Front Matter

Parachute Rigger Handbook August 2015 Change 1 (December 2015) U.S. Department of Transportation FEDERAL AVIATION ADMINISTRATION Flight Standards Service

Preface

The Parachute Rigger Handbook introduces the basic skills necessary for acquiring a Parachute Rigger Certificate. It is developed by the Flight Standards Service, Airman Testing Standards Branch, in cooperation with various aviation educators and industry.

This handbook is primarily intended to assist individuals who are preparing for the parachute rigger airman knowledge test and the oral and practical test. The material presented in this handbook is appropriate for senior and master parachute riggers. The handbook contains information on regulations and human factors, design and construction, materials, operations, inspection and packing, hand tools, sewing machines, the parachute loft, repairs, alterations, and manufacture. This handbook conforms to training and certification concepts established by the Federal Aviation Administration (FAA). There are different ways of teaching, as well as performing specific rigging procedures, and many variations in the explanations of repairs, alterations, and manufacture of parachutes. The discussion and explanations reflect commonly used practices and principles. This handbook provides a basic knowledge that can serve as a foundation on which to build further knowledge. Occasionally the word “must” or similar language is used where the desired action is deemed critical. The use of such language is not intended to add to, interpret, or relieve a duty imposed by Title 14 of the Code of Federal Regulations (14 CFR).

It is essential for persons using this handbook to also become familiar with and apply the pertinent parts of 14 CFR and appropriate technical standards. Performance standards for demonstrating competence required for parachute riggers are prescribed in the appropriate practical test standard.

This handbook is available for download, in PDF format, from www.faa.gov. The current Flight Standards Service airman training and testing material and learning statements for all airman certificates and ratings can be obtained from www.faa.gov. The FAA greatly acknowledges the valuable assistance provided by many individuals and organizations throughout the aviation community whose expertise contributed to the preparation of this handbook. This handbook contains material and pictures of various products often used by industry. It is presented here as a means of communicating information to be used for training purposes only. The FAA neither endorses nor recommends any specific trademark item in this handbook. This handbook is published by the U.S. Department of Transportation, Federal Aviation Administration, Airman Testing Standards Branch, AFS-630, P.O. Box 25082, Oklahoma City, OK 73125.

Comments regarding this publication should be sent, in email form, to the following address: AFS630comments@faa.gov. /s/ John Barbagallo, for John S. Duncan

Director, Flight Standards Service

Acknowledgments

The Parachute Rigger Handbook was produced by the Federal Aviation Administration (FAA) with the assistance of Safety Research Corporation of America (SRCA). The FAA wishes to acknowledge the following contributors:

Parachute Labs, Inc., for images used in Chapters 1, 2, and 4

Ilse Ungeheuer, for images used in Chapters 3 and 5

Tim Taykalo, for images used in in Chapter 6

Tom Dolphin, for images and content used in Chapter 7 and the Appendix

Record of Changes

Change 1 (December 2015)

This is an updated version of FAA-H-8083-17A, Parachute Rigger Handbook, dated August 2015. This version contains error corrections, revised graphics, and updated performance standards. All pages containing changes are marked with the change number and change date in the page footer. The original pagination has been maintained so that the revised pages may be replaced in lieu of repurchasing or reprinting the entire handbook. The changes made in this version are as follows:

Table of Contents

Preface....................................................................iii

• Acknowledgments ..................................................v
• Record of Changes...............................................vii
• Table of Contents ..................................................ix
• Chapter 1
• Introduction to Parachute Rigging ....................1-1
• Regulations and Human Factors ....................................1-1

Parachute Rigger Certificates .........................................1-2

Eligibility and Requirements .....................................1-2

Earning a Parachute Rigger Certificate ......................1-2

Testing ....................................................................1-3

Alternate Means of Qualifying for a Parachute

Rigger Certificate ...................................................1-3

Retesting .................................................................1-3

Responsibilities of a Certificated Parachute Rigger ......1-5

Facilities and Tools ....................................................1-5

Performance Standards ..............................................1-5

Currency Requirements .............................................1-6

Record Keeping .........................................................1-7

Sealing the Parachute .................................................1-8

Regulatory Compliance .................................................1-8

14 CFR part 1—Definitions .......................................1-8

14 CFR part 21, subpart O—Technical Standard

Orders (TSO) ..............................................................1-8

14 CFR part 39—Airworthiness Directives (ADs) ....1-8

14 CFR part 91—General Operating and Flight

Rules ..........................................................................1-9

14 CFR part 105, subpart C—Parachute

Equipment and Packing .............................................1-9

Rigging Ethics ...............................................................1-9

Certification Specifications ........................................1-9

Pilot Versus Parachute Size........................................1-9

Parachute Service Life................................................1-9

Chapter Summary ........................................................1-10

• Chapter 2
• Design and Construction ....................................2-1

Introduction ....................................................................2-1

Parachute Design and Construction ...............................2-2

Component Parts ...........................................................2-2

• Main Parachute Canopy ............................................2-2
• Reserve Parachute Canopy .........................................2-2
• Emergency Parachute Canopy....................................2-2

Harness/Container ......................................................2-2

Pilot Chutes and Bridles for the Main and

Reserve Parachutes ................................................2-2

Ripcords or Equivalent Devices for the Main and Reserve Parachutes .........................................2-3

Deployment Devices for the Main and Reserve

Parachutes ...............................................................2-3

• Main Parachute Release Mechanism and
• Associated Handles or Static Lines .......................2-3
• Risers and Associated Steering Toggles .................2-3

TSO Standards ...............................................................2-4

Canopy Design ...............................................................2-5

Nomenclature .............................................................2-5

Construction Concepts and Techniques ....................2-5

Operational Theory.....................................................2-6

Materials .....................................................................2-6

Damage.......................................................................2-6

Containers...................................................................2-6

Configuration ..............................................................2-7

Harness Design ..............................................................2-9

Bridles and Deployment Devices.................................2-11

Deployment Types ...................................................2-12

• Type 1: Canopy First Deployment ......................2-12
• Type 2: Two-Stow Diaper or Half Diaper ...........2-12
• Type 3: Ascuitto or Piglet-Style Flat Diaper .......2-13
• Type 4: Handbury or Preserve Full Diaper ..........2-13
• Type 5: Free Bag .................................................2-13

Type 6: Sleeves .....................................................2-13

Bridles ......................................................................2-15

Pilot Chutes .................................................................2-17

• Spring-Loaded Pilot Chutes .....................................2-17
• Hand Deploy Pilot Chutes .......................................2-17
• Automatic Activation Devices (AADs) and

Reserve Static Lines (RSLs) .......................................2-18

Automatic Activation Devices ................................2-18

Operation ..................................................................2-19

Reserve Static Line (RSL) Systems ........................2-21

RSL Designs .............................................................2-21

• Main Riser Attachment .........................................2-22
• Ripcord Cable Routing ........................................2-23
• RSL Lanyard and Container Mount ....................2-23

Joint Efficiency .....................................................2-24

Chapter Summary ........................................................2-25

• Chapter 3
• Materials ...............................................................3-1

Introduction ....................................................................3-1

Specifications .................................................................3-2

Fabrics ............................................................................3-2

Webbing and Tapes........................................................3-3

Webbing Selection .....................................................3-4

Cords, Lines, and Threads ............................................3-8

Hardware ......................................................................3-12

Plastics and Synthetics .................................................3-20

Fasteners ......................................................................3-21

Housings ......................................................................3-22

Ripcords, Cables, and Swages .....................................3-24

Miscellaneous ..............................................................3-26

Chapter Summary ........................................................3-26

• Chapter 4
• Operations............................................................4-1

Introduction ...................................................................4-1

Sport Parachute Main Packing Techniques ...................4-2

Deployment and Inflation Characteristics......................4-8

Main Pilot Chute ........................................................4-9

Bridle Length............................................................4-10

Rubber Bands ...........................................................4-10

Assembly of the Main Canopy To The Harness and Container ..............................................................4-11

• Assembly of Components and Compatibility ..............4-13
• Reserve Bag Extraction Force ..................................4-14
• TSO Certification and Placard Limitations ..............4-14

Harness Strength.......................................................4-14

Volume .....................................................................4-16

Deployment Type .....................................................4-16

Chapter Summary ........................................................4-17

• Chapter 5
• Inspection and Packing ......................................5-1

Introduction ....................................................................5-1

Identification ..................................................................5-2

Inspection .......................................................................5-2

Component Compatibility ..........................................5-4

Round Canopies and Pilot Emergency Systems.........5-7

Straightening the Canopy ...........................................5-7

Damage Identification ................................................5-8

Pilot Chute and Bridle ................................................5-8

Reserve Canopy..........................................................5-9

Suspension Lines and Connector Links ...................5-10

Harness .....................................................................5-11

Container ..................................................................5-12

Ripcord .....................................................................5-12

Airing and Drying ....................................................5-13

• Ram-Air Reserves and Sport Piggyback Systems....5-13
• Pilot Chute and Free Bag/Bridle ...........................5-13
• Ram-Air Reserve Canopy .....................................5-13
• Canopy Assembly and Line Continuity ................5-14

Inspection ..............................................................5-16

Harness .................................................................5-17

Container...............................................................5-17

Ripcord .................................................................5-18

Rigging and Repairs.....................................................5-19

Packing.........................................................................5-19

Round Canopy into a Pilot Emergency

Parachute System .....................................................5-20

Layout ...................................................................5-20

Pleating the Canopy ..............................................5-21

Fold the Skirt ........................................................5-22

• Closing the Diaper and Stowing the Lines ...........5-23
• Skirt or Diaper Placement .....................................5-24
• Accordion Folding the Canopy .............................5-25
• Closing the Container ...........................................5-25

Ripcord Pull Force ...................................................5-27

Sealing the Parachute ...............................................5-27

• Ram-Air Reserve into a Sport Piggyback System....5-28
• Assembling the Reserve System ...........................5-28
• Ram-Air Reserve into a Two-Pin Piggyback ..........5-38

Documentation .............................................................5-39

Chapter Summary ........................................................5-42

• Chapter 6
• Hand Tools, Sewing Machines, and the

Parachute Loft .....................................................6-1

Introduction ....................................................................6-1

Hand Tools .....................................................................6-2

Hand Tools Description..............................................6-2

Sewing Machines .........................................................6-14

Identification and Nomenclature ..............................6-16

Sewing Theory .............................................................6-18

Needles .....................................................................6-20

Operation ..................................................................6-21

• Installing the Needle and Threading the Machine....6-21
• Machine Maintenance ..............................................6-23
• Sewing Machine Attachments ..................................6-24

The Parachute Loft.......................................................6-24

• Packing and Inspection Area ................................6-25
• Work Area Including Layout Tables and
• Sewing Machines ..................................................6-26

Harness Table and Machines ................................6-27

Cutting Table ........................................................6-27

Metal Working Area .............................................6-27

Office Area ...............................................................6-27

Materials Storage Area .............................................6-28

Chapter Summary ........................................................6-28

• Chapter 7
• Repairs, Alterations, and Manufacture ..............7-1

Introduction ....................................................................7-1

Inspection Process..........................................................7-2

Major or Minor Repairs .................................................7-8

Contamination Conditions .............................................7-8

Acid Contamination .................................................7-10

Action ...................................................................7-10

Salt Water Contamination ........................................7-10

Action ...................................................................7-10

Removal of Perspiration ...........................................7-10

Removal of Fresh Water...........................................7-10

Removal of Mildew ..................................................7-10

Removal of Petroleum Products ...............................7-10

Removal of Bloodstains ...........................................7-10

Removal of Soil ........................................................7-10

Drying a Parachute ...................................................7-11

Cleaning the Parachute ............................................7-11

Hand Washing (If Absolutely Necessary) ............7-11

Approved Data .............................................................7-11

Types of Approved Data ..........................................7-12

Repair Techniques .......................................................7-12

Section 1, Canopy and Lines .......................................7-13

Detailed Information on Square Canopy Repairs.....7-14

Materials ...................................................................7-14

Seam Restitching ......................................................7-15

Procedure ..............................................................7-15

Inspection ..............................................................7-15

Canopy Ripstop Tape Repair ...................................7-16

Procedure ..............................................................7-16

Inspection ..............................................................7-17

Round and Square Canopy—Basic Patch Repair.....7-17

Procedure ..............................................................7-18

Round Canopy—Panel Replacement .......................7-21

Procedure ..............................................................7-21

Inspection ..............................................................7-22

Square Canopy—Partial Panel Replacement ...........7-22

Procedure ..............................................................7-22

Inspection ..............................................................7-25

Square Canopy—Rib Repair ....................................7-25

Procedure ..............................................................7-25

Inspection ..............................................................7-28

Square Canopy—Pilot Chute Attachment Point

Repair .......................................................................7-28

Procedure ..............................................................7-28

Inspection ..............................................................7-30

Round Canopy—Non-continuous Line

Replacement .............................................................7-30

Procedure ..............................................................7-30

Inspection ..............................................................7-31

Square Canopy—Main Line Replacement ...............7-31

Procedure ..............................................................7-31

Inspection ..............................................................7-32

Square Canopy—Control Line Replacement ...........7-33

Procedure ..............................................................7-33

Continuous Line Method ..........................................7-34

Non-continuous Line Method ..................................7-34

Inspection ..............................................................7-35

Square Canopy—Crossport Repair ..........................7-36

Procedure ..............................................................7-36

Inspection ..............................................................7-36

Square Canopy—Trim Check and Re-trim ..............7-37

Procedure ..............................................................7-37

Inspection ..............................................................7-38

Section 2, Container .....................................................7-38

Container Fabric Panel Repair .................................7-38

Procedure ..............................................................7-39

Binding Tape Repair or Splice .............................7-39

Hidden Patches .....................................................7-40

Overlay Patches ....................................................7-40

Single-Side Fabric Patches ...................................7-41

Inspection ..............................................................7-42

Container Grommet Replacement ............................7-42

Procedure ..............................................................7-42

Material Repair and Grommet Replacement ............7-43

Inspection ..............................................................7-43

Container Velcro® Replacement ..............................7-43

Procedure ..............................................................7-43

Inspection ..............................................................7-44

Container Plastic Stiffener Replacement..................7-44

Procedure ..............................................................7-44

Main Container Side Flap Replacement...................7-46

Procedure ..............................................................7-46

Inspection ..............................................................7-48

Bottom of Container (BOC) Pocket Replacement ...7-48 Procedure ..............................................................7-48

Inspection ..............................................................7-49

Ring Release Housing Replacement ........................7-49

Procedure ..............................................................7-49

Inspection ..............................................................7-50

Section 3, Harness and Risers ......................................7-51

Chest Strap Replacement..........................................7-51

Procedure ..............................................................7-51

Inspection ..............................................................7-54

Lower Leg Strap Shortening ....................................7-54

Procedure ..............................................................7-54

Inspection ..............................................................7-55

Ripcord Pocket Velcro® Replacement .....................7-55

Procedure ..............................................................7-55

Inspection ..............................................................7-56

Articulated Upper Leg Hardware Replacement .......7-56

Procedure ..............................................................7-56

Inspection ..............................................................7-56

Standard Harness Main Lift Web Replacement .......7-57

Background ...........................................................7-58

Procedure ..............................................................7-59

Inspection ..............................................................7-62

Main Riser 3-Ring Locking Loop Replacement ......7-62

Procedure ..............................................................7-63

Main Riser Steering Toggle Velcro® Replacement..7-64 Procedure ..............................................................7-64

Inspection ..............................................................7-65

Section 4, Accessory Components...............................7-65

Reserve Pilot Chute Repair—Mesh, Tackings, and Bad Grommet ....................................................7-65

Procedure ..............................................................7-65

Inspection ..............................................................7-66

Inspection ..............................................................7-67

Reserve Free Bag Repair—Grommet Pullout ..........7-67

Procedure ..............................................................7-67

Inspection ..............................................................7-68

Main Pilot Chute Repair—Top Canopy

Reinforcing ...............................................................7-68

Procedure ..............................................................7-68

Inspection ..............................................................7-69

Main Pilot Chute Collapsible Bridle Replacement ..7-69 Procedure ..............................................................7-69

Inspection ..............................................................7-71

Main Deployment Bag Repair—Closing Flap

Grommet Pullout ......................................................7-72

Procedure ..............................................................7-72

Inspection ..............................................................7-73

Section 5, Alterations ...................................................7-73

Articulated Harness Main Lift Web (MLW)

Resizing ....................................................................7-73

Procedure ..............................................................7-74

Leg Pad Resizing ......................................................7-74

Procedure ..............................................................7-75

Inspection ..............................................................7-77

Automatic Activation Device (AAD) Installation....7-77

Procedure ..............................................................7-77

• Built-In Channel Modification Configuration ......7-78
• Adhesive Channel Installation ..............................7-78
• Cutter Channel and Elastic Installation ................7-79

Inspection ..............................................................7-80

Section 6, Manufacturing .............................................7-80

Main and Reserve Closing Loop Manufacture.........7-80

Procedure ..............................................................7-80

Inspection ..............................................................7-82

Main Deployment Bag .............................................7-82

Procedure ..............................................................7-83

Inspection ..............................................................7-84

Bottom of Container (BOC) Pocket .........................7-85

Procedure ..............................................................7-85

Inspection ..............................................................7-86

Section 7, Manufacturing .............................................7-86

Hand Tacking Techniques ........................................7-86

Procedure ..............................................................7-87

Cleaning and Washing Procedures ...........................7-89

Background ...........................................................7-89

Colorfastness ............................................................7-89

Procedure ..............................................................7-89

Chapter Summary ........................................................7-90

Appendix A.......................................................... A-1

Glossary ..............................................................G-1

Index ......................................................................I-1