Construct, Catch, Train: Delivering Cradle-to-Grave European Theater Aircraft Arresting Systems

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By Lt. Col. Grant Harwell, M.SAME, USAF

In preparation for a delivery of F-16 fighter aircraft to Malacky AB, the 435th Construction & Training Squadron completed the overseas repair of an aging aircraft arresting system, confronting timing challenges to complete the installation ahead of schedule.

When there are difficult aviation-related engineer problems to get done in U.S. European Command, higher headquarters routinely calls on the 435th Construction & Training Squadron (435 CTS). This was the case following a delegation visit from the Slovak Air Force in May 2023 to the Directorate of Logistics, Engineering & Force Protection, U.S. Air Forces in Europe-Air Forces Africa.

The Slovak Air Force was set to receive new Block 70 F-16 fighter aircraft in July 2024 and requested assistance from the United States to repair a permanently installed aircraft arresting system at Malacky AB near Bratislava prior to the aircraft arrival.

In conducting this project, the 435 CTS was challenged by an aging system that required serious overhaul. Careful control of risk factors and timelines delivered the repair ahead of schedule and under budget, in time for the arrival of the F-16.

System Overhaul

After meeting with Slovakia Air Force leadership in May 2023 and receiving approval for the project, the 435 CTS quickly mobilized to perform a site visit and system inspection in June. There, the unit discovered a Barrier Arresting Kit-12 more than 20 years old and with significant issues. Originally constructed and installed by the 435 CTS in 2002, this specific system, it became apparent, required a complete overhaul prior to the arrival of the new F-16s.

Both barrier shelters were in poor condition. The sump pump for one of them and drainage system were failing, flooding the foundation and allowing significant organic material growth. The energy absorber system was mounted to the older, outdated metal base design. Rollers were seized in the fairlead beams that allow the energy absorber to be set back from the runway and provide wingtip clearances for larger aircraft.

The concrete foundations had settled as well. This resulted in concrete pad height differences that would interfere in the runway shoulder clear zone, or “tape sweep,” area, and potentially damage the nylon tape as it unwinds during an engagement.

Phasing Project Success

Following the site visit, the field team went to work with planning, design, and cost calculations. With the initial data captured, funding of $859,000 through the European Deterrence Initiative was approved while the airmen continued planning the project across three primary phases.

Getting Underway. Phase One occurred in October 2023 with the removal of the dilapidated Barrier Arresting Kit energy absorber units and their transportation back to Ramstein AB, Germany. A normal energy absorber system overhaul occurs every 10 years and typically uses 60 percent to 70 percent of the previous assembly. However, due to system age and condition, less than 5 percent of the original system could be re-used at Malacky. Additionally during this period, as the official Letter of Intent was not transmitted to the Slovakia Ministry of Defense until December 2023, the team spent the fall months rebuilding the system at Ramstein to prevent valuable time being lost.

Little additional risk was accepted at this point in the project. Because the 435 CTS continually rebuilds arresting system barriers for the other U.S. air bases in Europe, if for some reason this project fell through, the system would simply be sent to another installation.

Onsite Execution. Once the work was fully coordinated and approved, the unit moved to Phase Two in January and February 2024. Over the course of three weeks, a five-person team demolished the existing infrastructure and prepared the site for future construction. Except for the fairlead beam foundation, all infrastructure on the west side of the runway was removed. This included the barrier shelter and foundation, underground tape tube, and tape sweep ramps. The east side system was in better condition and more infrastructure was able to be reused, with only the barrier shelter and portions of the tape sweep ramps removed. The airmen removed a total of 273-T of debris and earth, followed by the backfill and compaction of the excavated areas with base course to enable flight operations between phases. The engineering team also was on site during this time taking survey measurements to confirm which foundations to remove and finalize the design and ensure proper elevations during final construction.

After a five-week reset period, the airmen returned in mid-March for the longest and final phase to construct and install the arresting system. Over a 10-week period, the team completely rebuilt the west side foundations of both the barrier shack, fairlead beam ramps, and tape sweep areas, placing over 256-yd² of reinforced concrete. The 16-in diameter ductile iron tube connecting the barrier shelter to the fairlead beam was re-installed, correcting for new elevations from the previous settled foundations. New fairlead beams were installed, along with the completely re-built energy absorber units that were covered by new barrier shelter systems with fresh high-visibility red and white paint.

The Standard Arresting System

The Barrier Arresting Kit-12 is the U.S. Air Force’s standard arresting system for tail-hook equipped fighter aircraft. The system aids in an aircraft being able to follow a safe and controlled deceleration when landing or aborting take off in emergency situations.

The arresting kit uses a 1.25-in steel pendant cable stretched across an active runway, attached at each side by a woven nylon tape. These tapes are, in turn, connected to and then wound on a reel-based, friction brake energy absorber assembly held with approximately 2,000-lb of static tension through the unit’s hydraulic system. As the aircraft’s tailhook engages (or “catches”) the arresting cable, each tape storage reel drives the hydraulic system pump and the rotation of a control cam regulating hydraulic fluid pressure. The pressure is applied to the arresting brakes, which slows and stops the aircraft.

Once the aircraft is disconnected after a successful engagement event, the arresting system is re-wound using the onboard diesel engines and re-tensioned for the next engagement.

Confronting Challenges

During planning and construction, the 435 CTS identified and overcame several challenges. Since the unit had not performed construction in Slovakia in many years, contracting and procurement processes faced several hurdles such as translating forms and explaining Value Added Tax exemptions to local vendors.

Working on an active runway is always complicated. The squadron had to contend with very narrow work windows of only a few hours. During active flying operations, the runway must be cleared of equipment and swept of foreign object debris prior to aircraft arrival or departure. Most of the demolition work was performed during a large airfield closure. Construction and concrete pours were carefully coordinated to ensure zero impact to the base’s flying mission.

The engineer team also had to overcome the challenge of connecting existing and new foundations to meet geometric and structural engineering requirements while aligning the system to match the difficult terrain and stormwater conditions.
Finally in June, the 435 CTS partnered with air advisors from its sister unit, the 435th Contingency Response Support Squadron, also based at Ramstein AB, to lead a mobile team to train Slovak Air Force engineers on operations, maintenance, and emergency reset procedures of the new system.

This foreign-support project was completed under budget and ahead of schedule with a ceremonial handover and then was certified with a test engagement by the 31st Fighter Wing from Aviano AB, Italy, on July 10, in time for the arrival of the first two Slovak Air Force F-16s just 12 days later.

Our Nation and Allies

The work at Malacky AB integrated capabilities and personnel from each of the three core mission areas of the 435 CTS: “Construct Anything, Catch Everything, and Train Everyone.” The repair project strengthened the U.S.-Slovak partnership and emphasized the importance of initiatives to maintain and reinforce readiness, collaboration, and interoperability across NATO.

The refurbishment of a critical emergency airfield capability enables military forces from the United States, allies, and partners to rapidly deploy and sustain air operations across the European Theater enabling Agile Combat Employment. Additionally, the new arresting system will allow the United States to work closely with European allies and partners to deliver lethal combat power, remain agile in execution, and strategic in deterrence.

The men and women of the 435 CTS are proud to continue their great legacy supporting European and NATO allies across the continent, always prepared for what the mission requires.

Airfield Support Specialists

The 435 CTS is uniquely suited to accomplish international airfield support. Founded in September 1950 as the 7329th Labor Service Unit-Engineer Construction at Rhein-Main AB in Frankfurt, Germany, the unit was established as part of a larger Marshall Plan initiative to provide economic assistance and restore the infrastructure of post-World War II Europe. Specifically, an all-German civilian workforce was organized and charged with the repair and construction of airfields and air bases as the U.S. Army Corps of Engineers quickly ran out of capacity to support airfields west of the Rhine River.

The aircraft arresting system depot mission and associated military personnel were transferred to the unit in May 1971, when it added its first military commander and was re-designated as the 7002nd Civil Engineering Flight. In this role, the unit leads one of three Air Force arresting system depots conducting Barrier Arresting Kit-12 Level 3 maintenance, inspection, repair, overhaul, and refurbishment beyond unit or organization level capability. The 435 CTS also owns, deploys, and employs mobile versions of the kit across the theater to provide a contingency airfield and landing zone capability for exercises and real-world operations.

Further mission changes over the years added a military training function, a military construction flight, and humanitarian and civic assistance missions. This evolution enables the squadron today to perform cradle-to-grave theater construction completely in-house, specializing in airfield support.

Lt. Col. Grant Harwell, M.SAME, USAF, is Deputy Chief, Asset Management Division, HQ U.S. Air Force (formerly Commander, 435th Construction & Training Squadron: June 2022–June 2024); grant.harwell@us.af.mil.

Published in the January-February 2025 issue of The Military Engineer