Accident: 170883995 - Burn - Electrical Fault In Panelboard

An employee was working as warehouse worker and laborer at an aluminum recycling plant. His duties included cleaning ground aluminum particles from a drum, cleaning miscellaneous material from the grindings, and putting the aluminum into bags for transport. At the time of the accident, he was operating a forklift, transferring and screening material from a drum. He was working near a panelboard. The aluminum dust caused an electrical fault in the panelboard. The ensuing electric arc or the ignited aluminum dust caused a hydraulic line on the forklift to fail. The hydraulic oil leaking from the line then ignited. The employee sustained mild first- and second-degree burns to the left side of his face and his left arm and leg. The employee was hospitalized for 5 days for his injuries.

electrical, burn, aluminum dust, fire, electric arc, electrical fault, hydraulic fluid, panelboard, industrial truck, e gi iii

Accident: 14383608 - Two Employees Killed, 25 Injured In Metal Dust Explosion

Employees #1 through #27 were working inside a building that contained various equipment for assembling aluminum alloy bicycle rims. This equipment included three conveyor-fed booths in which brushing and polishing were done. The booths had exhaust systems that deposited the aluminum dust into an enclosed basement. Heat or sparks from wheels that were being polished or brushed caused a fire that traveled from a booth to the basement and resulted in a tremendous explosion and additional fire. Employees #1 and #2 died; Employees #3, #4, #5, and #6 were critically injured; ten more workers were hospitalized with various injuries; and eleven other workers were treated at the hospital and released.

aluminum dust, spark, explosion, fire, combustible dust, work rules

Accident: 170672430 - Dies In Aluminum Powder Explosion

Employee #1, acting within the scope of his normal job duties, was attempting to change an aluminum powder sensor for a storage/convey tank at a facility that manufactures aluminum powder and paste. The electrical power to the sensor was still present when the unit went into operation and generated an aluminum cloud. The combination of these factors caused two successive explosions and ensuing fires in which Employee #1 was killed. Electrical test instruments belonging to Employee #1 were found in another location. The electrical power had not been eliminated and the pneumatic energy source had not been identified and controlled.

explosion, fire, work rules, aluminum dust, lockout, maintenance, storage tank, aluminum processing

Accident: 170068167 - Burned By Aluminum Dust Explosion/Fire

Five barrels of aluminum dust that had been removed from an outdoor dust collector were sealed and stored in the plant adjacent to electrical panels. One had somehow been contaminated with water, which exothermically reacted with the aluminum dust to form hydrogen gas. The top of the barrel deformed and glowed red. Smoke was observed and an employee sounded a vocal alarm. The lid blew off the barrel and the mushroom cloud of aluminum dust exploded in a fireball. Nearby combustible material ignited and the sprinkler system activated. Employee #1, the closest employee, sustained second-degree burns of the arm and neck and went to the emergency room for treatment. Due to the warning, there were no other serious injuries.

explosion, fire, chemical reaction, hydrogen, burn, neck, aluminum dust, smoke, arm, combustible dust

Accident: 14322382 - Dies From Aluminum Dust Explosion

Employee #1 poured approximately 21 lb of highly explosive aluminum powder (elemental aluminum) into a rotating metal bucket that contained other powdered metal pigments. During the pouring, a dust explosion and fire occurred. Employee #1 was burned on 60 percent of his upper body and died. One possible explanation for the chemical explosion was that a buildup of static charge had occurred during the pouring of the powder in combination with dust conditions in the metal rotating bucket. No precautions were taken for hazardous atmospheres.

explosion, chemical burn, aluminum dust, chemical reaction, work rules, fire, ppe