MARCO A. CHAVEZ
Army Support Activity Soto Cano Air Base/Army
Soto Cano Air Base
Palmerola, Honduras

Securing a U.S. military installation requires robust physical defenses, and Soto Cano Air Base in Honduras is no exception. At the entrance points, denial barriers serve as the most effective mechanical systems to control access. Available in a variety of sizes and designs depending on protection requirements, these barriers form a critical line of defense. However, like any mechanical system, denial barriers require periodic inspections and maintenance to ensure the integrity of the structure and proper operation. When those fundamental maintenance protocols break down, the results can prove disastrous.

Soto Cano Air Base features four denial barrier systems installed on three adjacent roads near the main entry gate. One barrier is located on a two-way, north-to-south road heading into the U.S. side of the base. Another barrier sits behind the guard cabin, providing access from the vehicle inspection lot. The remaining barriers are installed on two one-way roads running west to east toward the Honduran side of the base.

Every barrier is equipped with an independent activation control panel located inside each of the secondary guard cabins. Additionally, one main control panel operates all the barriers individually and simultaneously from inside the main Honduran guard cabin at the front gate. However, the physical location of this main guard cabin makes it impossible for an operator to maintain eye contact with all the barriers while operating the main control panel.

Recently, a team of two contractors was deployed to troubleshoot and conduct an operational check on a one-lane westbound denial barrier that failed to deploy during a test. The two maintainers were sufficient to accomplish the task, with one acting as the operator and the other serving as the safety observer. Unable to find the problem locally, the team decided to check the main control panel inside the Honduran guard cabin. Both workers went inside in an attempt to activate the westbound barrier. While one maintainer worked on the panel, the safety observer stood behind him rather than watching for vehicles approaching the barrier outside. Fortunately, the barrier did not deploy, preventing an initial mishap.

After almost two hours with no results, the workers’ frustration increased. They took it upon themselves to conduct further troubleshooting beyond their abilities and without proper clearance from their maintenance control dispatch office. The workers opened the main control panel and started toggling switches and activation keys with complete disregard for safety precautions. They failed to realize that their actions energized all the barriers simultaneously, with the exception of the westbound barrier they originally set out to check.

Depending on a driver's vantage point, an activated barrier can appear as a ramp or a low wall. While the workers continued to fiddle with the switches and keys, a motorcycle carrying a local national contractor and a passenger approached the main gate. As the motorcycle’s front tire began to roll over the barrier, the system suddenly activated, creating a 45-degree angle ramp. The motorcycle became airborne, ejecting the operator and passenger onto the pavement a few yards away. Fortunately, both were wearing helmets. The passenger sustained minor scratches, while the operator dislocated his shoulder and suffered other minor injuries.

The investigation into the mishap revealed the maintenance crew was neither cleared nor authorized to conduct the troubleshooting or to operate the main control panel without assistance from the military police. The standard operating procedure for this type of equipment requires patrols to block vehicle and pedestrian traffic on both sides of the barriers. Protocol also mandates a reliable means of communication between the operator and the maintenance crew when the system becomes energized, and it requires a qualified operator to activate the barriers during tests. Furthermore, the maintainers conducted their work without consulting the required maintenance or operation manuals.

In their interviews with the mishap investigators, the maintenance crew stated that during past operations of this type, they simply placed orange cones on one side of the barriers. However, they noted that drivers tended to disregard the presence of the cones, driving around them without stopping or slowing down.

Lessons Learned

• Adhere strictly to standard operating procedures: Maintenance crews must never bypass required safety steps, such as coordinating with the military police to block traffic or establishing clear communication lines between operators and ground personnel.
• Never troubleshoot beyond authorization: Workers must obtain proper clearance from their dispatch office before expanding the scope of a repair. Frustration is not an excuse to blindly toggle switches on an energized system.
• Always utilize technical manuals: Relying on memory to repair critical security infrastructure is a dangerous practice. Maintenance personnel must always consult the required operation and maintenance manuals, regardless of their tenure or experience level.
• Combat workplace complacency: Years of experience can lead to dangerous overconfidence. Organizations must actively fight complacency by enforcing fresh training plans, utilizing strict checklists and routinely auditing maintenance habits.
• Employ effective traffic control: Relying on passive measures like orange cones is insufficient when working on active roadways. Physical patrols must actively halt vehicle and pedestrian traffic to protect both the public and the maintenance crew.

While the maintainers had good intentions and the motivation to fix the problem with the barriers, they did not follow the basics. Ignoring maintenance manuals and conducting maintenance by memory is a common factor in workplace mishaps. In response to the incident, the contract manager and the safety office developed a comprehensive training plan. They also implemented new checklists and processes to eradicate bad habits among the workforce and restore operational discipline.