Air Corps grounds aircraft after safety audit raises concerns over bolt tightening

It is understood an internal safety audit uncovered issues that rendered the planes unsuitable for flying until each aircraft had undergone extensive checks. File photo

The Air Corps has grounded a number of planes over safety concerns about how the nuts and bolts holding them together are tightened, the Irish Examiner can reveal.

It is understood an internal safety audit uncovered issues that rendered the planes unsuitable for flying until each aircraft had undergone extensive checks.

The main concerns are understood to centre around the type of tools used to tighten the planes’ bolts, and the application of what is known as “proper torque”.

This is the specified tightening force needed to apply to an aircraft’s nuts and bolts and which has a force with a specific range prescribed in that particular aircraft’s maintenance manual.

If specially calibrated torque wrenches are not used to tighten nuts and bolts every time, this can lead to problems — including propellers falling off and internal engine damage. 

The General Officer Commanding of the Air Corps Brigadier General Rory O’Connor is understood to have summoned all Air Corps engineers officers to meet him about the results of the audit.

The meeting, which was held at the Air Corps base at Baldonnel during the week, is understood to have led to a number of crews being “berated” over safety standards.

The Chief of Staff of the Defence Forces Lieutenant General Seán Clancy has been briefed on the issue and it is understood there is now an investigation underway about what happened and why.

A source told the Irish Examiner: “The Air Corps may pass this off as a routine inspection and that planes being grounded is also a routine thing.

“But this is extremely serious and the findings are an appalling indictment on what is going on.

“Everyone in Baldonnel is talking about the audit, and the fact that some of the tools used on these very expensive aircraft were bought from a supermarket.” 

Another source has claimed that one of the tools used was “bought at Lidl”, but this has not been confirmed or commented on by the Air Corps or the Defence Forces.

A Defence Forces spokesperson said: “The Defence Forces can confirm that on completion of annual routine internal audit, an operational pause was initiated to rectify discrepancies identified.

“Operational pauses are routinely initiated, for example safety training and other reasons, and this particular operational pause did not have any adverse impact on operational availability.

“The Air Corps routinely carries out internal audits to ensure adequate checks and balances to maintain national and international standards.”

It has not been confirmed exactly how many planes were affected or which type of aircraft were involved.