PFD report

Colour Sergeant Martyn HORTON and 3 others · Prevention of Future Deaths report

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Issued 28 Apr 2015•Wiltshire and Swindon

Report record

Published report and response evidence

This page connects the concerns raised in this report with statements found in recipients’ published responses. A link shows a clear evidence connection; it does not assign responsibility.

View original report
Concerns
6

Raised in this report

Recipients
1

Named on the report

Responses found
1

Of 1 recipient

Stated actions
11

Described in responses

Recipients and published responses

Source document

Full report text

This is the full text from the original published report.

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Concerns and recipient responses

Select any concern, action or position to view the source wording.

Report evidence summary

Concerns raised6

  1. Failure to provide a maintenance-section cross-reference to front spring hanger torque settings
    Part of recurring concern: Inadequate torque specifications for safety-critical equipment
  2. Failure to apply height restrictions to remote weapon system gunners
  3. Lack of capability to achieve specified vehicle tyre pressures
    Part of recurring concern: Unreliable vehicle tyre safety controls
Responses linked to these concerns

Each statement is shown once, even when linked to more than one concern.

Actions described in response An action is something a recipient says it has done, is doing, or plans to do in response to a concern raised.9

  1. Action

    Review Ridgback height-policy wording and issue clarified guidance based on seating position rather than crew role.

    Stated by Ministry of DefenceStated plannedThe respondent said that this action was planned when they made their response on 28 April 2015.
  2. Action

    Review torque-reference cross-referencing across Cougar-based vehicle publications and issue major findings in a safety notice before publication.

    Stated by Ministry of DefenceStated in progressThe respondent said that this action was in progress when they made their response on 28 April 2015.
  3. Action

    Amend vehicle-crew height policy across in-service platforms to emphasise command responsibility for selecting and training suitable personnel.

    Stated by Ministry of DefenceStated completedThe respondent said that this action was complete when they made their response on 28 April 2015.

Respondent positions A position is what a recipient says about a concern when it does not describe a specific action.2

  1. Position

    Army Light Aid Detachments have sufficient capability to maintain deployed vehicle tyres at the required pressure without returning to a main operating base.

    Stated by Ministry of DefenceExisting arrangements considered sufficientThe respondent said that existing arrangements were sufficient, so no further action was needed.

Source evidence

How this individual concern was interpreted

PFD Monitor created a concise, searchable interpretation from the report wording shown below. Response links show a clear evidence connection; they do not assign responsibility.

PFD Monitor interpretation

Failure to provide a maintenance-section cross-reference to front spring hanger torque settings

Wider context from the report

“(V) AESP Torque references. During the course of the evidence I heard that the maintenance of the Ridgeback vehicle was governed by AESP documentation. I was told by Craftsman ████████ that regularly at MOB Price during Herrick 12 whilst maintaining these vehicles that he was unaware of the correct torque settings in relation to the front spring hanger assembly bolts and would ensure in the circumstances that the bolts, to quote him, were “fucking tight”. There were however torque settings on these settings appear to have been confined in the repair section of the AESP documentation in Section 5 as opposed to the maintenance section in Section 6. I fully accepted the evidence I heard that the AESP documentation is voluminous but I am concerned and believe that it would be of assistance to REME personnel and those responsible for the maintenance of the vehicles that consideration be given to ensuring mention of a cross reference pointing in Section 6 at the relevant section to where the torque settings can be found in Section 5 rather than repeating the verbatim torque settings again. I would ask that you give consideration to this so as to ensure correction maintenance procedures are carried out. ”

Is this part of a recurring concern?

Yes — Inadequate torque specifications for safety-critical equipment.

Open source report

Source evidence

How this individual concern was interpreted

PFD Monitor created a concise, searchable interpretation from the report wording shown below. Response links show a clear evidence connection; they do not assign responsibility.

PFD Monitor interpretation

Failure to apply height restrictions to remote weapon system gunners

Wider context from the report

“(II) Height restrictions. During the course of hearing evidence, I heard that there were height restrictions relative to the driver of Ridgeback vehicles as well as the designated Commander of the vehicle. Ordinarily both the driver and Commander sit in the two front seats of the vehicle. The vehicle involved in this particular incident was a remote weapon system variant Ridgeback and unlike other variants, the right hand seat is occupied by the remote weapon gunner and the Commander is moved to a position sitting at right angles to the driver who of course is occupying the left hand front seat. Depending on operational assessment, I am concerned that if there is a height restriction for a driver and Commander that if a gunner is required to occupy the front right hand seat, as is the case in the remote weapon system variant, that a height restriction ought to apply to the gunner as well. In this particular tragic incident I found no evidence that the height of Private Alexander Isaac contributed to his inability to escape from the stricken Ridgeback once it had entered the canal as he was able to remove his helmet and body armour and in fact was one of the first bodies to have been recovered through the top hatch. ”

Is this part of a recurring concern?

No recurring-concern membership is currently published.

Open source report

Source evidence

How this individual concern was interpreted

PFD Monitor created a concise, searchable interpretation from the report wording shown below. Response links show a clear evidence connection; they do not assign responsibility.

PFD Monitor interpretation

Lack of capability to achieve specified vehicle tyre pressures

Wider context from the report

“(IV) Tyre pressures. The Ridgeback in question following recovery was found to have under inflated rear tyres some 13% less than the recommended PSI which I believe is 110. During the course of the evidence I heard the REME maintenance crew at MOB Price did not have equipment to inflate tyres to that pressure and the on board compressor again did not have the necessary capability to inflate tyres over and above 100 PSI. I was told that if the required tyre pressure was to be achieved that the only equipment available was at Camp Bastion and of course the vehicles were not regularly, when on operational service in Afghanistan, travelling to Camp Bastion. I would ask that you review this concern. Tyre pressures are important. Both under inflated and over inflated tyres can materially affect the handling of the vehicles and if there is a specification for a certain tyre pressure then those operating or maintaining the vehicle ought to have the ability to ensure the correct tyre pressure is achievable. Again this potentially is applicable across the Cougar family fleet. ”

Is this part of a recurring concern?

Yes — Unreliable vehicle tyre safety controls.

Open source report

Source evidence

How this individual concern was interpreted

PFD Monitor created a concise, searchable interpretation from the report wording shown below. Response links show a clear evidence connection; they do not assign responsibility.

PFD Monitor interpretation

Inadequate operational effectiveness of Ridgeback lighting

Wider context from the report

“(III) Lighting. At the end of the day a Commander of a vehicle has overall control and a driver is required to use his or her skill and judgement relative to road conditions and the vehicle capabilities to drive at an appropriate speed taking into account speed limits. When responding to an emergency such as the QRF (Quick Reaction Force) role as is the case when UK civilian emergency response vehicles are responding to a legitimate emergency, speed limits may not ordinarily be adhered to and I very much take the view that it should be a matter of military judgement taken by those who have situational awareness at the time. The evidence I heard was that operationally drivers could realistically only see using white light approximately 10-15 metres in front of the vehicle. There was an issue with the Ridgeback involved in this incident in that for some reason the main head lights had a lower specification bulb fitted 75/70 watts as opposed to the specified 100/80 watt bulb. The Ridgeback is also fitted with 70 watt fog lamps and set of 70 watt additional lights which were moved following the incident to the outside of the bar armour. The main lights however still lie behind the bar armour and that must impede their effectiveness. I would like you however to review the effectiveness of Ridgeback lighting and arguably as it is part of the Cougar fleet, the lighting of the Mastiff and Wolfhound also as they are similar vehicles with the addition of an additional axle, as regards operational effectiveness especially if such vehicles are intended to be used in a QRF role or when operational requirements dictate a need to travel at speed. An operational limit of only 10-15 metres in front of the vehicle is in my view restrictive and significantly restricts the safe speed of the vehicle allowing for reaction and stoppage time. ████████ (retired) attempted as part of the LAIT investigation to carry out tests on Salisbury Plain, although I do have some concerns in relation to the accuracy and usefulness of the data obtained from those tests. ”

Is this part of a recurring concern?

No recurring-concern membership is currently published.

Open source report

Source evidence

How this individual concern was interpreted

PFD Monitor created a concise, searchable interpretation from the report wording shown below. Response links show a clear evidence connection; they do not assign responsibility.

PFD Monitor interpretation

Failure to review the whole suspension system for the additional operational load of UK specification vehicles

Wider context from the report

“(I) Suspension issues. During the course of the Inquest I heard how Ridgeback had been introduced into UK operational service as part of an urgent operational requirement to provide greater protection to UK service personnel on operation in Afghanistan due to the ever increasing threat that had been developing from improvised explosive devices. I heard how the original shell vehicle provided by the US manufacturer was modified to UK specifications by UK Government contractors and I heard that the resultant additional weight appears to have in particular resulted in an unusually large number of failures to the front spring hanger assembly, mounting bracket as well as leaf spring failures with four of those failures. Morgan Advanced Materials have been contracted to remedy the problem and I understand that additional information following the involvement of ████████ and members of the team of 710 Naval Squadron will be helpful in trying to find a solution. I have been provided with a timetable in respect of which various steps will be covered leading to a solution being found and rolled out which will exceed the usual 56 day time period to respond to a Regulation 28 Report. As part of my Regulation 28 duty I would like to monitor the resolution of the issue relative to the failures in the front suspension area and I am sure that the families of the four who died on 23 June 2010, even though that the failure to that particular vehicle (Spring hanger bolt failure) did not cause or contribute to their deaths, would also like to be appraised of developments insofar as sensitive material is not disclosed. I am however still concerned that the focus appears to be solely on the front suspension where the vast majority of the failures occurred. I would therefore ask for confirmation that given the modifications affected the overall operational load of the vehicle that the whole suspension system is reviewed with a view that ultimately it is fit for purpose having regard to the additional operational load that UK specification vehicles are required to deal with as compared to its American counterparts. In this respect I have suggested quarterly updates as a way forward. For the avoidance of any doubt although the inquest focussed on the Ridgeback, I am aware from the same Cougar family that the problem affected Wolfhound and Mastiff as well which of course the UK Government purchased as well. ”

Is this part of a recurring concern?

Yes — Unreliable vehicle suspension safety controls.

Open source report

Source evidence

How this individual concern was interpreted

PFD Monitor created a concise, searchable interpretation from the report wording shown below. Response links show a clear evidence connection; they do not assign responsibility.

PFD Monitor interpretation

Failure to capture recurring component bolt retightening as an issue warranting investigation

Wider context from the report

“(VII) Component failure awareness. It was clear in 2010 that failures associated with the front suspension and spring hanger assembly in the Cougar fleet were starting to develop and following an incident involving a Ridgeback vehicle in Bovingdon in 2012, Qinetiq were instructed to analyse these failures. During the course of the evidence I heard from those that were maintaining these vehicles back in 2010 that the bolts on the front spring hanger assembly were in need of regular tightening and the vehicle was subject to 21 day inspection checks. The joint opinion of ████████ and members of the team at 1710 Naval Squadron was that it should not be necessary to repeatedly have to tighten the bolts relative to a component such as the spring hanger assembly. The need for the retightening of bolts was in their view indicative of a component issue and I would ask that you review from a learning point as regards raising the awareness of Craftsmen and Technicians and not just in relation to Ridgeback or Mastiff but in relation to any component across the services, that if an issue arises requiring regular or unusually frequent tightening of component bolts that matter ought to be highlighted as a concern warranting proportionate investigation relative to other similar pieces of equipment experiencing the same issue, such as was the case here with the Cougar fleet of vehicles. The retightening of bolts on a regular basis was something that was not captured as an issue in itself. ”

Is this part of a recurring concern?

Yes — Failure to identify and address recurring safety issues through organisational learning.

Open source report

Source evidence

How this respondent action was interpreted

PFD Monitor created a concise, searchable interpretation from the published response wording shown below.

PFD Monitor interpretation

Review Ridgback height-policy wording and issue clarified guidance based on seating position rather than crew role.

Verbatim wording from the response

“Following the conclusion of combat operations in Afghanistan, the Army Capability Directorate for Combat has amended the height policy for vehicle crewmen across the range of in-service platforms to maximise safety for those operating the vehicles. The new policy emphasises the chain of command’s responsibility to select and train personnel able to safely and effectively carry out the tasks required of them. Commanders on operations are still able to re-impose specific height restrictions on crew members should operational circumstances or the enemy threat require it. In response to your concerns the Army Capability Directorate for Combat will further review the wording of current policy on height restrictions for Ridgback and will ensure this is based on seating position, rather than the individual’s role as part of the crew.”

Source location

2015-0164-Response-by-Ministry-of-Defence
Page 2 · response
Published 28 April 2015

Open published response

Source evidence

How this respondent action was interpreted

PFD Monitor created a concise, searchable interpretation from the published response wording shown below.

PFD Monitor interpretation

Review torque-reference cross-referencing across Cougar-based vehicle publications and issue major findings in a safety notice before publication.

Verbatim wording from the response

“We are reviewing documentation to check for cross-referencing as you recommend. This review will encompass all of the publications for the 21 different in-service Cougar-based vehicle variants. The AESPs for the Cougar-based vehicle fleets are subject to a major update release every six months. The next is due 31 August 2015; the review work is due to be completed ahead of this date and any major findings will be issued in a Safety Notice prior to the formal publication.”

Source location

2015-0164-Response-by-Ministry-of-Defence
Page 3 · response
Published 28 April 2015

Open published response

Source evidence

How this respondent action was interpreted

PFD Monitor created a concise, searchable interpretation from the published response wording shown below.

PFD Monitor interpretation

Amend vehicle-crew height policy across in-service platforms to emphasise command responsibility for selecting and training suitable personnel.

Verbatim wording from the response

“Following the conclusion of combat operations in Afghanistan, the Army Capability Directorate for Combat has amended the height policy for vehicle crewmen across the range of in-service platforms to maximise safety for those operating the vehicles. The new policy emphasises the chain of command’s responsibility to select and train personnel able to safely and effectively carry out the tasks required of them. Commanders on operations are still able to re-impose specific height restrictions on crew members should operational circumstances or the enemy threat require it. In response to your concerns the Army Capability Directorate for Combat will further review the wording of current policy on height restrictions for Ridgback and will ensure this is based on seating position, rather than the individual’s role as part of the crew.”

Source location

2015-0164-Response-by-Ministry-of-Defence
Page 2 · response
Published 28 April 2015

Open published response

Source evidence

How this respondent action was interpreted

PFD Monitor created a concise, searchable interpretation from the published response wording shown below.

PFD Monitor interpretation

Complete Vehicle Emergency Lighting System modifications across the Cougar fleet, including RODET trainers, and restrict active-fleet use without the modification.

Verbatim wording from the response

“The Vehicle Emergency Lighting System (VELS) modification is on-going. The VELS kits were originally released to the Army and other users in June 2013; as at 02 June 2015 the percentage of the Cougar fleet that has been modified is as follows, with the percentage of the active fleet (vehicles actually being used by the Army and not in storage) shown in brackets: Ridgback 74% (85%), Mastiff 72% (77%), Wolfhound 49% (61%). Based on the time taken to complete modifications to date, the Army are expected to complete modifications on the active fleet² by 30 June 2016 and will not be able to use active fleet vehicles after this date unless VELS is fitted, with the whole of the fleet expected to be completed no later than the end of 2016.”

Source location

2015-0164-Response-by-Ministry-of-Defence
Page 3 · response
Published 28 April 2015

Open published response

Source evidence

How this respondent action was interpreted

PFD Monitor created a concise, searchable interpretation from the published response wording shown below.

PFD Monitor interpretation

Review suspension data to determine the Cougar fleet maintenance schedule and issue a safety notice with findings.

Verbatim wording from the response

“In response to your concerns we are conducting a review of the whole vehicle suspension system with consideration also being given to the rest of the Cougar fleet of vehicles (Mastiff and Wolfhound). This includes:”

Source location

2015-0164-Response-by-Ministry-of-Defence
Page 1 · response
Published 28 April 2015

Open published response

Source evidence

How this respondent action was interpreted

PFD Monitor created a concise, searchable interpretation from the published response wording shown below.

PFD Monitor interpretation

Review the Ridgback suspension system and options for implementation, then make recommendations to Army Headquarters.

Verbatim wording from the response

“4. A full vehicle review of the Ridgback vehicle to determine the most effective suspension system and options for implementation. This is a more complex piece of work with a direct read-across from Ridgback to Mastiff and Wolfhound and will involve extensive physical prototyping and trialling before design and testing of the safety and operational”

Source location

2015-0164-Response-by-Ministry-of-Defence
Page 1 · response
Published 28 April 2015

Open published response

Source evidence

How this respondent action was interpreted

PFD Monitor created a concise, searchable interpretation from the published response wording shown below.

PFD Monitor interpretation

Assess the performance of the upgraded vehicle lighting against the existing system from crew positions.

Verbatim wording from the response

“In response to your concerns, Morgan Advanced Materials will provide an upgraded, legislatively compliant lighting system across the Cougar fleet of vehicles. Establishing what this means, and checking compliance with the Road Vehicle Lighting Regulations 1989, will be different for each vehicle. As well as checking legislative compliance we will conduct a subjective assessment of the performance of the lights in comparison with the old system from the position of the crewmen. The final design review is planned for July 2015. The production of circa 750 modification kits of a bespoke design will take 5 months after the final design review has formally signed-off the modification; therefore modification kits are expected by 30 November 2015 and implementation will be complete by 31 December 2016.”

Source location

2015-0164-Response-by-Ministry-of-Defence
Page 2 · response
Published 28 April 2015

Open published response

Source evidence

How this respondent action was interpreted

PFD Monitor created a concise, searchable interpretation from the published response wording shown below.

PFD Monitor interpretation

Investigate options for providing on-vehicle or carried capability to inflate Cougar tyres to 110 PSI.

Verbatim wording from the response

“As your report identified, there is presently no on-board means (either in terms of vehicle capabilities or by those of use of carried tools) to inflate the tyres to the required pressure. The requirement to check and adjust where necessary, tyre pressures is a daily task defined in the relevant Army Equipment Support Publication (AESP). The MOD is currently investigating means to provide the capability of inflating tyres to 110 PSI from systems contained or carried on the vehicle; this work is being conducted in parallel with work to provide a similar capability for the Jackal and Coyote fleets, consisting of circa 700 vehicles. We expect to have identified options to provide this capability by 30 September 2015.”

Source location

2015-0164-Response-by-Ministry-of-Defence
Page 2 · response
Published 28 April 2015

Open published response

Source evidence

How this respondent action was interpreted

PFD Monitor created a concise, searchable interpretation from the published response wording shown below.

PFD Monitor interpretation

Review component-failure-awareness training and direct inclusion of lessons on fault reporting and experienced diagnosis.

Verbatim wording from the response

“A review of current training in respect of component failure awareness has been completed. This has resulted in direction to include additional lessons to reinforce the reasons and timeframe for raising fault reports, and the importance of experienced tradespersons diagnosing and reporting equipment failure to effective equipment support.”

Source location

2015-0164-Response-by-Ministry-of-Defence
Page 3 · response
Published 28 April 2015

Open published response

Source evidence

How this respondent position was interpreted

PFD Monitor created a concise, searchable interpretation from the published response wording shown below.

PFD Monitor interpretation

Army Light Aid Detachments have sufficient capability to maintain deployed vehicle tyres at the required pressure without returning to a main operating base.

Verbatim wording from the response

“As your report identified, there is presently no on-board means (either in terms of vehicle capabilities or by those of use of carried tools) to inflate the tyres to the required pressure. The requirement to check and adjust where necessary, tyre pressures is a daily task defined in the relevant Army Equipment Support Publication (AESP). The MOD is currently investigating means to provide the capability of inflating tyres to 110 PSI from systems contained or carried on the vehicle; this work is being conducted in parallel with work to provide a similar capability for the Jackal and Coyote fleets, consisting of circa 700 vehicles. We expect to have identified options to provide this capability by 30 September 2015.”

Source location

2015-0164-Response-by-Ministry-of-Defence
Page 2 · response
Published 28 April 2015

Open published response

Source evidence

How this respondent position was interpreted

PFD Monitor created a concise, searchable interpretation from the published response wording shown below.

PFD Monitor interpretation

The chain of command is responsible for selecting and training personnel able to operate vehicles safely and effectively.

Verbatim wording from the response

“Following the conclusion of combat operations in Afghanistan, the Army Capability Directorate for Combat has amended the height policy for vehicle crewmen across the range of in-service platforms to maximise safety for those operating the vehicles. The new policy emphasises the chain of command’s responsibility to select and train personnel able to safely and effectively carry out the tasks required of them. Commanders on operations are still able to re-impose specific height restrictions on crew members should operational circumstances or the enemy threat require it. In response to your concerns the Army Capability Directorate for Combat will further review the wording of current policy on height restrictions for Ridgback and will ensure this is based on seating position, rather than the individual’s role as part of the crew.”

Source location

2015-0164-Response-by-Ministry-of-Defence
Page 2 · response
Published 28 April 2015

Open published response

Other statements in published responses

These actions and other statements could not be clearly connected to one concern in this report.

Recipient-stated actions An action is something a recipient says it has done, is doing, or plans to do in response to a concern raised.2

  1. 1

    Analyse the Cougar spring-hanger arrangement and assess, design, prototype and test potential modifications or upgrades.

    Stated by Ministry of DefenceStated plannedThe respondent said that this action was planned when they made their response on 28 April 2015.
  2. 2

    Implement resulting spring-hanger improvements across the Cougar fleet and review associated maintenance regimes.

    Stated by Ministry of DefenceStated plannedThe respondent said that this action was planned when they made their response on 28 April 2015.

Source evidence

How this respondent action was interpreted

PFD Monitor created a concise, searchable interpretation from the published response wording shown below.

PFD Monitor interpretation

Analyse the Cougar spring-hanger arrangement and assess, design, prototype and test potential modifications or upgrades.

Verbatim wording from the response

“3. An analysis of the entire spring hanger arrangement (front and rear) to identify potential improvements. This will consist of an initial feasibility review of options, followed by the design, prototyping and testing of proposed modifications or upgrades to ensure that the issues identified have been successfully addressed. We aim to complete this by 30 September 2015 and will then make those improvements across the Cougar fleet of vehicles (and review the associated maintenance regimes) by 31 January 2016.”

Source location

2015-0164-Response-by-Ministry-of-Defence
Page 1 · response
Published 28 April 2015

Open published response

Source evidence

How this respondent action was interpreted

PFD Monitor created a concise, searchable interpretation from the published response wording shown below.

PFD Monitor interpretation

Implement resulting spring-hanger improvements across the Cougar fleet and review associated maintenance regimes.

Verbatim wording from the response

“3. An analysis of the entire spring hanger arrangement (front and rear) to identify potential improvements. This will consist of an initial feasibility review of options, followed by the design, prototyping and testing of proposed modifications or upgrades to ensure that the issues identified have been successfully addressed. We aim to complete this by 30 September 2015 and will then make those improvements across the Cougar fleet of vehicles (and review the associated maintenance regimes) by 31 January 2016.”

Source location

2015-0164-Response-by-Ministry-of-Defence
Page 1 · response
Published 28 April 2015

Open published response
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Data last updated 7 September 2026