Air Force just brushed aside in their answer by saying they won’t change their communications requirements:

“Spec requires basic comms capabilities — have quick SINCGARS, UHF-SATCOM, etc. However, HH-60G is acquiring new suite of multi-band radios that will also provide crypto modernization, full compliance with GATM (ED-23B) [DID: Global Air Traffic Management], and advanced waveforms such as SRW and MUOS. Won’t CRH be a step backwards from what will be fielded on HH-60G in FY14?

The government’s curt answer is disconcerting, given that CRH deliveries are expected several years after said HH-60G upgrades. GATM retrofits were also made on KC-135s an on C-5s among others, to meet new FAA standards and allow shared access within both civil and military airspace.

Finally, the USAF found that answers to an earlier round of classified questions were not mailed out back in July, leaving contractors hanging dry for the expected clarifications. This is to be corrected promptly.

The final RFP was originally scheduled earlier in 2012, and was postponed a couple of times. At the time of this writing its new release date is not known, though Wright-Patterson Public Affairs tells DID that it should be “very soon” as the 3rd draft should be the last iteration before a finalized RFP. As of July 2012, the date for the award was set to Q3 FY2013, but this now looks likely to slip by at least a quarter. Contractors will have 60 days to submit their proposals.

Sept 18/12: AW101. Northrop Grumman and Finmeccanica’s AgustaWestland announce they will partner to bid on CRH, as well as the future presidential helicopter. They will offer the 3-engined, AW101-derived “HH-71” to compete for CRH.

Subsequent displays reveal a number of distinguishing features beyond the 3 engines, including a custom-designed medical suite, 7.62mm minigun turret mounted above the ramp, and rotor blades that push air away to reduce brownout during landings. Release | DoD Buzz.

March 21/12: Industry Day. interested contractors are briefed during an Industry Day whose information package is available on FBO (CCR validation required).

Feb 2012: In the FY2013 President Budget, the USAF starts ramping up RDT&E funding for the CRH with 2 test airframes in FY13.

Jan 30/12: HH-60Gs. Rotorhub reports that he HH-60G fleet carried out more than 9,700 sorties in 2010, recovering over 1,900 personnel, but falling to around 8,000 sorties in 2011. With respect to cracking and other issues, the past 6 years have seen 83 structural issues that required unscheduled depot maintenance. Col. Chad Franks, the commanding officer of the 347th Rescue Group adds some thoughts:

“What we have done over the last few years is we have put add-ons onto the [HH-60G] aircraft but it has not been integrated the way it should have been. So for us, getting that total integration of our mission systems and our rescue systems all in one package would be ideal… Given the aircraft we have lost over the last nine years, our first job is to get back to 112. We are doing that by buying UH-60Ms right off the line and outfitting them with our rescue equipment.”

August 2011: the Air Force issues a Sources Sought solicitation for a HH-60 Recap Program. This later morphed into the CRH, as per entries above.

May 26/11: Defense Tech reports on the HH-60 Recap program. Meanwhile:

“The service has initiated a band aid program to replace the 13 lost [HH-60] aircraft in the next couple of years with UH-60M airframes purchased from the Army. Still, this does little to address the fact that the vast majority of the CSAR fleet is aging and overused, with dozens of airframes developing stress cracks.”

April 27/11: AW101. AgustaWestland announces that they’ll offer the AW101-derived “HH-71” for the HH-60 RECAP program, and the AW139M for the USAF’s CVLSP utility helicopter competition. Vertical.

July 16/10: Boeing & EADS. Flight International reports that Boeing and EADS Eurocopter have each submitted data 2 alternatives for the HH-60 replacement program:

“Boeing has submitted data on the CH-47 and V-22 to the US Air Force as potential replacements for the HH-60G Pave Hawk fleet of combat search and rescue helicopters (CSAR), a spokesman says… the UH-60M [is] a helicopter less than half the size of the heavylift CH-47 and barely one-third the maximum takeoff weight of the V-22 tiltrotor.

The same variance in size, roughly put, also applies to the aircraft proposed by EADS, which are the NH-90 and EC-725 Super Cougar. EADS submitted data on both aircraft because they believe they “offer proven capabilities at best value and lowest cost to the taxpayer,” says EADS NA chief operating officer Dave Oliver.”

July 15/10: HH-60? Sikorsky and Lockheed Martin announce that they’ll compete together for the HH-60 Recap program, using a modified H-60M Black Hawk. The HH-60M is already in service as a US Army MEDEVAC platform. Sikorsky.

Additional Readings

• DID – CSAR-X: Canceled for Convenience. The CRH’s predecessor program would have bought HH-47 Chinooks.

• DII – Sikorsky’s $7.4-11.6B “Multi-Year VII” H-60 Helicopter Contract. Explains the UH-60M that sits at the contract’s center, though MYP-VII also buys HH-60M, MH-60S, and MH-60R helicopters.

• USAF – HH-60G Pave Hawk. The current CSAR helicopter.