U.S. Combat Air Power

Aging Refueling Aircraft Are Costly to Maintain and Operate Gao ID: NSIAD-96-160 August 8, 1996

The military's KC-135 tanker fleet used for air refueling is now 30 to 40 years old, and these aircraft are taking longer and costing more to maintain and operate. Moreover, the Air Force could spend more than $6 billion on modifications and structural repairs to keep the KC-135 fleet operational. Despite increasing demands on the tanker fleet, the Air Force has deferred a replacement program and is relying on reserve personnel to relieve pressure on active duty tanker crews. The reserve forces have been able to assume more of the tanker workload because many crew members have volunteered extra time, thus exceeding the reserves' legal training requirement of 38 days per year. In fact, many have served more than 100 days a year in training and flying sorties.

GAO found that: (1) the long-term serviceability of the KC-135 tanker is questionable; (2) the cost per KC-135 flying hour is projected to increase from $8,662 in 1996 to $10,761 in 2001; (3) as KC-135 aircraft age, the number of aircraft available for operation declines; (4) from fiscal year 1991 to 1995, labor hours for KC-135 overhauls increased 36 percent; (5) depot maintenance levels increased due to a shortage of spare parts, maintenance delays, and reduced aircraft availability; (6) the Air Mobility Command (AMC) doubts that KC-135 aircraft can operate economically beyond 2020; (7) the Air Force could enhance the operational flexibility of C-5A aircraft by acquiring dual-use aircraft that combine airlift and refueling capabilities; (8) the Air Force is procuring a new transport aircraft to replace its C-5A aircraft and a new tanker to replace the KC-135; (9) the deployment rates for individual tanker crew positions approached the 120-day management limit during fiscal years 1994 and 1995; (10) air reserve units are operating at 95 percent of their potential availability; and (11) the Air Force is able to support its peacetime tanking requirements because many of its reserve crew members volunteer their time and spend more than 100 days annually training and flying sorties.

Recommendations

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