Mistakes made by reserve packers generally fall into two categories: failure to do a thorough inspection for serviceability or failure to do a separate inspection after assembly. It's also important that they work in a controlled and safe packing area, with a reliable tool control system. They must make sure that all component parts are compatible with the complete system. Finally they must have read the reserve packing manual for the specific rig that they're packing.
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Home - Assembly - Safety System - Equipment - Maintenance
Main Packing - Rigging - Training - Tandem
During a routine reserve inspection and repack a rigger found a damaged reserve pilot chute that had been repaired with ripstop sticky tape (2 Patches), a freebag was damaged and also repaired with ripstop sticky tape (3 Patches) and the canopy was also damaged and repaired with ripstop sticky tape (1 Patch). This system was converted from a round reserve to a square reserve however there is no record of who had done the work.
All this damage was probably caused by bad packing techniques and the repairs were certainly not acceptable, this was the first time the owner had it repacked by a rigger as he normally does the repacks himself, the repairs have been on this system since he first started packing it.
This situation may have been acceptable many years ago, however, the sport is progressing very fast and keeping up to date is a full time task, consulting a rigger every now and then may be the answer here.
This report was written by Allan Hewitt
During a routine equipment inspection, the person inspecting the documents noticed that the paperwork had no information about having a Cypres installed.
The person packing this reserve did so when it had no Cypres fitted and he was not aware that one was added later. The person who fitted the Cypres did so without doing a new reserve inspection and repack, and he never signed that he fitted the Cypres, probably hoping that every one would assume it was the reserve packer who later fitted it.
We have had similar incidents of people tampering with other peoples reserve pack jobs. Let’s remember that no one can tamper with another persons reserve repack.
This report was written by Allan Hewitt
During a routine reserve inspection and repack, the rigger noticed that it had been packed twice before according to the documents, however he became suspicious when he noticed that the second repack done in the UK was exactly like the factory repacks done in the USA by the rig manufacturer.
After confronting the UK packer with this information he found out that this repack was only a pencil pack job as he had suspected.
Do not pencil pack reserve parachutes, this is a simple request but it has the backing of the BPA with all its power, to remove your BPA ratings. The word fraud also springs to mind.
This report was written by Allan Hewitt
A rigger attempted to deploy a reserve prior to a repack but was surprised at the resistance he encounted. He decided to get the scales and do a poundage pull test. The result was a staggering fifty-six pounds.
Conclusions
If this reserve was needed during a malfunction, the jumper would have been surprised at how difficult it was to pull and it would probably have required two hands to achieve. Depending on the circumstances, it could have very easily been a fatality. Can you pull a reserve at fifty-six pounds?
Recommendations
Your reserve packer has a duty to ensure that your reserve deployment is no greater than twenty-two pounds. In the UK the reserve packer has to sign to say that he has tested the poundage but this is not the case in other countries. However, the final responsibility lies with you, it's your life on the line and you should know that you can deploy your reserve when you need it. I have always recommended that skydivers deploy their reserve prior to a reserve repack so they get a feel for what it's actually like to deploy. In my career as a rigger I have come across five skydivers who failed to deploy their reserve parachute. Admittedly, this is over many years but if I have come across five skydivers then how many other reserve packers could have done the same. One light weight girl couldn't deploy the legal maximum of 22 pounds. Her maximum was ten pounds so this issue deserves a lot of thought.
This report was written by Allan Hewitt
The RSL system on an Atom container is set up so that both risers have to be released before the RSL system deploys the reserve. The way that this is achieved is that both sides of the RSL have a separate pin and when packed, both of these pins have to be put through the reserve ripcord loop and into 2 separate loops. One rig however, was found to be packed with only one RSL pin being through the reserve ripcord loop.
The RSL system was still affective however if the jumper was to have a total malfunction on the main parachute then the reserve ripcord would not have deployed the reserve parachute and would have fatal consequences.
This type of incident demonstrates the need to continue to work logically and use the manufacturer’s manuals step by step, especially when the packer is not completely familiar with this type of deployment system. Remember, if you come across something different don't continue packing until you've checked it out in the user manual, or asked someone about it.
This report was written by Allan Hewitt
During a routine reserve inspection and repack, the reserve packer hung the reserve parachute and a shirt sleeve fell out of the canopy. This shirt sleeve had been used to clean the yellow teflon cable and coat it with silicone during previous inspection and repacks.
Conclusions
This may have just been a piece of material but it was coated with chemicals and it was used as a packing tool that should have been recorded during the reserve repack. When it was found to be missing, the reserve packer should have deployed the newly packed reserve to look for it and recover it.
Recommendations
When inspecting and packing reserves always do so in a well organised and controlled environment and make sure that all tools are accounted for after the reserve repack.
This report was written by Allan Hewitt
I have received many reports about reserve documents that have not been filled in correctly. Here is a list of the most common mistakes: no reserve packing card with the reserve check list, no poundage recorded on the inspection check list, no signature next to the poundage, no serial number on the reserve packing card, serial numbers on the reserve packing cards that do not match the canopy serial number.
Conclusions
Documents that have not been filled in correctly is one of the reasons why skydivers have been told that they can't jump their kit. If an incident was to occur with that skydiver then the drop zone would be liable, the reserve packer would be liable even if it was not a contributing factor to an incident.
Recommendations
Take care with the documents and look at all the details properly. Make sure that every part of the inspection check list has been completed. If a reserve packer has not taken care of the administration details which are easily noticed, then how can a skydiver rely on that same reserve packer taking care of the inspection and packing details that are important for a safe repack. A reserve packer has to be detail orientated, every detail matters when inspecting safety notices, inspecting for manufacturing faults, inspecting for wear and tear damage and correct assembly and packing etc.
This report was written by Allan Hewitt
I have had two reports about Javelin containers having the reserve flaps closed in the wrong sequence. The last two flaps were reversed. This sequence means that the reserve pin had no pocket for the end of the pin to fit into. Both these reports show that the reserve packers were highly qualified and very experienced.
Conclusions
These reserves were packed in a method that is correct for some other containers but not for this model of Javelin. It's easy to assume something is correct because you've done it many times in the past.
Recommendations
When packing reserves it's very important that you have the packing manual for the rig you're working on and that it's the right manual for that generation of rig. The closing sequence can change when a manufacturer releases a new product.
This report was written by Allan Hewitt
During a routine reserve inspection and repack a rigger noticed that the old reserve inspection check list stated that the reserve was a GQ 175R but the reserve packing card stated that it was a GQ X210R. On checking the canopy he found that it was neither of these canopies and the canopy was in fact not cleared for use as a reserve parachute.
Conclusions
The person assembling this kit should never have installed this canopy in the first place, however, it had been in service for years without anyone noticing.
Recommendations
It is the responsibility of the reserve packer to make sure that the canopy information has been correctly copied onto the documents during each reserve repack. Don't assume that the last reserve packer must have done it properly.
This report was written by Allan Hewitt
A jumper was walking to the aircraft ready to emplane when his reserve pilotchute deployed.
Conclusions
The cause of this was due to the reserve closure loop washer, which was sharp and had cut the reserve closure loop. The rig was new and the washer was supplied by the manufacturer. The reserve packer used it without a proper inspection which resulted in the washer slowly cutting through the closure loop.
Recommendations
When assembling a set of kit, it's the reserve packers responsibility to ensure that every part of the system gets a thorough inspection. Just because something is new doesn't make it fault proof. During a first assembly the reserve packer should be inspecting for manufacturing faults and faulty components.
This report was written by Allan Hewitt
I have had three reports of this nature since my last reports. During routine inspection and repacks riggers have noticed that the reserve pins were bent and the pull force had been increased because of this. One report stated that the pin had cracked.
Conclusions
It's a common theory that bent pins are caused by a direct collision from a person or object while in use, however, the reality is very different. Some bent pins could have been caused by a direct blow against the pin but the majority are caused by bad packing techniques. The main cause is when a reserve pin is installed into the reserve closure loop and then the reserve packer shortens the closure loop to pull the pop top pilot chute closer into the reserve tray. Some reserve packers use tools to make this easier which causes even more direct force on the closing loop. The result, when you turn the container over and take a look at the reserve pin, is a bent pin. It's also possible to bend a pin when packing a rig with a fixed length closure loop, but less common.
Recommendations
Reserve packers need to take much more care when packing reserves. One rig manufacture bans the use of packing tools that help to force a shorter closure loop into position. It's also a good habit to use a temporary pin to prevent the normal pin from being bent, the reserve handle pin can then be installed after the closure loop length has been set. Finally, the majority of rigs have a set length closure loop for different size reserves and the packing manuals can give you the closure loop length prior to packing so you don't end up using a closure loop that is to short. These are generally a guide line but the finished length shouldn't be far off this.
This report was written by Allan Hewitt
During a routine kit check prior to tagging, the instructor refused to clear the equipment for use because the reserve closure loop was badly frayed. The possibility of a premature reserve deployment was very high. The instructor also noticed that the inspection check list stated that the rig had an RSL installed but when checking the rig, it had no RSL attached.
Conclusions
The instructor informed the owner and said he needs to talk to the person who did the reserve inspection and repack because it was only done recently, and done very badly. The owner then said that the damage to the reserve closure loop may have been damaged by a friend who removed the RSL for him. The person who removed the RSL opened the reserve container, removed the RSL without doing a full inspection and repack, therefore, he had just tampered with someone else's reserve repack.
Recommendations
The instructor was correct to ground the rig because a premature reserve deployment is not just a nuisance, it can be extremely dangerous if it deployed during exit or when another jumper is above it and that's why a new reserve closure loop should be used on every new repack. Such an incident would have put the blame on the reserve packer who probably did a good reserve repack and put the rig into service with an undamaged reserve closure loop. Anyone caught tampering with a reserve deployment system is liable for disciplinary action by the BPA riggers committee or STC committee and depending on the actual incident they may have to defend themselves against legal action as well. In short, never tamper with a reserve repack, the owner's friend may have thought he was doing a favour but in this case he never did the owner a favour, instead he put him at risk and he put himself at risk of liability if something had gone wrong.
This report was written by Allan Hewitt
A rigger had a customer drop a rig off for a reserve inspection and repack. He noted that the documents stated that he was the last reserve packer. When he deployed the reserve he noted that it had been side packed, which was a big surprise considering he had never side packed a reserve in his life. It obviously wasn't his pack job.
Conclusions
The rigger could not find out who had packed the reserve and the owner said he had not had it redone by anyone else, just him. This is one argument for sealing reserves and this rigger started to seal all his reserves after this incident. If another rigger or reserve packer had accepted responsibility for the pack job without completing the paperwork then he would have had to explain the the BPA riggers committee why he left his reserve repack under the name of another person.
Recommendations
Tampering with someone's reserve repack is not allowed and anyone caught doing so could lose all their ratings. Riggers have debated the use of seals for a long time and it's an issue that still can't be agreed up. This is why the BPA have made sealing reserves optional. One school of thought is that a rig with a sealed reserve holds the reserve packer responsible until the reserve seal has been removed or the reserve has been used. Another thought is that once the seal has been removed or the reserve deployed then at that second the reserve packer is no longer responsible because he can't verify that his seal was on just prior to use. The first thought holds the reserve packer responsible for a good safe deployment the second doesn't. By the way it's not the main reason why seals were made optional but that's another story.
This report was written by Allan Hewitt
This month two skydivers deployed their reserve parachutes without cutting away from their malfunction. This resulted in two canopies out at the same time on both occasions. One skydiver cutaway after his canopies went into a down plane and he landed safely under his reserve. The other landed with both canopies very dazed saying he didn't know what to do.
Conclusions
In these cases it seems that both jumpers did exactly what they should have done but it was more luck than judgment. There has been a lot of research into how people react when faced with a stressful situation and a sudden unexpected malfunction is one of these situations. The natural thing to do is react first and think later. Because of this phenomenon it's important to education your body to the correct reaction. Practicing your reserve drills until they become second nature will make sure that you react properly when you suddenly become faced with a malfunction.
Recommendations
It easy to say practice your reserve drills on a regular basis but at the same time you should imagine being in that situation and having to deal with a malfunction. Think about the types of malfunctions and how to recognise them quickly and decide what action you would take without hesitation. Prepare yourself for the day when it does happen and you won't be so surprised. When it happens and it's not such a shock you may even be calm enough to think about what's best before reacting but always keep altitude awareness as your first priority.
This report was written by Allan Hewitt
After a successful parachute display, the team leader asked three of his team, who were all advanced riggers, to do some reserve repacks on the team equipment. One of the riggers deployed the reserve that he had just jumped to find a molar strap wrapped around the reserve parachute. This would have prevented the reserve from deploying. The team leader and all the team witnessed this and agreed that it would have been a total malfunction
Conclusions
The rigger who had just jumped it was not impressed as he had just done a CRW jump on the demo. He called up the last packer who denied that the molar strap was his and said that someone else must have packed it since him. The rigger pointed out that it was his name that was written on the molar strap. The reserve packer then admitted to losing a molar strap and thought someone had stolen it six months earlier. He writes his name on all of his tools because he's had a lot stolen. The reserve packer was an advanced instructor and was currently acting as a CCl. He agreed to hand in his reserve packers qualification as he was not able to stay as current as he should be.
Recommendations
Reserve packers and riggers have a duty to control their tools. It's mandatory that all tools are accounted for before and after every reserve repack. Some reserve packers use a shadow board which is without doubt the best method, others count the tools into and out of service. This issue is a big problem and it's one that happens a lot, almost every type of tool has been found inside a reserve repack. On one occasion a 7lb weight bag was found inside the freebag with the canopy so when I say all types of tools I mean all types. If your reserve packer does not have an obvious tool control system or he has more tools in use than the number he has written on the inspection check list, then this is a good indication that you've got a bad reserve packer. What else can't he control or what else is he failing to do? Finally, if you find that you've lost a reserve packing tool then make sure you find it again even if it means opening all reserve repacks until you've found it. Don't assume it's been stolen.
This report was written by Allan Hewitt
During a reserve inspection and repack a rigger noticed that a piece of webbing with velcro was fixed across the lines of the free bag restricting the lines from deploying. This was a packing tool that had been left inside the reserve repack. He contacted the last reserve packer who said it wasn't his tool as he still has his so it must have been left their by the previous packer.
Conclusions
The signature on the last reserve repack prior to this tool being found was from a very experienced rigger who admitted to pencil packing the reserve, in other words he said he had done a full inspection and repack and charged the jumper for the service but now admitted to lieing. He preferred to admit to fraud as opposed to leaving a rig in a potentially dangerous condition. The person who packed the reserve before him, however, denied leaving the tool in the freebag. The investigation by the BPA held the rigger responsible for pencil packing and saying it was safe for use.
Recommendations
Tool control is one of the most important aspects of a reserve repack and all reserve packers are taught how to make sure all reserve packing tools are counted for after each repack. If your reserve packer has not got an obvious and secure tool control system in place then don't use him. Pencil packing is nothing short of fraud and in this case, if it was a previous reserve packer who left the tool in the reserve, then instead of jumping a potentially dangerous rig for six months it was jumped for a year increasing the risk to the jumper. If this had been a fatality, I think it's pretty clear that a criminal charge would have been taken against the pencil packer.
This report was written by Allan Hewitt
During a flight line check a jumper noticed that the yellow cable going through the riser locking loop was only 1" long. He pulled on the cable which produced an extra 5" and he tucked the excess cable into it's sheath. The owner said it's a regular occurrence and once he found it almost out while he was under his canopy.
Conclusions
Some soft housing designs allow the cable to move during use and unfortunately, the cable always moves in the direction of the container and then becomes trapped preventing it from returning until pulled back into place. This only happens on containers that don't have a full dedicated cable housing throughout the length of the cable.
Recommendations
If you have one of these designs then you need to make this a regular inspection prior to every jump. It should be done at the very least at the start of each day prior to skydiving.
This report was written by Allan Hewitt
During a routine inspection of a set of kit prior to tagging it for use, the inspecting rigger pushed the pop top on one edge and this caused the spring to move and expand to the point that the base of the spring came out from under the pop top.
Conclusions
The container was built for a canopy with a pack volume of 400 cu.in but a rigger recently installed a reserve with a pack volume of 200 cu.in
Recommendations
When swapping or assembling equipment, it's the responsibility of the person doing the job to make sure that all components are compatible. This reserve canopy was not compatible with this container. This was obvious for two reasons; visually, it looked way to small as the reserve had no bulk to it and the figures of 200 to 400 should also have been a clue. This rigger obviously didn't know what he was doing or didn't care.
This report was written by Allan Hewitt
During a routine reserve inspection and repack a rigger noticed that the yellow cutaway cable was visible inside the reserve tray. After further inspection he also noticed that the cable was only through the riser locking loop by approx 1". This had been in service and used like this for the past 6 months.
Conclusions
The last reserve packer had routed the cutaway cable through the reserve tray instead of through the channel around the neck of the container. The incorrect routing reduced the effective length of the cable by up to 5". It's amazing that this didn't cause an unplanned cutaway. What intrigues me though is how this fault was found. Usually the main is cutaway and placed to one side while doing a reserve inspection and repack. To do this the cutaway cable had to be pulled by the reserve packer. I can only assume that this rigger was packing the reserve without removing the main canopy which is not a safe thing to do, at least it's a bad habit that should be avoided.
Recommendations
This reserve packer had obviously not read the user manual. This container also needs a tool to route the cable correctly. Because the cable had been reduced it should have been obvious to all flight line checkers, the person doing the kit check prior to tagging and the owner of the equipment when he did his daily checks. Complacency strikes again!
This report was written by Allan Hewitt
I've received some more reports on incompatible components which were found during a reserve inspection and repack; cutaway cables were found that were the wrong length for the container, cutaway housing being too small for the container (this one is actually rare), reserve handle being too small for the container and a freebag that was incompatible for the reserve tray.
Conclusions
These reports are typical of problem encounted after a reserve ride, when equipment loses one of the above items. A rigger then installs new ones but ones that were not manufactured according to the manufacturers specifications. If a manufacturer supplies cutaway cables that have 6" of cable through the locking loop, then it's not acceptable for a rigger to install a cutaway cable with only three inches through the loop. When a manufacturer supplies a reserve handle with 6" of spare cable below the reserve handle then it's not acceptable for a rigger to replace it with one that has only 1" showing below the handle. The free bag used was one that had the grommets in the wrong place making it difficult to distribute the volume and deforming the internal pack job compared to the shape of the container.
Recommendations
When replacing component parts due to lost items after a reserve ride always try to get the correct ones direct from the manufacturer. If you install generic ones, make sure the sizes are correct. Also a reserve handle that is installed on a rig with an RSL is much stronger than a reserve handle installed on a rig that doesn't have an RSL.
This report was written by Allan Hewitt
We have had three reports of reserve pilot chutes being restricted during deployment prior to a reserve inspection and repack, this is caused by packing the bridle line into the corners of the reserve container.
These reports were all on different rigs and it's interesting to note that none of the rig manuals demonstrated packing the bridle lines this way. Although the bridle restricted the pilot chutes from being extracted to the complete length required, the reserve deployment would probably have been fine had it been needed.
There is no need to put the bridle line into the comers so give this some thought. If in doubt, do a pull test and see how far the pilot chute launches, if the launch can be restricted by the bridle line then it is not correct.
This report was written by Allan Hewitt
