The Most Dangerous 60 Secs on a Fighter Jet Flight Line: Hot Pit Refueling

Hot pit refueling is a high-risk, rapid turnaround process where fighter jets are refueled with engines still running, enabling them to land, refuel, and relaunch without shutting down. This method significantly reduces downtime compared to traditional refueling, which historically required full engine shutdowns, extensive safety checks, and manual inspections, often resulting in turnaround times of two to three hours. The technique emerged from the need to increase sortie rates, especially during the Vietnam War and Cold War, and draws inspiration from carrier aviation’s rapid “gas-and-go” cycles. Despite its speed advantages, hot pit refueling involves careful management of fuel flow rates to prevent hazards like static discharge, vapor ignition, or tank over-pressurization. On advanced stealth aircraft such as the F-35, refueling also serves to regulate avionics and sensor temperatures, adding complexity to the process. The procedure requires precise coordination, with fuel trucks staged near runways and crews ready to refuel jets landing with minimal fuel.