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Vertical replenishment

Vertical replenishment (VERTREP) is a method of transferring cargo, personnel, and supplies between ships at sea using helicopters while the vessels remain underway, serving as a key component of naval underway replenishment (UNREP) operations.^[1] This technique enables rapid resupply without requiring ships to come alongside, typically involving helicopters lifting palletized loads via external hooks, slings, or nets from a combat logistics force vessel to receiving ships in a battle group.^[1] VERTREP supports a wide range of deliveries, including ammunition, missiles, provisions, and even specialized operations like submarine replenishment, with transfer rates potentially reaching up to 180 short tons per hour using multiple helicopters.^[1] The development of VERTREP began in the mid-1960s as part of U.S. Navy efforts to enhance at-sea logistics during the Cold War era.^[2] The first operational deployment occurred on November 27, 1964, aboard the USS Sacramento (AOE-1), utilizing UH-46A Sea Knight helicopters from Helicopter Combat Support Squadron One to demonstrate the feasibility of helicopter-based transfers.^[2] This innovation built on earlier concepts of aerial resupply, evolving from basic sling-load experiments to a standardized procedure that addressed limitations of traditional connected replenishment methods, such as alongside transfers, by allowing operations in adverse weather or dispersed formations.^[2] By the late 1960s, the Navy planned to acquire approximately 20 UH-46A helicopters dedicated to VERTREP, marking its integration into routine fleet support.^[2] In practice, VERTREP operations require coordinated efforts between delivery and receiving ships, including load preparation, helicopter staging, and deck handling by specialized teams like the Helicopter External Load Team (HELT) under a Combat Cargo Officer.^[1] Helicopters such as the CH-53E Super Stallion (with dual-point hooks for up to 32,000 pounds), CH-46 Sea Knight, and MH-60S Knight Hawk are employed, using equipment like the Mk 105 hoisting sling (6,000-pound capacity), cargo nets, and pallets for secure transport.^[1] Procedures emphasize safety protocols, including static electricity mitigation, rotor downwash management, and emergency contingencies, with night operations supported by specialized lighting and signaling.^[1] VERTREP offers significant advantages over other UNREP methods, including flexibility for multiship deliveries, reduced risk from ship proximity, and efficiency in heavy seas or shallow waters, though it is constrained by weather, sea state, helicopter availability, and lower overall transfer rates compared to connected methods.^[1] As of 2025, the U.S. Navy increasingly relies on contractors like Air Center Helicopters Inc. for heavy-lift VERTREP, utilizing Airbus H225 Super Puma helicopters under a $77.3 million contract to support carrier strike groups, amid the retirement of the CH/MH-53E fleet in fiscal year 2025^[3] and limitations on platforms like the CMV-22B Osprey.^[4] This contractor dependence highlights ongoing challenges in maintaining organic heavy-lift capacity while ensuring mission readiness in regions like the Indo-Pacific and Middle East.^[4]

Fundamentals

Definition

Vertical replenishment, or VERTREP, is a method of transferring cargo, supplies, personnel, and mail between ships at sea using helicopters or other vertical-lift aircraft, without requiring the vessels to physically connect or come alongside one another. This technique relies on helicopter external sling-load operations, where loads are rigged on the supply ship, lifted by the aircraft, transported to the receiving ship, and lowered via cargo hooks or nets directly onto the deck or designated areas. VERTREP augments traditional underway replenishment (UNREP) methods but functions independently, enabling logistics support in scenarios where connected transfers are impractical.^[1] Key characteristics of VERTREP include its use of standardized sling systems, such as the Mk 105 cargo sling, with a typical maximum payload per lift of 2,722 kg (6,000 lbs) for general cargo, though heavier loads up to 4,536 kg (10,000 lbs) are possible depending on helicopter capability and load type. Operations involve coordinated Helicopter External Load Teams (HELT) on both ships to prepare, hook, and secure loads, ensuring safe transfers of items like ammunition, provisions, mail, and small equipment. The process emphasizes precision to mitigate risks from rotor downwash, static electricity, and sea state, and can occur day or night while ships are underway or stationary.^[1] In distinction from horizontal or connected replenishment (CONREP), which necessitates towing lines, tensioned cables, and close ship-to-ship proximity (typically 30-60 meters), VERTREP eliminates these requirements, allowing transfers over greater distances of up to 160 km (100 miles) within helicopter range. This flexibility supports dispersed fleet formations without halting operations for maneuvering. Basic prerequisites for VERTREP include the supply and receiving ships maintaining parallel courses at speeds of 5-15 knots, with optimal relative wind over deck of 15-30 knots to facilitate stable hovering.^[1]

Purpose and Benefits

Vertical replenishment (VERTREP) serves as a critical logistical method for rapidly resupplying combat vessels in high-threat environments, where connected replenishment exposes ships to increased risks from enemy targeting during close-proximity transfers. By employing helicopters to deliver cargo without requiring physical ship-to-ship connections, VERTREP supports distributed maritime operations, enabling forces to maintain dispersion and maneuverability while sustaining combat readiness. This approach is particularly valuable for augmenting alongside replenishment in scenarios where urgency or environmental factors preclude traditional methods.^[1] The primary benefits of VERTREP include enhanced operational flexibility, allowing receiving ships to continue at full speed and unaltered courses without the hindrances of rigging or hookup procedures associated with connected replenishment. It significantly reduces the duration ships remain vulnerable during resupply, often completing transfers in 1-2 hours compared to several hours for connected evolutions that involve approach, connection, and disconnection phases. Furthermore, a single logistics vessel can simultaneously supply multiple dispersed ships, minimizing the time support assets are off-station and optimizing fleet-wide sustainment.^[1]^[2] Tactically, VERTREP excels in urgent resupply missions, such as delivering ammunition, missiles, or provisions to forward-deployed units, and facilitates medical evacuations or personnel transfers in contested areas. It bolsters endurance during extended deployments, including those of carrier strike groups, by providing rapid access to critical stores without withdrawing from operational zones. In high-risk settings, the method avoids the safety hazards of ship proximity and tightline tensions, thereby preserving personnel and assets.^[1]^[6] Compared to connected replenishment, VERTREP delivers perishables like food more expeditiously for small-scale loads under 75 short tons, reducing spoilage risks through quicker transit and handling. Sling-load capacities, typically limited to 5,000-10,000 pounds per lift depending on helicopter type, further enable these efficient, targeted deliveries.^[1]

Historical Development

Origins and Early Trials

Vertical replenishment, or VERTREP, originated in the early 1960s as the U.S. Navy sought innovative methods to enhance logistical support for fleet operations amid escalating Cold War tensions in the Mediterranean. The concept was driven by the need for faster resupply to combat vessels without halting maneuvers, building on helicopter advancements developed after the Korean War, such as improved turbine-powered designs that offered greater range and payload capacity. In 1962, the U.S. Sixth Fleet conducted the initial trials of VERTREP using SH-3 Sea King helicopters deployed from auxiliary ships, including the fleet oiler USS Mississinewa (AO-144) and the combat stores ship USS Altair (AKS-32). These experiments marked the first operational use of helicopters for at-sea cargo transfer, focusing on delivering essential supplies to warships.^[7]^[8] Early trials emphasized conservative approaches to ensure safety and reliability, with initial loads restricted to small pallets of lightweight cargo, such as ammunition and provisions, to minimize risks during transfer. Operations were confined to daylight hours to leverage better visibility for pilots and deck crews, as nighttime conditions posed additional hazards in the open sea. The SH-3 Sea Kings, equipped with external sling loads, demonstrated feasibility by hovering above receiving ships and lowering cargo via cables, but these tests revealed significant challenges, including helicopter stability issues caused by swinging sling loads that could induce oscillations and affect control. Integrating VERTREP with ship deck operations also proved difficult, requiring precise coordination to avoid collisions and ensure secure landings on makeshift helicopter platforms.^[8]^[9] These pioneering efforts in 1962-1963 established the foundational procedures for VERTREP, later evolving to incorporate helicopters like the CH-46 Sea Knight for expanded capabilities.^[7]

Evolution and Key Milestones

The standardization of vertical replenishment (VERTREP) procedures in the U.S. Navy occurred in 1964, marking a pivotal advancement in at-sea logistics. On November 27, 1964, the USS Sacramento (AOE-1) departed Long Beach, California, embarking two UH-46A Sea Knight helicopters from Helicopter Combat Support Squadron One (HC-1) to initiate formal VERTREP operations.^[2] These helicopters enabled the delivery of ammunition and other supplies to receiving ships up to 100 miles away without intermediate refueling, at speeds reaching 140 knots, while carrying loads of up to 6,000 pounds internally or 10,000 pounds externally via cargo hook.^[2] This introduction established the first comprehensive procedures for helicopter-based resupply, transitioning VERTREP from experimental phases—such as early trials with SH-3 Sea King helicopters—to a standardized fleet capability.^[2] A significant milestone came in 1965 with the first night VERTREP to an aircraft carrier, conducted by the USS Altair (AKS-32) in the Mediterranean, which broadened the operational envelope to include low-visibility conditions and extended mission durations.^[10] This achievement built on daytime trials and demonstrated the feasibility of round-the-clock resupply, enhancing fleet endurance in dynamic environments. During the Vietnam War era from the mid-1960s to the 1970s, VERTREP saw widespread adoption for resupplying destroyers, cruisers, and aircraft carriers in the Seventh Fleet, allowing ships to remain on station without interrupting combat operations.^[11] By 1970, the Sixth Fleet conducted over 2,500 underway replenishments annually, with approximately 10% involving helicopter-delivered VERTREP, underscoring its integration into naval logistics doctrine as a reliable method for delivering ammunition, provisions, and other stores amid high-tempo operations off Vietnam.^[11] Post-Vietnam advancements in the 1980s focused on handling heavier loads to meet evolving fleet requirements, exemplified by the introduction of the CH-53E Super Stallion helicopter, which entered service in the early 1980s to support heavy-lift VERTREP and vertical onboard delivery missions.^[12] During the Gulf War in 1991, VERTREP operations were extensively applied in the Persian Gulf, with CH-46 Sea Knights conducting transfers to carriers like the USS Midway (CV-41, incorporating refined safety protocols such as enhanced coordination and lighting to mitigate risks in contested waters.^[13] Key events in the early 2000s further highlighted VERTREP's maturity, including its use during the 2003 Iraq War (Operation Iraqi Freedom), where CH-46 helicopters performed resupply missions to support carrier strike groups in the Persian Gulf.^[14] Over time, procedures evolved to incorporate multi-helicopter evolutions, typically involving two or more aircraft simultaneously, to boost efficiency and achieve transfer rates up to 180 short tons per hour on large deck ships like aircraft carriers.^[1] This shift, formalized in updated naval warfare publications like NWP 4-01.4, emphasized coordinated aircrew positioning and load balancing to maximize throughput while minimizing exposure.^[1]

Operational Procedures

Preparation and Planning

Preparation for vertical replenishment (VERTREP) begins with meticulous logistics setup on the supply ship, where inventory assessment ensures adequate stocks of commodities such as fuel, ammunition, provisions, and stores to meet the receiving ship's requirements.^[1] Cargo is palletized on standard 40x48-inch pallets using nylon strapping and secured with adjustable slings, cargo nets, or specialized rigs like the Mk 89, Mk 90, or Mk 91 to prevent shifting during transport, typically handling loads up to 9,000-10,000 pounds per pallet.^[1] Pre-loading sequences are planned 3-15 days in advance based on the receiving ship's priorities—such as fuel first, followed by ammunition and perishables like food—to optimize efficiency, with cargo staged near transfer areas using forklifts and pallet jacks for quick access.^[1] Coordination steps are directed by the Officer in Tactical Command (OTC), who assigns VERTREP stations and flight patterns to the helicopter coordinator, positioning the delivery and receiving ships on parallel courses 300-1,000 yards apart at speeds of 12-16 knots to minimize flight distances.^[1] Weather and sea state evaluations are critical, with operations ideally conducted in winds of 15-30 knots from 330° to 030° relative to the bow and sea states calm to 3 (less than 4 feet), avoiding conditions that could compromise helicopter stability or load integrity.^[1] These assessments, along with liaison meetings to review loading plans, ensure ships maintain steady courses while preparing designated VERTREP areas on deck.^[1] Personnel roles are clearly defined to support safe and effective operations, with deck crews trained in cargo handling, rigging, and signaling using flags, hand signals, or radios to guide helicopters like the CH-46 or MH-60.^[1] Helicopter pilots receive briefings on flight paths, load weights, and ship positions from the Combat Cargo Officer (CCO), who supervises the Helicopter External Load Team (HELT) including team leaders, static discharge personnel, and hookup crews.^[1] Communication occurs via dedicated radio circuits, sound-powered phones for station-to-station coordination, and bridge-to-bridge channels to maintain real-time situational awareness.^[1] Safety planning emphasizes risk assessments for hazards like static electricity and rotor downwash, requiring all personnel to wear appropriate protective gear and review precautions prior to operations.^[1] Foreign object debris (FOD) prevention involves clearing decks and securing loose items, while emergency abort procedures—such as immediate load jettison or ship maneuvering—are briefed and drilled to address issues like equipment failure or adverse weather changes.^[1] The CCO and helicopter coordinator conduct final checks on rigging, tools, and personnel readiness to mitigate risks before flight quarters are set.^[1]

Execution and Transfer Process

The execution of a vertical replenishment (VERTREP) begins with the launch of helicopters from the delivery ship, typically combat logistics force vessels such as fast combat support ships (AOEs), equipped with slung loads of palletized cargo rigged by the Helicopter External Load Team (HELT).^[1] These helicopters, such as the CH-46 or CH-53E, depart the flight deck after a pre-launch briefing that includes rendezvous details, load weights, and emergency procedures, maintaining a relative wind of 15-30 knots from 330° to 030° relative to the bow for optimal control.^[1] During transit, the aircraft fly at low altitudes, typically 50-100 feet above the sea surface, to the receiving ship stationed 300-1,000 yards away (or 300-500 yards at night), with pilots using visual or radar contact guided by the Helicopter Coordinator to account for ship motion and maintain station-keeping.^[1] Upon arrival at the receiving ship, the helicopter enters a hover position over the designated drop zone or VERTREP area, typically at 20-50 feet above the deck to minimize downwash hazards, as directed by the Landing Signalman Enlisted (LSE) and aircrew signals.^[1] The delivery sequence involves the aircrew lowering the load—secured by slings like the Mk 105 (up to 6,000 pounds)—via a hoist, Cargo Drop Reel (capacity 5,700 pounds), or controlled free-drop onto the deck, where the receiving ship's crew promptly secures it using a sliding padeye system for positioning and unloads the cargo to clear the area.^[1] Once the load is released and confirmed stable, the helicopter departs for the return transit to the delivery ship, repeating the cycle after unrigging, with the entire approach and delivery phase estimated at around 12 minutes under standard conditions.^[1] This process follows preparation checklists to ensure equipment readiness and load integrity prior to launch.^[1] In multi-ship operations, multiple helicopters—often 4-6 in rotation—are coordinated by the Helicopter Coordinator using predefined VERTREP patterns to sustain cargo flow across several receiving ships, such as aircraft carriers, cruisers, and destroyers, spaced 300-1,000 yards apart to avoid saturation of landing areas.^[1] Cycle times per delivery typically range from 10-15 minutes, enabling transfer rates up to 180 short tons per hour with two helicopters, though the number scales with mission demands and sea state (up to state 3).^[1] Communication via radio, flags, and hand signals ensures synchronization, with pilots adjusting for dissimilar aircraft types and weather to prevent interference.^[1] For personnel transfers, a variant of VERTREP employs baskets, transfer chairs, or Stokes litters for mail, small teams, or casualties, with the helicopter hovering at 20-30 feet to facilitate safe hoisting (maximum 600 pounds) or internal transport if landing is feasible.^[1] Receiving crew members, equipped with life jackets and helmets, secure the individuals upon deck contact, and operations limit night transfers to emergencies while adhering to the same station-keeping protocols as cargo runs.^[1]

Equipment and Systems

Helicopters and Aircraft

The Sikorsky SH-3 Sea King served as one of the earliest helicopters adapted for vertical replenishment operations by the U.S. Navy, with initial trials conducted in 1962 using aircraft from the store ship USS Altair (AKS-32) and the fleet oiler USS Mississinewa (AO-144).^[7] These early efforts demonstrated the feasibility of helicopter-based resupply at sea, transitioning from experimental concepts to routine procedures by the mid-1960s. The SH-3's utility role, including its anti-submarine warfare capabilities, allowed integration of replenishment missions, though it was gradually phased out as more specialized platforms emerged. The Boeing Vertol CH-46 Sea Knight, introduced in the 1960s, became the first helicopter specifically developed for vertical replenishment, entering service with the U.S. Navy and Marine Corps for operations through the 2010s.^[2] With an external cargo capacity of up to 10,000 pounds via sling load, the CH-46 enabled efficient transfer of supplies over distances of approximately 100 miles, supporting squadrons like Helicopter Combat Support Squadron 3 (HC-3) during Vietnam War-era deployments.^[15] It typically operated with a crew of four, consisting of a pilot, co-pilot, and two crewmen to manage loads and navigation.^[2] The platform's tandem-rotor design facilitated stable sling-load operations, proving instrumental in proving the concept's viability for fleet sustainment. The Sikorsky SH-60F Seahawk variant supplemented replenishment efforts in the 1980s and 1990s, particularly in anti-submarine warfare-integrated resupply missions for carrier groups. Assigned to Helicopter Antisubmarine Squadrons (HS), the SH-60F delivered supplies during underway operations, such as those aboard USS Dwight D. Eisenhower (CVN-69) in 2007, before being retired in the 2000s as the MH-60S took over primary duties. Like its predecessors, it supported crew configurations of four personnel, emphasizing dual-pilot operations for safety over extended ranges of 100-150 miles. The Sikorsky MH-60S Seahawk currently serves as the U.S. Navy's standard helicopter for vertical replenishment, equipped with a cargo hook for sling loads and operated by Helicopter Sea Combat Squadrons (HSC) such as HSC-9 and HSC-25.^[16] Introduced in the early 2000s as a replacement for the CH-46, it features dual-pilot controls and can handle loads up to 4,000 pounds per transfer, enabling high-tempo resupply for carriers like USS Gerald R. Ford (CVN-78).^[17] Typical missions involve a four-person crew—pilot, co-pilot, and two loadmasters—conducting operations within a 100-150 mile radius to deliver essentials like mail, ammunition, and provisions.^[18] The Sikorsky CH-53E Super Stallion, introduced in 1981, provides heavy-lift capability for VERTREP, operated by Heavy Helicopter Squadrons (HMH) with an external load capacity of up to 36,000 pounds using single or dual-point hooks.^[19] It supports transfers of large equipment and is used in multiship operations. The CH-53E is scheduled for retirement by fiscal year 2027, with heavy-lift VERTREP increasingly supported by contractors using Airbus H225 Super Puma helicopters as of 2025.^[4] For heavier or faster lifts, the Bell Boeing V-22 Osprey (including MV-22B and CMV-22B variants) has been integrated into vertical replenishment since the 2010s, offering capacities up to 6,000 pounds and speeds exceeding those of conventional helicopters.^[20]^[21] Operated by Marine Medium Tiltrotor Squadrons (VMM), such as VMM-364, the MV-22B supports naval resupply, including demonstrations to submarines like USS Lewis B. Puller (ESB-3) in 2023.^[22] Its vertical takeoff and fixed-wing cruise capabilities extend effective ranges beyond 150 miles, with a standard crew of four including pilots and loadmasters. While rotary-wing aircraft dominate vertical replenishment, fixed-wing options like the Boeing C-17 Globemaster III have been used rarely for airdrop resupply, as in the 2020 delivery of payloads to the Ohio-class submarine USS Henry M. Jackson (SSBN-730) near Hawaii.^[23] Emerging drone integrations, such as the unmanned aerial vehicle test with USS Henry M. Jackson in October 2020, represent experimental non-rotary approaches to reduce crew risks in contested environments.^[24]

Cargo Handling Mechanisms

In vertical replenishment (VERTREP) operations, cargo handling mechanisms encompass specialized equipment designed to secure, lift, and transfer loads safely between ships using helicopters. Primary systems include cargo hooks, ordnance slings, and cargo nets, which enable the handling of diverse payloads while maintaining stability and preventing damage during transit. These mechanisms are engineered for compatibility with helicopter external load systems, ensuring efficient transfers at sea.^[1]^[25] Cargo hooks serve as the central attachment point for external loads, typically featuring electrical or manual release mechanisms to allow controlled deployment and recovery. Standard hooks in VERTREP are rated for 5,000 to 10,000 pounds, accommodating helicopters such as the CH-46 (10,000-pound capacity) and MH-60 (4,000 to 9,000 pounds), with higher-rated options like the CH-53E supporting up to 36,000 pounds for dual-point suspensions. These hooks incorporate safety features, such as positive locks, to prevent accidental release, and are often paired with cargo drop reels rated for up to 5,700 pounds to manage load descent. The hooks interface directly with the helicopter's underbelly cargo hook via short pendants, facilitating quick rigging.^[1]^[25]^[2] Ordnance slings, used specifically for munitions, consist of triple-braided nylon construction to provide high strength and abrasion resistance, with models like the Mk 105 hoisting sling rated up to 6,000 pounds across multiple legs. These slings secure ammunition in sealed containers or palletized configurations, ensuring containment and preventing shifting during flight; examples include Mk 89 through Mk 92 slings (4,000-pound capacity) made from 1-inch nylon rope in lengths of 6 to 20 feet. Special weapons slings further adapt for sensitive loads, such as missiles on Mk 1 strongbacks.^[1]^[25] Cargo nets handle palletized goods, typically constructed from 1-1/2-inch nylon webbing in sizes of 12x12 feet or 14x14 feet, capable of securing 2 to 4 standard pallets with a total capacity of 5,000 to 10,000 pounds. These knotless nets enclose loose items or wrapped pallets, using corner loops attached to the cargo hook for lifting, and are particularly suited for non-sensitive supplies like provisions or repair parts.^[1]^[25] Common load types transferred via these mechanisms include ammunition in sealed, palletized containers to maintain safety and integrity; fuel in flexible bladders for liquid transfer without spillage; perishables in insulated bags or nets to preserve temperature control; and personnel via Stokes litters rigged for hoist operations, limited to 600 pounds including the litter. Each type is selected based on the cargo's characteristics, with ordnance and fuel requiring additional containment to mitigate hazards.^[1]^[25] Attachment protocols emphasize load stability and safety, beginning with center-of-gravity balancing to ensure even weight distribution across slings or nets, preventing pendulum-like swings during flight. Tag lines, typically 6- to 12-foot nylon ropes, are employed by ground crew to guide and steady the load during hookup and release, minimizing twisting or drift. Overload protection devices, such as weak links (e.g., 30,000-pound breaking strength) and safety hooks, are integrated to avert structural failure if loads exceed ratings.^[1]^[25] Maintenance of these mechanisms involves rigorous pre-flight inspections for wear, cuts, or abrasion using visual and dye-penetrant methods, conducted per the ship's Planned Maintenance System before each operation. Compatibility with helicopter swivels is verified to allow 360-degree rotation and prevent line twisting, with lubrication and testing required for pendants and hooks; defective items are repaired or replaced to comply with NAVSEA standards.^[1]^[25]

Performance Characteristics

Transfer Rates

Vertical replenishment operations under ideal conditions achieve efficient cycle times, with a typical round trip—including cargo pickup, transit to the receiving vessel, delivery, and return—lasting 10-15 minutes for short distances of 300-1,000 yards. This enables 4-6 tons per hour per helicopter, based on average payloads of around 3,000 pounds (1.5 short tons) per lift for platforms like the H-46 Sea Knight, allowing 3-4 deliveries per hour.^[1] Aggregate transfer rates scale with multiple helicopters, reaching up to 180 short tons per hour using multiple helicopters under ideal conditions on large-deck ships, as demonstrated in Pacific Fleet operations during the late 1960s and early 1970s. For lighter loads, aggregate rates can reach up to 120 lifts per hour under ideal conditions. Rates vary by cargo type, with lighter loads such as food supplies enabling faster transfers—up to 50 pallets per hour aggregate—compared to heavier munitions, which are limited by sling load capacities and rigging times.^[1]^[26] Efficiency is highly distance-dependent, with rates decreasing with distance and optimal performance occurring within a few miles; operations are generally limited to less than 35 miles for heavy loads and 25 miles for light loads without refueling, where multi-helicopter operations can simultaneously resupply 3-5 vessels without interference.^[1] Historical benchmarks show significant evolution, with 1960s operations using early UH-46 helicopters achieving approximately 18-24 short tons per hour per aircraft based on 1968-1969 operational data; modern platforms like the MV-22 Osprey have increased this to up to 10 tons per helicopter through higher speeds and capacities of 5 tons per load.^[26]^[27] Weather conditions can reduce these rates, though ideal operations assume winds of 15-30 knots and calm seas.^[1]

Limitations and Challenges

Vertical replenishment (VERTREP) operations are highly susceptible to environmental conditions that can halt or severely restrict transfers. High winds exceeding 30 knots, particularly when abaft the beam, increase helicopter drift, yaw instability in smaller vessels, and rotor downwash hazards, often necessitating the cessation of operations. Similarly, sea states above 3 limit heavy-lift capabilities (9,000–10,000 lb loads) to calm conditions up to Sea State 3, while general operations may extend to Sea State 5 with increased ship separation of 120–150 feet to maintain stability, though heavy seas exacerbate deck motion and station-keeping challenges. Poor visibility, especially during night operations, reduces pilot depth perception and increases hookup times due to helicopter drift, further compounded by adverse weather such as cold spray ice or turbulent ship-induced winds. Helicopter lift capacity can be reduced in hot, high-altitude, or humid environments due to lower air density, impacting overall transfer efficiency.^[1]^[1]^[2]^[28] Technical challenges further constrain VERTREP's flexibility and spontaneity. Pre-loading requirements mandate staging cargo on the supply ship (e.g., for two H-46 helicopters at a time), which delays rapid response and demands precise coordination per rigging standards like OH 5-3A. Risks of foreign object damage (FOD) to helicopter engines and rotors are elevated on cluttered decks, where rotor downwash can propel debris, necessitating rigorous pre-flight clearances. Additionally, operational range is limited to less than 35 miles for heavy loads and 25 miles for light loads for round-trip deliveries without refueling, restricting its utility for deep-ocean logistics beyond helicopter fuel constraints.^[1]^[1]^[2] Safety risks pose significant threats during VERTREP evolutions, particularly from dynamic load handling and environmental interactions. Sling-loaded cargo can swing uncontrollably, leading to collisions, tipping, tangling, or unbalanced shifts that damage equipment or personnel. Crew members face exposure to intense rotor wash velocities of 50–95 knots (exceeding 120 knots with CH-53E helicopters), hazardous within 60–70 feet of the hook, which can cause injuries or scatter debris. Historical data from the 1970s indicates elevated accident rates for helicopter sling-load operations, with a mean of 58 incidents annually across services, often tied to external cargo dynamics during naval replenishments. Static electricity buildup up to 200,000 volts in ungrounded slings adds electrocution risks during transfers.^[1]^[1]^[29] Mitigations have evolved to address these limitations, emphasizing rigorous preparation and technology. Comprehensive training, including periodic walk-through drills for emergency breakaways and certification per NWP 3-04.1M, equips deck crews, pilots, and winch operators to handle sling-load instabilities and FOD prevention. Early VERTREP doctrines prohibited night operations due to visibility constraints, but modern protocols enable them using night vision goggles (NVGs), amber wands, chemical lights for load identification, and reduced pilot endurance limits of 2–3 hours to maintain safety. Protective measures, such as rubber matting for ammunition areas and minimal deck personnel during emergencies, further reduce exposure to rotor wash and static hazards. Weather-induced rate reductions, such as halved transfer speeds in marginal conditions, are managed through optimized ship positioning and wind orientations of 330°–030° on the bow.^[1]^[1]

Modern Applications

Recent Operations

In 2020, the U.S. Navy conducted a demonstration of drone-based vertical replenishment for submarine resupply, involving an unmanned aerial vehicle launched from an Air Force C-17 Globemaster III to deliver a payload to the Ohio-class ballistic missile submarine USS Henry M. Jackson (SSBN-730) in the waters around the Hawaiian Islands on October 19.^[30] This test highlighted emerging capabilities for covert and rapid logistics support to submerged vessels, marking a milestone in integrating unmanned systems into traditional VERTREP operations.^[31] During 2023 and 2024, U.S. Navy carrier strike groups routinely employed VERTREP in training and operational scenarios. For instance, the aircraft carrier USS Gerald R. Ford (CVN-78) executed VERTREP evolutions using MH-60S Seahawk helicopters from Helicopter Sea Combat Squadron (HSC) 9 during its Composite Training Unit Exercise (COMPTUEX) in March 2023 and again in the Atlantic Ocean in August 2024, transferring supplies to sustain extended at-sea periods.^[32]^[33] Similarly, the expeditionary sea base USS Lewis B. Puller (ESB-3), operating in the Arabian Gulf as part of U.S. 5th Fleet activities, received VERTREP support from HSC-26 on January 11, 2023, to maintain mission readiness amid regional security operations.^[34] In 2025, VERTREP continued to play a critical role in fleet sustainment. The aircraft carrier USS Nimitz (CVN-68) performed vertical replenishment-at-sea operations with the fleet replenishment oiler USNS John Lewis (T-AO-205) on April 7 in the Pacific Ocean, enabling the carrier strike group to extend its deployment in the U.S. 3rd Fleet area.^[35] Later that year, U.S. 2nd Fleet assets conducted mid-ocean VERTREP during Exercise Chesapeake 2025 in April, incorporating sustainability measures such as optimized fuel-efficient helicopter routing to reduce environmental impact during bilateral training with French naval forces.^[36] Internationally, VERTREP has been integral to allied operations, including NATO exercises like BALTOPS 2025, where U.S. and partner nation ships practiced replenishment-at-sea to enhance collective maritime security in the Baltic Sea.^[37] In July 2024, the U.S. Navy awarded a $77.3 million contract to Air Center Helicopters Inc. for heavy-lift VERTREP services, supporting contractor-operated CH-53E Super Stallion helicopters to deliver oversized cargo to naval vessels worldwide.^[4] In combat-related applications, VERTREP has facilitated rapid ammunition delivery during Indo-Pacific patrols. These evolutions underscore VERTREP's role in enabling persistent presence amid contested logistics environments.^[38]^[39]

Future Innovations

Advancements in drone and unmanned systems are poised to transform vertical replenishment by enabling autonomous operations that minimize human risk in contested environments. Building on demonstrations like the Blue Water Maritime Logistics UAS program, which delivered a prototype in October 2020 for long-range unmanned cargo transport to naval vessels, the U.S. Navy is expanding toward fully autonomous VERTREP capabilities.^[40] These systems aim to handle light cargo deliveries over distances up to 500 miles, reducing exposure during high-threat resupply missions.^[41] Integration with platforms like the MQ-25 Stingray, primarily an aerial refueling drone, could extend to cargo roles for time-sensitive parts delivery to carriers, leveraging its carrier-based operations and extended range.^[42] Heavy-lift upgrades are addressing gaps in military helicopter availability through civilian contracts and propulsion innovations. In July 2024, the U.S. Navy awarded Air Center Helicopters Inc. a $77.3 million contract to provide heavy-lift VERTREP services using commercial platforms, supplementing organic assets through 2030.^[4] This approach ensures sustained capability for large cargo transfers, such as munitions and fuel, in scenarios where military helicopters are limited. Hybrid electric propulsion systems are also emerging to enhance range and efficiency; Sikorsky's HEX demonstrator, a hybrid-electric VTOL prototype, targets up to 500 nautical miles of range, potentially revolutionizing extended VERTREP missions by reducing fuel dependency and emissions.^[43] Procedural innovations are incorporating artificial intelligence to optimize VERTREP planning and execution. AI-assisted weather routing tools, such as the Navy's partnership with Sofar Ocean's Wayfinder platform, enable real-time ocean data analysis for safer, more efficient resupply paths, scaling operations across heterogeneous fleets.^[44] Emerging concepts include VERTREP from submarines, supported by designs like inflatable sails for future attack submarines to facilitate stable helicopter approaches without surfacing fully.^[45] Similarly, droneships—unmanned surface vessels—could serve as mobile logistics nodes, with the Navy's Modular Autonomous Ship Concept envisioning containerized payloads for distributed resupply by the late 2020s.^[46] Doctrinal shifts emphasize distributed logistics to counter great power competition, integrating VERTREP into resilient supply chains. The Navy's Distributed Maritime Operations concept prioritizes agile resupply to sustain dispersed forces, with VERTREP playing a key role in contested theaters like the Indo-Pacific.^[47] By the 2030s, hypersonic cargo delivery via reentry vehicles, such as those under development for rapid global transport, could complement traditional VERTREP, enabling sub-hour resupply of critical items from orbit to sea-based units.^[48] Key challenges include bolstering cybersecurity for unmanned VERTREP systems and advancing international standardization. As unmanned platforms proliferate, vulnerabilities to cyber threats necessitate robust protections; the Navy's Cybersecurity Program Office is prioritizing secure architectures for robotic systems to prevent disruptions in logistics chains.^[49] NATO's MPP-02.3.3 standard for VERTREP marking and lighting provides a foundation, but broader harmonization of procedures across allies is essential for seamless multinational operations in future coalitions.^[50]

References

[1]
[PDF] UNDERWAY REPLENISHMENT NWP 4-01.4
NWP 4-01.4, UNDERWAY REPLENISHMENT, is an Unclassified naval warfare publication. It shall be handled by Department of the Navy holders in accordance with the ...
[2]
Vertical Replenishment and the UH-46A - U.S. Naval Institute
The UH-46A can deliver its cargo to ships within a 100-mile radius and return without refueling at speeds up to 140 knots. The arm of replenishment ships thus ...
[3]
Navy Depends on Contractor for Heavy Lift Vertical Deliveries
Jan 8, 2025 · The Navy in July announced the award of a $77.3 million contract to Air Center Helicopters Inc. to provide heavy lift vertical replenishment ...
[4]
https://www.nationaldefensemagazine.org/articles/2025/1/8/navy-depends-on-contractor-for-heavy-lift-vertical-deliveries
[5]
Historic Aircraft - The King of the Sea | Naval History Magazine
As early as 1962 an SH-3A assigned to the store ship Altair (AKS-32) and another on the fleet oiler Mississinewa (AO-144) carried out vertical replenishment ( ...Missing: trials USS
[6]
[PDF] PART 9 The Sixth Decade 1960–1969
Jan 26, 2025 · shakedown cruise off San Diego. Although the con- cept of vertical replenishment at sea had been dis- cussed and tested as early as 1959 and ...
[7]
Altair II (AK-257) - Naval History and Heritage Command
Jun 1, 2020 · In 1959, the ship received a helicopter landing platform to enable her to carry out early vertical replenishment operations. She also ...Missing: trial SH-
[8]
1965 Chronology of Aviation History - Skytamer Images
1965 saw the first night VERTREP, UK's purchase of US aircraft, Operation Flaming Dart, a fatal crash, first non-stop helicopter flight across North America, ...
[9]
The Service Force in Action - December 1970 Vol. 96/12/814
During a normal year this force conducts more than 2,500 underway replenishments (UnReps) with about 10% being helicopter-delivered vertical replenishment ( ...<|control11|><|separator|>
[10]
A Joint Heavy-Lift Helicopter? | Proceedings - U.S. Naval Institute
The CH-53E was introduced in the early 1980s to fulfill the Navy's heavy-lift vertical onboard delivery requirement and the Marine Corp's requirement for heavy ...Missing: advancements | Show results with:advancements
[11]
US Navy in Desert Shield/Desert Storm
This summary of the role of the United States Navy in Operations DESERT SHIELD and DESERT STORM was compiled from the reports of operational commanders and ...
[12]
Operation Iraqi Freedom - Naval History and Heritage Command
Mar 14, 2025 · On 20 March 2003, Operation Iraqi Freedom (OIF) began with preemptive airstrikes on former Iraqi dictator Saddam Hussein's presidential palace and selected ...
[13]
[PDF] UNDERWAY REPLENISHMENT NWP 4-01.4
1. NWP 4-01.4, UNDERWAY REPLENISHMENT, is an Unclassified naval warfare publication. It shall be handled by Department of the Navy holders in accordance with ...
[14]
CH-46D Sea Knight - Naval History and Heritage Command
The CH-46D Sea Knight (Bureau Number 151952) suspended in Hangar Bay One spent many hours at sea performing the vertical replenishment (VERTREP) mission, ...
[15]
MH-60S Seahawk - NAVAIR
The MH-60S Seahawk missions are Anti-Surface Warfare, combat support, humanitarian disaster relief, Combat Search and Rescue, aero medical evacuation.
[16]
Ford Perfects Sustainability at Sea with First Vertical Replenishment
Mar 26, 2020 · USS Gerald R. Ford (CVN 78) completed its first vertical replenishment (VERTREP) with MH-60S Sea Hawk helicopters.
[17]
An MH-60S Seahawk conducts a vertical replenishment exercise
Mar 20, 2020 · An MH-60S Seahawk, attached to Helicopter Sea Combat Squadron (HSC) 9, conducts a vertical replenishment (VERTREP) exercise with the ...
[18]
Bell-Boeing Delivers First CMV-22B to Navy for COD Mission
Feb 8, 2020 · The new Ospreys are based on the Marines existing MV-22B with key differences. “The CMV-22B will be capable of transporting up to 6,000 pounds ...
[19]
U.S. Marine Corps MV-22B Osprey resupplies U.S. Navy submarine
Jul 29, 2022 · ... vertical replenishment of a U.S. Navy submarine near the coast of California, July 26, 2022. This resupply demonstrates the Marine Corps ...
[20]
C-17 Globemaster III Airdrops Payload to USS Henry M. Jackson
Oct 23, 2020 · The Ohio-class ballistic-missile submarine USS Henry M. Jackson (SSBN 730) retrieves an airdropped payload from an Air Force C-17 Globemaster III in the ...
[21]
The Navy Just Sent A Drone To Deliver Cargo To One Of Its Ballistic ...
Oct 21, 2020 · The replenishment by drone took place on Oct. 19, 2020, according to the Navy. It's not clear how long the USS Henry M. Jackson has been ...
[22]
None
Below is a merged summary of the cargo handling for helicopter sling loads based on the provided segments from MCRP 4-11.3E Vol. I and MCRP 4-23E Vol. I. To retain all information in a dense and organized manner, I will use tables where appropriate (in CSV format for clarity) and narrative text for procedural and contextual details. The response consolidates overlapping information while preserving unique details from each segment.
[23]
[PDF] The Use of Helicopters in Underway Replinishment - DTIC
The other method in vertical replenishment (VERTREP) which involves the use of helicopters. Fuel is the only item which is not adaptable to VERTREP. Often a ...<|separator|>
[24]
[PDF] Physics-Based Modeling and Assessment of Mobile Landing ... - DTIC
MV-22 Osprey ... With the container containing 16 pallets at 1000 lbs each, a transfer rate of 96 tons/hr is used.
[25]
Boeing/Vertol Ch-46 Sea Knight - Pacific Aviation Museum
Nov 18, 2014 · 50-caliber side guns and gunners, plus the hot climate that lowered air density, sapped its lifting capacity.) It had a big rear ramp that ...
[26]
Helicopter sling load accident/incident survey: 1968 - 1974
Mar 1, 1977 · There was a mean of 58 incidents each year and 51 percent of these occurred during cruise.Missing: VERTREP risks historical rates
[27]
VIDEO: Ballistic Missile Submarine Tests Aerial Resupply With Air ...
Nov 18, 2020 · USS Henry M. Jackson (SSBN-730) tested out aerial resupply concepts in and around the Hawaiian Islands with at least four aircraft.Missing: replenishment | Show results with:replenishment
[28]
Watch a Navy drone resupply a ballistic missile submarine at sea
Oct 22, 2020 · An unmanned aerial vehicle delivers a payload to the Ohio-class ballistic-missile submarine Henry M. Jackson around the Hawaiian Islands on Monday.Missing: vertical | Show results with:vertical
[29]
Vertical Replenishment: USS Gerald R. Ford (CVN 78) - YouTube
Mar 29, 2023 · The Daily Navy•1.2M views · 13:33 · Go to channel · “THE NAVY'S DEVELOPMENTS IN VERTICAL REPLENISHMENT” 1963 U.S. NAVY HELICOPTER SUPPLY SYSTEMS ...Missing: crew | Show results with:crew
[30]
Vertical Replenishment [Image 6 of 17] - DVIDS
Aug 25, 2024 · ATLANTIC OCEAN (Aug. 24, 2024) A MH-60S Seahawk assigned to the "Tridents" of Helicopter Sea Combat Squadron (HSC) 9 sits ready on the ...
[31]
HSC-26 Vertical Replenishment aboard Lewis B. Puller - DVIDS
HSC-26 Vertical Replenishment aboard Lewis B. Puller · ARABIAN GULF · 01.11.2023 · Photo by NAVCENT Public Affairs · U.S. Naval Forces Central ...Missing: 2024 | Show results with:2024
[32]
Nimitz Conducts a Replenishment-at-Sea [Image 8 of 27] - DVIDS
Aug 4, 2025 · ... vertical replenishment-at-sea in the Pacific Ocean, April 7, 2025. Nimitz is underway in the U.S. 3rd Fleet area of operations on a ...
[33]
U.S., French Strengthen Interoperability During Exercise ... - 2nd Fleet
Apr 26, 2025 · ... vertical replenishment (VERTREP) training evolution ... Exercise Chesapeake 2025 is a bilateral U.S.–French naval exercise in the U.S. ...
[34]
Video Gallery - Military Sealift Command - Navy.mil
Replenishment At Sea During BALTOPS 2025 · Iwo Jima Conducts a Replenishment at Sea · USS Iwo Jima Conducts Replenishment at Sea · USS Iwo Jima Conducts RAS with ...Missing: 2023-2025 | Show results with:2023-2025
[35]
Fleet Replenishment Oilers T-AO - Navy.mil
Aug 19, 2025 · Last updated: 19 Aug 2025. Fifteen fleet replenishment oilers are operated by Military Sealift Command (MSC) and provide underway replenishment ...Missing: 2nd | Show results with:2nd<|control11|><|separator|>
[36]
Fleet at Risk as Navy Struggles to Refill Missile Stores - Military.com
Oct 25, 2025 · Between October 2023 and January 2025, Navy ships fired more defensive missiles at incoming Houthi drones and rockets than they used in ...
[37]
Navy Considering Drone Delivery for Essential Parts At Sea
Aug 5, 2021 · The Navy has demonstrated that small drones could take the place of manned platforms in delivering critical spare parts, most of which weigh less than a large ...Missing: demo | Show results with:demo
[38]
Navy Tests Autonomous Aerial Supply Drone From Its Newest ...
Feb 23, 2021 · The manufacturer says that this unmanned aircraft features an artificial intelligence-driven flight system, has a maximum range of 500 miles, ...
[39]
MQ-25 Stingray's Extreme Range Gives It Massive Potential Far ...
Apr 7, 2025 · Finally, the Stingray could even work in a cargo-carrying capacity, to deliver small time-sensitive parts and other cargoes to the carrier ...
[40]
Sikorsky bets on hybrid-electric propulsion as the future of vertical lift
Jul 14, 2025 · Sikorsky is developing a prototype hybrid-electric vertical take-off and landing (VTOL) demonstrator known as HEX that will boast a range of some 500nm (926km).Missing: Navy | Show results with:Navy
[41]
U.S. Navy pilots Sofar's Wayfinder to enhance safe routing at sea
Nov 18, 2024 · Powered by our real-time ocean weather sensor network, Wayfinder will help the Navy scale its routing operations to support a heterogeneous ...Missing: AI planning VERTREP
[42]
21.1 SBIR - Inflatable Deployable Sail Systems for Future Submarines
The sail structure also provides freeboard necessary to enable vertical and underway replenishment (VERTREP and UNREP, respectively) operations without flooding ...
[43]
Navy Unmasks Its Vision For Fleet Of Uncrewed Modular Surface ...
Jul 31, 2025 · The Navy's plans for a family of MASC drone vessels are centered on containerized missile launchers and sensor packages.<|control11|><|separator|>
[44]
Naval Logistics in Contested Environments - RAND
Mar 6, 2024 · To support the DMO concept, the Navy needs new approaches to logistics and the resupply and sustainment of distributed units. Giving particular ...Missing: competition VERTREP
[45]
U.S. military investing in reentry vehicles for space-to-Earth cargo ...
Sep 10, 2024 · The US military is investing in reusable reentry capsules designed by space startups to return cargo from space and deliver it to precise locations on Earth.
[46]
https://www.twz.com/sea/navy-unmasks-its-vision-for-fleet-of-uncrewed-modular-surface-attack-craft
[47]
NATO - MPP-02.3.3 - VERTICAL REPLENISHMENT (VERTREP ...
Jun 23, 2016 · The aim of this standard is to establish the minimum requirements for the marking and lighting of shipboard Vertical Replenishment Operating ...Missing: international | Show results with:international