For almost 40 years, the CH-53E Super Stallion heavy-lift helicopter has been a workhorse in the logistical support of naval and Marine Corps missions throughout the world.
The Sikorsky-built aircraft is one of the largest helicopters ever produced by the Defense Department, and can transport up to 30 personnel or accommodate 30,000 pounds of cargo.
Super Stallions are found in naval squadrons on both coasts of the country, and those assigned to Marine Corps Air Station Miramar (MCAS) are maintained and repaired by Fleet Readiness Center Southwest (FRCSW).
Of the more than 100 personnel who comprise the FRCSW CH-53 program, about 70 are artisans who are sheet metal mechanics (the largest group), electricians, and mechanics.
The command's CH-53 program operates in Building 333 where fiberglass and component work is completed and 378 where the remaining airframe work is done.
Super Stallion maintenance is under a 54-month cycle of the Integrated Maintenance Program (IMP).
Requiring about 16,000 manhours per aircraft, the IMP focuses on structural repairs to the fuselage and includes replacing the skin, transition bulkhead, cockpit floorboard, any KAPTON electrical wiring upgrades and corrosion repairs throughout the aircraft.
FRCSW artisans disassemble the helicopter prior to undertaking the IMP inspection specifications. Disassembly typically includes electronic and mechanical components so artisans can access areas of the airframe for metalwork.
The IMP is a combination of organizational level (O-level), or work handled by the Marine Corps squadrons, and depot-level work.
The squadrons are notified if the IMP inspection reveals an O-level maintenance item or system, like the landing gear, is in need of repair. Squadrons have the option to request the depot handle an O-level issue through an in-service repair.
FRCSW returns about 10 Super Stallions to the fleet annually.