Ground Support Equipment – The Overlooked Hero of Aviation Operations

Aircraft Ground Support Equipment

In aviation, attention naturally gravitates toward aircraft — the stars of the show. But behind every safe departure and smooth turnaround lies a less glamorous, often forgotten enabler: Ground Support Equipment (GSE). From tugs and tow bars to ground power units, air start carts, and baggage loaders, GSE is the unsung hero that keeps aircraft moving efficiently and safely.

Yet, across the industry, these vital assets are frequently underinvested, poorly tracked, and inconsistently maintained — leading to unnecessary downtime, safety risks, and operational inefficiencies.

The True Cost of Ground Support Equipment Ownership

GSE is not cheap. A single aircraft tug can cost upwards of $500,000, while a modern ground power unit or air start cart can range from $50,000 to $250,000. When you add in baggage handling systems, belt loaders, towbars, stands, and hydraulic service carts, the investment quickly climbs into the millions of dollars for even a modest operation.

But the purchase cost is just the beginning. Like any mechanical equipment, GSE requires ongoing maintenance, inspections, and periodic overhauls to remain safe and reliable. When maintenance is neglected, breakdowns occur — often at the worst possible times, like during peak flight schedules or in remote locations where replacements aren’t readily available.

Maintenance and Tracking – The Forgotten Discipline

Unlike aircraft, which are meticulously tracked under continuing airworthiness programs, GSE often exists in a grey zone of accountability. Many organisations do not have robust systems for tracking the location, usage hours, maintenance status, or repair history of their equipment.

It’s not uncommon to see:

• Towbars bent or damaged from misuse.

• Flat batteries in ground power units left idle for months.

• Tyres on tugs worn down to the belts.

• Equipment cannibalised for parts with no record of when or why.

Without proper asset tracking, preventive maintenance schedules are missed, breakdowns increase, and the cost of reactive repairs skyrockets.

Long Service Life, Little Love

Most GSE assets remain in service for 10–20 years or more, often outlasting multiple fleet renewals and management changes. Over time, they become the forgotten assets — sitting in corners of the ramp or workshops, patched together just enough to keep them running.

This longevity, combined with a lack of visibility, leads to chronic underinvestment. Organisations focus their capital on aircraft, tooling, or hangar upgrades, while GSE budgets are trimmed year after year. The result? Equipment that lets us down when we need it most — delaying turnarounds, increasing safety risks, and frustrating frontline teams.

Why It Matters

When GSE fails, the entire operation feels it. Flights are delayed, ground crews are left idle, and the reputation of the airline or maintenance provider takes a hit. Poorly maintained GSE also increases the risk of aircraft damage, personnel injury, and regulatory non-compliance under occupational health and safety obligations. In contrast, organisations that treat GSE as a critical part of the operational ecosystem — with clear ownership, regular maintenance programs, and data-driven tracking — see significant benefits in efficiency, safety, and cost control.

Investing in the Hidden Hero

It’s time to change how the industry views Ground Support Equipment. The next time budgets are reviewed, or capital investments are planned, GSE deserves a seat at the table. Implementing an asset management system, scheduling preventive maintenance, and conducting annual condition audits can extend service life, improve reliability, and protect operational performance.

Because when the aircraft is ready to go, but the tug won’t start — it’s clear that GSE is the backbone we can’t afford to overlook.

Stay Safe,

Craig.