The tire was from a bomblift, a piece of aerospace ground equipment also referred to as a munitions loader or “jammer.” It’s just one of many items I worked on as an aerospace ground equipment mechanic.

Two other mechanics had been working on that same tire earlier that morning. But they both had left for appointments, so I had no idea what either of them had done. I asked the floor chief if he knew where the last person had stopped.

He replied, “I’m pretty sure it just needs to be inflated.”
So I thought to myself, “Easy enough.” I figured the floor chief had to be right, because he was a technical sergeant with years of experience. He knew what was going on since he was responsible for assigning maintenance and keeping track of his people.

Nevertheless, I decided to look the tire over. I noticed that the rim halves were bolted together.

I then got the technical orders and found the procedures for this particular job. I reviewed them and determined where mechanic number two had finished after considering all that I knew, which was ... practically nothing.

I decided to double-check the tightness of the rim bolts before I started servicing the tire just to make sure, because the tech order called for inflation to 95 psi. The bolts were secure, so I positioned the tire assembly upright and serviced it to the required pressure.

Afterward, I decided to check the bolts again. Why? I have no idea.

The first bolt was good, so was the second and the third, then ... BOOM!!!

The rim halves blew apart.

Dazed and not knowing exactly how to react, I instinctively turned and walked away from the workbench, put my hands on my hips and began shaking my head in disbelief.

Then I started to tremble from the instant dose of adrenaline.

A supervisor immediately rushed over and asked if I was all right.

“I’m OK, I’m OK,” I uttered, as my knees buckled and my body settled to the floor, submitting to the pain that suddenly surged through my arms. As I was on the floor, I rolled up my coveralls to see if I had any external injuries. Fortunately, there were only a couple of cuts and scratches, but it felt like my right arm may have been broken since I couldn’t really move it.

By this time, others had gathered and helped me to my feet as the section chief frantically approached the scene to also render assistance. They rushed me to the emergency room, where X-rays revealed that my arm wasn’t broken after all. This was a surprising miracle considering one of the rim bolts shot through a metal locker approximately 60 feet from where the tire exploded.

Immediately after this incident and for the next couple of weeks, safety investigators conducted interviews and gathered facts.

Cause of the Accident

• First, the explosion was caused by a pinched inner tube, which could’ve been prevented if the first mechanic had followed the tech order and installed a rubber tube guard between the rim and inner tube.
  
• Second, the next mechanic failed to notice the missing tube guard and installed improper hardware, which is why the rim halves blew apart. If he had installed the correct hardware per the tech order, the rim assembly would’ve held together.
  
• Third, if I paid attention to detail, I would’ve noticed the improper hardware and, upon replacing it, would’ve also noticed the missing tube guard.
  Most importantly, quality training with emphasis on tech order usage, attention to detail and job continuity could have prevented this whole incident.
  Nearly eight years have passed, and I still remember it vividly. I even wonder sometimes what might have happened if the tire was lying flat and I was positioned over it when it exploded. Fortunately, the consequences of this mishap weren’t fatal, and I’m still here to tell the story so others hopefully can learn from it.
  

Lessons Learned

• When continuing a job that someone else started, ask questions. Try to find out exactly what was done and where the work ended. The same applies if the roles are reversed. Tell someone what you did and what remains to be done.
  
• Supervisors must not only emphasize tech order usage, continuity and attention-to-detail, but practice them as well. This will ensure that these practices are integrated into the workplace and become second nature. (Checklists are risk control measures. Operational risk management works!)
  
• If any questions arise, slow down. Don’t be afraid of a temporary work stoppage to get the job done safely.
  

Continuity and attention to detail are vital issues in the workplace. They not only ensure quality maintenance and efficient production, but also guarantee personnel safety. In addition to adhering to tech orders, their practice should be persistently emphasized, especially now, as today’s Air Force is operating at a much faster tempo with fewer people.

I found out the hard way what could happen when these key processes aren’t considered during daily operations. Hopefully, you won’t have to.

Sergeant Boyer is an aerospace ground equipment instructor with the 372nd Training Squadron, Detachment 15, at Kadena Air Base, Japan.