Project Flat Top
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Project Flat Top was a
United States Army The United States Army (USA) is the primary Land warfare, land service branch of the United States Department of Defense. It is designated as the Army of the United States in the United States Constitution.Article II, section 2, clause 1 of th ...
project during the
Vietnam War The Vietnam War (1 November 1955 – 30 April 1975) was an armed conflict in Vietnam, Laos, and Cambodia fought between North Vietnam (Democratic Republic of Vietnam) and South Vietnam (Republic of Vietnam) and their allies. North Vietnam w ...
to convert , a
World War II World War II or the Second World War (1 September 1939 – 2 September 1945) was a World war, global conflict between two coalitions: the Allies of World War II, Allies and the Axis powers. World War II by country, Nearly all of the wo ...
-era
seaplane tender A seaplane tender is a boat or ship that supports the operation of seaplanes. Some of these vessels, known as seaplane carriers, could not only carry seaplanes but also provided all the facilities needed for their operation; these ships are rega ...
, into a forward theater, offshore
helicopter A helicopter is a type of rotorcraft in which Lift (force), lift and thrust are supplied by horizontally spinning Helicopter rotor, rotors. This allows the helicopter to VTOL, take off and land vertically, to hover (helicopter), hover, and ...
repair facility. Helicopters had been used during the
Korean War The Korean War (25 June 1950 – 27 July 1953) was an armed conflict on the Korean Peninsula fought between North Korea (Democratic People's Republic of Korea; DPRK) and South Korea (Republic of Korea; ROK) and their allies. North Korea was s ...
to ferry wounded and supplies. Some US combat officers recognized the possibility of using armed helicopters to provide
close air support Close air support (CAS) is defined as aerial warfare actions—often air-to-ground actions such as strafes or airstrikes—by military aircraft against hostile targets in close proximity to friendly forces. A form of fire support, CAS requires ...
. But other organizations and branches strenuously objected to allowing the Army to deliver ordnance via aircraft. The Army Staff in
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responded slowly to a study from the Army Aircraft Requirements Review Board chaired by
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(LTG) Gordon B. Rogers that suggested adopting helicopters for use in a combat role.
Defense Secretary The United States secretary of defense (acronym: SecDef) is the head of the United States Department of Defense (DoD), the executive department of the U.S. Armed Forces, and is a high-ranking member of the federal cabinet. DoDD 5100.1: Enclosu ...
Robert McNamara Robert Strange McNamara (; June 9, 1916 – July 6, 2009) was an American businessman and government official who served as the eighth United States secretary of defense from 1961 to 1968 under presidents John F. Kennedy and Lyndon B. Johnson ...
bypassed
Secretary of the Army The secretary of the Army (SA or SECARMY) is a senior civilian official within the United States Department of Defense, with statutory responsibility for all matters relating to the United States Army: manpower, personnel, reserve affairs, insta ...
Elvis Jacob Stahr Jr. and directed LTG Hamilton H. Howze, the Army's first director of aviation, to conduct a review of the tactical possibilities suggested by the study. The
Howze Board The Howze Board was the informal name given to the Tactical Mobility Requirements Board created at the direct request of Secretary of Defense Robert McNamara to review and test new concepts integrating helicopters as close air support into the Uni ...
report received by McNamara in September 1962 proposed huge changes in Army doctrine, prescribing an airmobility doctrine integrating helicopters into combat. With helicopters increasingly at the center of Army doctrine as a result of the Howze Board's recommendations, it became apparent that a logistical gap would arise between the operational area and repair bases in the US. Lieutenant Colonel (LTC) John Sullivan, a respected Army aviator, conceived of the idea to convert a ship into a floating helicopter repair facility. Sullivan was named by General Frank Besson, commanding general of the newly formed
United States Army Materiel Command The U.S. Army Materiel Command (AMC) is the primary provider of materiel to the United States Army. The command's mission includes the management of installations, as well as maintenance and parts distribution. AMC operates depots; arsenals; am ...
(AMC), to lead the project. After considerable research, Sullivan and his team selected the World War II USS ''Albemarle'' (AV-5). When progress slowed for almost a year, Sullivan bypassed Army leadership and persuaded influential Congressman Mendel Rivers of South Carolina, chairman of the
House Armed Services Committee The U.S. House Committee on Armed Services, commonly known as the House Armed Services Committee or HASC, is a standing committee of the United States House of Representatives. It is responsible for funding and oversight of the Department of ...
, to support the project. New shops, instruments, technology, communications, and storage were added to the ship over 15 months at a cost of $25 million. Rechristened as , a civilian
United States Merchant Marine The United States Merchant Marine is an organization composed of United States civilian sailor, mariners and U.S. civilian and federally owned merchant vessels. Both the civilian mariners and the merchant vessels are managed by a combination of ...
(USMM) crew was chosen to operate the bridge, engine room, and man the ship's
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. This was a controversial move that generated concern about their placement near a combat zone and their potential treatment under the
Geneva Conventions upright=1.15, The original document in single pages, 1864 The Geneva Conventions are international humanitarian laws consisting of four treaties and three additional protocols that establish international legal standards for humanitarian t ...
. US Army soldiers staffed the multiple repair shops that were equipped with custom facilities that could repair or fabricate parts to factory standards. The ship offered the same echelon of depot-level service available in the U.S. at the Army Aeronautical Depot Maintenance Center in Corpus Christi, Texas while it served off the coast of South Vietnam for 6½ years. The soldiers repaired as many as 20,000 aircraft components a month and saved the military millions of dollars. When the war was drawing down, the ship left for the U.S. in late 1972. On 17 July 1975, after more than 36 years of service, the ship was scrapped.


Background

At the beginning of the 1960s, the US Army evaluated a concept called FAMF (Floating Aircraft Maintenance Facility), a way to support aircraft far abroad on a mobile ship. The Army Materiel Command established a top-level Project Management Office called “Project Flat-Top”. It was originally envisioned the project would acquire and convert a mothballed WWII US Navy small aircraft carrier. In October 1961, LTC John F. Sullivan was selected by the Army Chief of Transportation in the US Army Transportation Materiel Command (TMC) to study production management at the Army Aeronautical Depot Maintenance Center (ARADMAC). In January, 1962, Sullivan passed a highly selective screening process and was temporarily assigned to attend the
Armed Forces Staff College The Joint Forces Staff College (JFSC), located in Norfolk, Virginia, was established as the Armed Forces Staff College in 1946 and incorporated into the National Defense University in August 1981. It educates and acculturates joint and multinat ...
in Norfolk, Virginia. When he returned to ARADMAC in May he was appointed Director of Production Control. On 20 August 1962, the
Howze Board The Howze Board was the informal name given to the Tactical Mobility Requirements Board created at the direct request of Secretary of Defense Robert McNamara to review and test new concepts integrating helicopters as close air support into the Uni ...
proposed significant changes to Army doctrine, including the use of helicopters for reconnaissance, command and control, troop transport, attack gunships, aerial rocket artillery, medical evacuation, and supply. In response, Sullivan suggested to his superiors at ARADMAC that the Army should build a ship-based helicopter repair facility, similar to the Aircraft Repair Unit-Floating (ARU(F)) of World War II. Sullivan had fought in World War II during 1942 in
New Guinea New Guinea (; Hiri Motu: ''Niu Gini''; , fossilized , also known as Papua or historically ) is the List of islands by area, world's second-largest island, with an area of . Located in Melanesia in the southwestern Pacific Ocean, the island is ...
as a 1LT and air controller in the 107th Quartermaster Company, 126th IR, 32nd Infantry Division, the first to be transported into combat as a division. Wounded in an air crash, he returned to duty and was assigned to an Aviation Ordnance Maintenance Company in Townsend, Australia. Once Sullivan persuaded his immediate superiors at ARADMAC to support the idea of a floating aviation repair depot, it took him more than two years to win over the heads of the Supply and Maintenance Command and then the Transportation Materiel Command. Sullivan assumed broad responsibility for initial development of a "floating aircraft maintenance facility" (FAMF) and put considerable effort into selling it to senior Army leadership. Sullivan wrote a number of reports and held conferences to advance his idea. He spent so much time in Washington D.C. that he was given a second office there. Sullivan made trips to Germany, Vietnam, Korea, Japan, Hawaii, both coasts of the United States and many bases between, gathering information. Sullivan then successfully sought the attention and approval of General Frank S. Besson, who had recently been appointed as commanding officer of the newly formed
United States Army Materiel Command The U.S. Army Materiel Command (AMC) is the primary provider of materiel to the United States Army. The command's mission includes the management of installations, as well as maintenance and parts distribution. AMC operates depots; arsenals; am ...
(AMC). The formation of AMC represented a major reorganization within the Army, consolidating all seven Army technical services: the Offices of the Quartermaster General, the Chief of Ordnance, the Chief of Engineers, the Surgeon General, the Chief Signal Officer, the Chief Chemical Officer, and the Chief of Transportation. Besson's success later resulted in his receiving the Merit Award of the Armed Forces Management Association in 1963. On 17 June 1964, Besson relieved LTC Sullivan of his role as Director of Production Control and assigned him full time as project officer of Project Flat Top. In August 1964 Besson directed the Transportation Materiel Command to explore the feasibility of using a ship as a floating maintenance facility to provide helicopter support in the Far East.


Ship selection

Sullivan's mission was to create a floating aircraft maintenance facility. Choosing a specific ship, planning and designing the changes for its new use, and then converting the ship was a complex, lengthy, frustrating, and expensive effort. Sullivan originally assumed that the selected ship would be one of the US Navy's World War II
escort carrier The escort carrier or escort aircraft carrier (U.S. hull classification symbol CVE), also called a "jeep carrier" or "baby flattop" in the United States Navy (USN) or "Woolworth Carrier" by the Royal Navy, was a small and slower type of aircraf ...
s. A special team, including several enlisted men who had started as aircraft mechanics trained by the Air Force in the mid-1950s, crawled through 17 mothballed World War II vessels of all sorts: escort carriers,
tank landing ships A tank is an armoured fighting vehicle intended as a primary offensive weapon in Front line, front-line Land warfare, ground combat. Tank designs are a balance of heavy firepower, strong Vehicle armour, armour, and battlefield Mobility (milit ...
, cargo ships, and seaplane tenders. They found that the cost of reactivating one of the mothballed escort carriers would be prohibitive. They also reasoned that the aircraft destined for repair would not be in flying condition anyway and that a seaplane tender already came equipped with some shops. They finally chose the recently decommissioned World War II ''Curtiss''-class seaplane tender USS ''Albemarle''. Compared to a , ''Albemarle'' was longer: 527 ft 4 in (160.73 m) vs. 495 ft (151 m), drew less water: 21 ft 1 in (6.43 m) vs 23 ft 3 in (7.09 m) vs, and was slightly faster: 20 kn (23 mph; 37 km/h) vs. 18 kn (33 km/h; 21 mph). Sullivan had to convince the Navy to give up a vessel to another service branch, which was highly unusual, particularly after the interservice difficulties following the establishment of the United States Air Force when the Army wanted organic fixed-wing aviation assets. The Army, which had been accused by the Air Force of beginning another "Air Corps", found the Navy wary of the Army's attempts to get its own "aircraft carrier", but the Navy agreed as long as the Army paid the costs of converting the ship.


Conversion


Reactivation

''Albemarle'' was laid down in Camden, New Jersey by the
New York Shipbuilding Company The New York Shipbuilding Corporation (or New York Ship for short) was an American shipbuilding company that operated from 1899 to 1968, ultimately completing more than 500 vessels for the U.S. Navy, the United States Merchant Marine, the United ...
on 12 June 1939. She was launched on 13 July 1940 and was commissioned into the fleet on 20 December 1940 as USS ''Albemarle'' (AV-5). On 6 February 1956, ''Albemarle'' was selected for conversion to tend Martin P6M Seamaster jet flying boats. During the transformation, the aft portion of the ship was lowered to berth a seaplane. The ship was equipped to serve as a highly mobile seadrome capable of supporting jet seaplanes anywhere. ''Albemarle'' was recommissioned at Philadelphia on 21 October 1957. The Seamaster program was cancelled in 21 August 1959 before the ship had a chance to carry out its new mission. After nearly two decades of service as a ''Curtiss''-class seaplane tender, ''Albemarle'' was decommissioned on 21 October 1960. She was consigned to the Norfolk group of the Atlantic Reserve Fleet and later transferred to the
James River, Reserve Fleet The James River Reserve Fleet (JRRF) is located on the James River in the U.S. state of Virginia at () near Fort Eustis. James River Reserve Fleet, a "ghost fleet", is part of the National Defense Reserve Fleet. The Reserve Fleet ships in stor ...
. She was struck from the
Naval Vessel Register The ''Naval Vessel Register'' (NVR) is the official inventory of ships and service craft in custody of or titled by the United States Navy. It contains information on ships and service craft that make up the official inventory of the Navy from t ...
on 1 September 1962. On 7 April 1964, ''Albemarle'' was moved from the James River Fleet near
Fort Eustis Fort Eustis is a United States Army installation in Newport News, Virginia. In 2010, it was combined with nearby Langley Air Force Base to form Joint Base Langley–Eustis. The post is the home to the United States Army Training and Doctrin ...
in
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. On 7 August 1964, the
United States Maritime Administration The United States Maritime Administration (MARAD) is an Government agency#United States, agency of the United States Department of Transportation. MARAD administers financial programs to develop, promote, and operate the United States Maritime ...
transferred the ship, earmarked for conversion to a floating aeronautical maintenance facility for helicopters, back to the Navy. On 27 March 1965 the ship was reinstated on the Navy Vessel Register and on 16 April 1965 she received a new name and classification as USNS ''Corpus Christi Bay'' (T-ARVH-1), named for
Corpus Christi Bay Corpus Christi Bay is a scenic semi-tropical bay on the Texas coast found in San Patricio and Nueces counties, next to the major city of Corpus Christi. It is separated from the Gulf of Mexico by Mustang Island, and is fed by the Nueces River ...
, the ship's future home port. The ship's designation, "T-ARVH-1", classifies the ship as (T) civilian-crewed (USMM), (AR)
repair ship A repair ship is a naval auxiliary ship designed to provide maintenance support to warships. Repair ships provide similar services to destroyer, submarine and seaplane tenders or depot ships, but may offer a broader range of repair capability incl ...
, (V) aircraft, (H) helicopter and, (1) the first in a series. The ship was transferred to
Military Sealift Command The Military Sealift Command (MSC) is an organization that controls the replenishment and military transport ships of the United States Navy. Military Sealift Command has the responsibility for providing sealift and ocean transportation for all U ...
(MSC) on 11 January 1966. By law, MSC ships are not commissioned warships, are unarmed, and are prefixed with "USNS", for
United States Naval Ship United States Naval Ship (USNS) is the prefix designation given to non- commissioned ships that are property of the United States Navy (USN). Definition United States Naval Ships are unarmed auxiliary support vessels owned by the U.S. Navy ...
, instead of "USS", for
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.


Design and construction issues

The project team had to design multiple shops. This was a cumbersome process because of the technology at the time. For each design, craftsmen built a three-dimensional model that was used to estimate funding required. Sullivan continued to advance his idea up the chain of command to the Department of the Army and then the Department of Defense. The project slowed down for almost a year and threatened to stall altogether over a host of issues, including legal gray area issues about a civilian crew under the
Geneva Convention upright=1.15, The original document in single pages, 1864 The Geneva Conventions are international humanitarian laws consisting of four treaties and three additional protocols that establish international legal standards for humanitarian t ...
in a combat zone, the costs of conversion, and interservice concerns. Eventually Sullivan contacted Congressman Mendel Rivers of South Carolina, chairman of the House Armed Services Committee. Rivers was an ardent supporter of the military and the war in Vietnam. Sullivan talked to Rivers about using the
Charleston Naval Shipyard Charleston Naval Shipyard (formerly known as the Charleston Navy Yard) was a U.S. Navy ship building and repair facility located along the west bank of the Cooper River, in North Charleston, South Carolina and part of Naval Base Charleston. ...
in his district for the ship conversion project. Rivers believed that Congress should set the priorities for the
Secretary of Defense A ministry of defence or defense (see spelling differences), also known as a department of defence or defense, is the part of a government responsible for matters of defence and military forces, found in states where the government is divided ...
and he successfully persuaded Robert McNamara to support the project. Sullivan repeatedly traveled between ARADMAC in Corpus Christi, the shipyard in Charleston, and the Pentagon in Washington D.C. to resolve the many challenges inherent in converting ''Albemarle'' to a floating helicopter repair depot. The project's initial cost, estimated at less than $5 million, ballooned with design changes to $25 million (equivalent to $ million in ). The ship also required standing up two Aircraft Maintenance Battalions. The battalions would alternate manning the ship and augmenting the ARADMAC at Corpus Christi when not deployed. When complete, the ship would provide services equal to those found at ARADMAC. At its peak, ARADMAC was the largest helicopter repair facility on Earth. ARADMAC was renamed in 1974 as the Corpus Christi Army Depot.


New shops and facilities

Along with his offices at ARADMAC in Corpus Christi and in Washington D.C., Sullivan set up an office in the Charleston shipyard and another in the Charleston Army Depot where production equipment was received. The entire project, from design to launch, took 3½ years. The conversion work aboard the ship in the
Charleston Naval Shipyard Charleston Naval Shipyard (formerly known as the Charleston Navy Yard) was a U.S. Navy ship building and repair facility located along the west bank of the Cooper River, in North Charleston, South Carolina and part of Naval Base Charleston. ...
in
North Charleston, South Carolina North Charleston is a city in Berkeley, Charleston, and Dorchester counties in the U.S. state of South Carolina.City Planning Department (2008-07)City of North Charleston boundary map. City of North Charleston. Retrieved January 21, 2011. As ...
took 15 months and employed up to 1,000 workers. ''Corpus Christi Bay'' emerged from the yard only faintly resembling her former self. The entire stern transom area and the prominent seaplane ramp aft was replaced by a built-up superstructure topped by a helicopter landing pad. A smaller forward deck pad was used by helicopters that were not being repaired. The hangar bay was and high. All remaining seaplane-related structures and equipment along with all World War II weapons, electronics, rangefinders, magazines, and support gear were removed. Two cranes were added to lift equipment and aircraft onto and off the ship. The redesigned ship contained of workshops and of storage. The interior provided space for 26 production and 16 support shops, including limited airframe repair, engine overhaul repair, rebuilding, and test, transmission repair and test, a hydraulics shop, a sheet metal shop, a gunsmith, a foundry, an electronics shop, and others. The ship was fitted with equipment ranging from hand tools to a USD$3 million, 36-ton test instrument. The shops included engine test stands where helicopter turboshaft engines could be run up to speed. About $2.5 million was spent on more than 8,000 specialized tools and equipment. Two unusual innovations were implemented on the ship. The first was an IBM 360/20
16 bit 16-bit microcomputers are microcomputers that use 16-bit microprocessors. A 16-bit register can store 216 different values. The range of integer values that can be stored in 16 bits depends on the integer representation used. With the two mos ...
computer with 32 KB
core memory Core or cores may refer to: Science and technology * Core (anatomy), everything except the appendages * Core (laboratory), a highly specialized shared research resource * Core (manufacturing), used in casting and molding * Core (optical fiber), ...
. Computers aboard warships were extremely new and it was at the time one of the most powerful computers ever sent to sea. The computer was used to manage an extensive technical library and inventory. The second innovation was the technical data library that contained a complete set of 180,000 engineer drawings on film of aircraft systems, components, and special tools. The library duplicated the library in Corpus Christi and included 35mm
aperture card An aperture card is a type of punched card with a cut-out window into which a chip of microfilm is mounted. Such a card is used for archiving or for making multiple inexpensive copies of a document for ease of distribution. The card is typical ...
s that allowed staff to print blueprints that they could take to the shop and use to fabricate the part. It was the only such printer in Vietnam. The library contained 785,000 images that could be broadcast to shops on the ship via closed circuit TV. There was an internal communications system that allowed multiple shops to talk with each other and production control about their work. This allowed the shops to respond in real-time to requests for repairs and quickly make decisions about whether they could immediately accommodate a request or if they needed additional parts. Previously, damaged helicopters had to be transported back to the US for refit; with the advent of this new ship type, repairs could be accomplished near the forward areas. Damaged helicopter components could be barged out to the ship and lifted on board by one of the cranes or flown out via helicopter. The Army estimated it would save 30 percent on the cost of repairing components by completing the work aboard the ship. While the ship was rebuilt, soldiers received extensive training to manage the various shops. One of the crew, a sheet metal fabricator and airframe repairman, received a year of training in airframe repair and sheet metal work at Fort Eustis, Virginia. He then received an additional year of training at the Army aircraft maintenance facility in Corpus Christi, as did most soldiers who served on the ship. The ship conversion was completed in December 1965 and the ship arrived in Corpus Christi Bay on 23 January 1966. During
sea trials A sea trial or trial trip is the testing phase of a watercraft (including boats, ships, and submarines). It is also referred to as a " shakedown cruise" by many naval personnel. It is usually the last phase of construction and takes place on o ...
, the inspection team found that the ship was excessively top-heavy due to the new superstructure aft. To resolve this, they poured in several tons of concrete ballast.


Deployed to South Vietnam


In-theatre aviation support

On 18 February 1966 the ship sailed for South Vietnam. After a six week transit, the ship arrived in
Cam Ranh Bay Cam Ranh Bay () is a deep-water bay in Vietnam in Khánh Hòa Province. It is located at an inlet of the South China Sea situated on the southeastern coast of Vietnam, between Phan Rang and Nha Trang, approximately 290 kilometers (180 miles) nor ...
on 2 April 1966 and began 6½ years of service. Cam Ranh Bay was chosen because it was the largest harbor facility in South Vietnam. In March 1967 she moved to
Vũng Tàu Vũng Tàu (''Hanoi accent:'' , ''Saigon accent:'' ) is an important port city in southern Vietnam. It serves as the maritime port of Ho Chi Minh City, the largest city in Vietnam. Vũng Tàu covers of area and consists of 16 urban wards and on ...
from which she would periodically move up the coast of South Vietnam to
Quy Nhon Quy Nhon ( ) is a coastal city in Bình Định province in central Vietnam. It is composed of 16 wards and five communes with a total of . Quy Nhon was the capital of the former Bình Định province. As of 2022 its population was 481.110. Hi ...
and Da Nang. On these trips, cargo was unloaded and unserviceable components taken aboard. Later on the ship moved back to Quy Nhon to be closer to the 1st Cavalry. The ship moved back to Vũng Tàu in 1970 which was in the vicinity of the parent 34th General Support Group and operated about off the coast. To avoid a repeat of the successful sapper attack on the escort carrier turned helicopter transport , security procedures were stepped up while in port. Helmets and flak jackets were kept at the ready topside, sandbags were placed around the bridge, screens were secured over portholes, bilge and ballast pumps were kept warmed up, and extra medical kits and firefighting equipment was kept ready. While the civilian merchant marine crew could not bear arms, the soldiers had been trained to handle weapons and maintained a large arms locker that included replacement
M60 machine gun The M60, officially the Machine Gun, Caliber 7.62 mm, M60, is a family of American general-purpose machine guns firing 7.62×51mm NATO Cartridge (firearms), cartridges from a disintegrating Belt (firearms), belt of M13 links. There are sev ...
s for the Huey gunships.


Crew and operations

The first commander of ''Corpus Christi Bay'' was
Captain Captain is a title, an appellative for the commanding officer of a military unit; the supreme leader or highest rank officer of a navy ship, merchant ship, aeroplane, spacecraft, or other vessel; or the commander of a port, fire or police depa ...
Harry Anderson. He had a crew of 129 civilian merchant marine crew under the
Military Sea Transport Service The Military Sealift Command (MSC) is an organization that controls the replenishment and military transport ships of the United States Navy. Military Sealift Command has the responsibility for providing sealift and ocean transportation for all U ...
(MSTS), a fraction of the ship's original complement of 1,135 crew members assigned to her during World War II. They manned the bridge, the engine room, and the ship's watches. The aircraft maintenance facilities aboard the ship were operated by the First Transportation Battalion (Seaborne), commanded by LTC Harry O. Davis, US Army, with 308 aircraft technicians, specialists and mechanics. There were 19 officers, 11 warrant officers, and 350 enlisted men. The Army formed the 1st Material Group on 26 May 1966, the first of its kind in the Army Material Command, and named COL Sullivan as its commander. On 7 October 1966, the Second Transportation Battalion (Seaborne) was formed at ARADMAC. Sullivan presented the unit's new colors to its commanding officer, LTC John Bergner on 8 October 1966. The unit was trained in Corpus Christi to prepare all personnel who would deploy to serve aboard the ship. The two battalions initially rotated about every 12 months from Corpus Christi to South Vietnam, until deployments were phased in year-round. In May 1967,
Colonel Colonel ( ; abbreviated as Col., Col, or COL) is a senior military Officer (armed forces), officer rank used in many countries. It is also used in some police forces and paramilitary organizations. In the 17th, 18th, and 19th centuries, a colon ...
(COL) Morgan C. Light assumed management of the 1st Material Group and Project FLATTOP, replacing COL Sullivan. Sullivan was transferred to head the Aviation Maintenance Depot for HQ US Army Europe in Mannheim, Germany.


Ship fails audit

In late 1969, the Army Audit Agency notified the ship's commander that ''Corpus Christi Bay'' was being recalled to the United States. The commander was informed that during the 1967 fiscal year the ship had failed to attain a Pentagon goal for parts repaired. ARADMAC strongly resisted the criticism of the ship's cost-effectiveness and the accuracy of the audit. Costs were in part controlled by the archaic procurement processes used by the federal government. The value of the ship's work varied depending on which organization was evaluating the cost. Production fell under two accounts, one type the Army in Vietnam paid for directly, while the other it didn't. The ship remained in South Vietnam while the recall was appealed and it was eventually overturned.


Services available

''Corpus Christi Bay'' had the largest and best equipped fabrication facilities in Vietnam, including milling machines, lathes, molten-salt heat-treating ovens, metal-plating, chemical and metallurgical testing, and presses. Her shops provided the highest echelon of repair services to Army aircraft. Every piece that came through the ship's shops was restored to factory specifications. These included components such as engines, avionics, and armament. The ship also provided a chemical laboratory in which soldiers could test the purity and viscosity of lubricants and hydraulic fluids. The ship's crew supported numerous other systems aside from aircraft. They conducted a limited fabrication program, including some non-aviation items and special projects. They manufactured flash suppressors for machine guns, skid shoes for the OH-6A Light Observation Helicopter, and helicopter flare racks that could be jettisoned. They manufactured parts for the
Patrol Air Cushion Vehicle The Patrol Air Cushion Vehicle (PACV), also known as the Air Cushion Vehicle (ACV) in Army and Coast Guard service, was a United States Navy and US Army, Army hovercraft used as a patrol boat in marshy and riverine areas during the Vietnam War ...
s which were relatively few in number and thus had a hard time obtaining parts. There was such a demand for hydraulic tubing and fuel lines that they fabricated them and kept them in inventory. The ship could perform all the maintenance functions of the depot level aircraft maintenance facility at Corpus Christi, including overhauling and rebuilding aircraft components, directly in service to
Military Assistance Command, Vietnam The U.S. Military Assistance Command, Vietnam (MACV) was a joint-service command of the United States Department of Defense, composed of forces from the United States Army, United States Navy, and United States Air Force, as well as their respecti ...
. Production increased slowly and stayed below planned through mid-1967 but was still highly valuable. The work avoided costs and, more importantly, returned aircraft to use more quickly. One veteran said, "The guys aboard this FAMF could fix anything."


Expedited repair

She had two
UH-1 The Bell UH-1 Iroquois (nicknamed "Huey") is a utility military helicopter designed and produced by the American aerospace company Bell Helicopter. It is the first member of the prolific Bell Huey family, Huey family, as well as the first turb ...
s assigned to the ship for administrative use and transporting light supplies and picking up and delivering light aircraft components. Flattop 086 (68-16086) and Flattop 045 (69-15045) each had its own operating and maintenance crews. During the height of the ship's service off Vietnam, crewmen worked three shifts to repair helicopter parts. Each shop was responsible for maintaining its repair parts listing, program, and production, and was expected to operate on a 24-hour schedule. Due to space constraints, the men's goal was to turn around as many unserviceable components as quickly as possible. They prioritized repairing the components that required the least amount of work and sent the components that required the greatest amount of work back to Corpus Christi. To maintain maximum aircraft readiness, they also responded to urgent requirements if a component was grounding an aircraft. Instead of flying entire helicopters onto the ship, it was preferable to extract aircraft and helicopter components or sub-components ashore and then bring them aboard. They were sometimes brought to the ship via helicopter, but they were typically delivered by an amtruc (wheeled 15-ton amphibious truck) or a “mike boat” (converted WWII landing craft). A barge was often tied alongside to allow the amtruc or boat to moor in a position that allowed the crane operator better visibility. The ship could repair minor damage to airframes, but if airframe was badly damaged, it was sent to Texas. When sent aboard a ship, the aircraft had to be wrapped in "Spraylot" (shrink-wrapped) coverings to protect it against the elements. The Army experimented with doped fabric, then blown plastic, and finally peel-off plastic to protect the aircraft while in transit.Mercogliano, Salvatore R
Fourth Arm of Defense: Sealift and Maritime Logistics in the Vietnam War
2017. Naval Historical Foundation
Space had to be found aboard one of the Seatrain chartered freighters or one of the converted World War II escort carriers such as . Then it took 18 days to ship the helicopter across the Pacific and through the Panama Canal to the ARADMAC in Corpus Christi. Once repairs were complete, the process had to be reversed. A repair that required a week of real-time labor could end up taking two months. On 1 April 1968, to lessen the time it took to return aircraft to service, the Army began to use Air Force C-133 and C-141 cargo aircraft of the
Military Airlift Command The Military Airlift Command (MAC) is an inactive United States Air Force major command (MAJCOM) that was headquartered at Scott Air Force Base, Illinois. Established on 1 January 1966, MAC was the primary strategic airlift organization of ...
to transport damaged helicopters, engines, and component parts to and from Vietnam. If ''Corpus Christi Bay'' did not have the necessary parts, they requested them from Texas. If the parts were deemed high priority, they were put aboard the C-133 or C-141 aircraft that were transporting repaired aircraft back to Vietnam. In 1968, ARADMAC inaugurated a Department of the Army approved Special Assignment Airlift Mission (SAAM) which involved the direct airlift of helicopter engines to South Vietnam. They were delivered to the Aviation Materiel Management Center (AMMC) depots. By the end of the year, 3,169 engines had been airlifted in 88 flights. In some circumstances they could pick up parts at
Tan Son Nhut Air Base Tan Son Nhut Air Base () (1955–1975) was a Republic of Vietnam Air Force (RVNAF) facility. It was located near the city of Saigon in southern Vietnam. The United States used it as a major base during the Vietnam War (1959–1975), stationing ...
or
Bien Hoa Air Base Bien Hoa Air Base (Vietnamese language, Vietnamese: ''Sân bay Biên Hòa'') is a Vietnam People's Air Force (VPAF) military airfield located in South-Central southern Vietnam about from Ho Chi Minh City, across the Dong Nai river in the norther ...
airport less than 48 hours after requesting them.


Shore teams

The crew provided contact teams nicknamed "Sand Crabs" that worked ashore. They gathered parts needing repair as they were sent in by combat units, boxed them up, and transported them aboard an amphibious boat to the ship. Service members also went ashore regularly to provide medical care, food, gifts, clothing, and toys at a Vietnamese orphanage near Cam Ranh Bay. They built a building to house the orphans and provided 60 beds, among other projects.


Final disposition

The ship left South Vietnam in late 1972 and was given one more mission; during Operation Hula Hoop 73, the ship, along with , monitored French nuclear tests in the
Tuamotu Archipelago The Tuamotu Archipelago or the Tuamotu Islands (, officially ) are a French Polynesian chain of just under 80 islands and atolls in the southern Pacific Ocean. They constitute the largest chain of atolls in the world, extending (from northwest to ...
. The Army troops were flown directly back to Texas. Only the civilian maritime crew remained aboard. During the voyage, the ship was hit by a typhoon that caused a crack in the hull. En route to
Mururoa Moruroa (Mururoa, Mururura), also historically known as Aopuni, is an atoll which forms part of the Tuamotu Archipelago in French Polynesia in the southern Pacific Ocean. It is located about southeast of Tahiti. Administratively Moruroa Atoll i ...
, the ship began to leak so badly that she needed immediate repair. Relying on the
Law of the sea Law of the sea (or ocean law) is a body of international law governing the rights and duties of State (polity), states in Ocean, maritime environments. It concerns matters such as navigational rights, sea mineral claims, and coastal waters juris ...
that allows a ship in distress to enter the nearest port, she anchored at
Papeete Papeete (Tahitian language, Tahitian: ''Papeʻetē'', pronounced ; old name: ''Vaiʻetē''Personal communication with Michael Koch in ) is the capital city of French Polynesia, an overseas collectivity of the France, French Republic in the Pacific ...
on Tahiti, French Polynesia. A US Navy repair crew was sent from Pearl Harbor to patch the ship. While returning to the US, she stopped in Guam and Hawaii. ''Corpus Christi Bay'' traversed the Panama Canal and sailed to her home base of Corpus Christi, arriving on 19 December 1972. Upon inspection in Charleston, the condition and age of the ship did not warrant the expense of further repair. The ship was ultimately determined by Military Sealift Command to be "in excess of current and future requirements". ''Corpus Christi Bay'' was taken out of service in 1973 and berthed in ready reserve status at Corpus Christi. By mid-1974 a host of factors converged and led HQDA to reject continuing use of the ship. Among considerations were direct costs of maintaining the ship due to fiscal constraints in the drawdown after the end of the Vietnam war, the increasing promise of being able to air transport aircraft to temporary repair facilities, and eliminating the cost of the two battalions. The ship was finally struck from the Naval Vessel Register on 31 December 1974, and on 8 January 1975 the ship left Corpus Christi for further disposal. On 17 July 1975, Brownsville Steel and Salvage, Inc. paid $387,766 (equivalent to $ in ) to scrap the ship.


Legacy

The Floating Aircraft Maintenance Facility allowed the Army to repair helicopters in-theater instead of shipping them back to Corpus Christi in the United States.The Early Years of AMC — 1962-1975
Army Material Command
Transporting damaged aircraft back to the United States for repairs was an expensive, logistical nightmare. The ship returned deadlined aircraft in an average of six days compared to 18 days for aircraft returned to the continental United States. The ship repaired as many as 20,000 aircraft components a month and saved the military millions of dollars. Productivity peaked in late 1969 and early 1970 when the soldiers repaired helicopter parts valued at roughly $3.76 million (equivalent to $ million in ) each month. Over the term of her service off the shore of Vietnam, the ship repaired about 270,000 items valued at $220 million (equivalent to $1.1 billion in 2021). This more than offset the cost of building and equipping the ship.


Awards

The First Transportation Corps Battalion (Aircraft Maintenance Depot) (Seaborne) earned four
Meritorious Unit Commendation The Meritorious Unit Commendation (MUC; pronounced ''muck'') is a mid-level unit award of the United States Armed Forces. The U.S. Army awards units the Army MUC for exceptionally meritorious conduct in performance of outstanding achievement or ...
s. The ship and its military crew was also awarded the
National Defense Service Medal The National Defense Service Medal (NDSM) is a service award of the United States Armed Forces established by President Dwight D. Eisenhower in 1953. It was awarded to every member of the U.S. Armed Forces who served during any one of four s ...
, the
Vietnam Service Medal The Vietnam Service Medal was a military award of the United States Armed Forces established on 8 July 1965 by order of President Lyndon B. Johnson. The medal is awarded to recognize service during the Vietnam War by all members of the U.S. ...
, and the
Republic of Vietnam Campaign Medal The Republic of Vietnam Campaign Medal, also known as the Vietnam Campaign Medal (), is a South Vietnamese military campaign medal which was created in 1949 and awarded during the First Indochina War. During the Vietnam War (Second Indochina War ...
. A plaque dedicated to her stated: The ship’s bell, a scale model of the ship and other artifacts are displayed at the Corpus Christi Army Depot in Texas. The US Army Transportation Museum revealed a large scale model of ''Corpus Christi Bay'' in September 2021. On 8 July 1967, COL Sullivan was awarded the
Legion of Merit The Legion of Merit (LOM) is a Awards and decorations of the United States military, military award of the United States Armed Forces that is given for exceptionally meritorious conduct in the performance of outstanding services and achievemen ...
, the US Army's second highest non-combat award, by GEN Frank Besson. He was cited for "developing a new versatile, mobile depot maintenance capability." He was credited with the planning, creativity, management ability, and leadership that made the ship available during the peak period when aircraft maintenance was initially needed in 1966. Initial plans called for a second floating aircraft maintenance depot to be named the USNS ''Oso Bay''. The ship was to be an escort carrier with a flight hangar built on the deck. After the cost of converting ''Albemarle'' ballooned, the second ship was considered cost prohibitive and never implemented. Interservice rivalries led to some criticism of the success of ''Corpus Christi Bay''. But according to a special operational report on the 34th Support Group published in November 1969, the efforts of the 1st Transportation Battalion made it possible for the US Army to "maintain helicopters in numbers sufficient to meet the full range of combat operations."


References


External links


Vietnam War Aircraft Repair Ship, Helicopter, T ARVH 1 at Cam Ranh Bay 1966 US Army
(video)
USNS Corpus Christi Bay (T-ARVH-1) - The Army Aviation Floating Workshop
(video) {{DANFS Vietnam War Curtiss-class seaplane tenders 1940 ships 1979 disestablishments in the United States Vietnam War ships of the United States Corpus Christi, Texas