104,543Records 70,659Employers 84,666Hospitalizations 27,563Amputations 2015-01-01 2025-09-30
Safety Incidents OSHA Severe Injury Reports · 2015–2025

OSHA Accident Investigation · Summary #14384986

BURN,ALUMINUM PROCESSING,EXPLOSION,ABRASION,CHEMICAL,CONTUSION

Event
BURN,ALUMINUM PROCESSING,EXPLOSION,ABRASION,CHEMICAL,CONTUSION
Linked inspection
No inspection record linked to this accident's victims.
Summary number
14384986
Report ID
524200

Event description

DIP TANK (SALT BATHS) EXPLOSION

Investigation abstract

ON APRIL 26, 1985, A MOLTEN SOLUTION OF 50% SODIUM NITRATE AND 50% POTASSIUM NIT PERATURE OF MORE THAN 970 DEGREES FAHRENHEIT IS REACHED. INSTEAD, THE CONTROLS F UNCTIONED IN REVERSE, CALLING FOR MORE HEAT UNTIL A VOLATILE TEMPERATURE WAS REA CHED, CAUSING THE MOLTEN SALTS TO EXPLODE. THESE PARTICULAR CONTROLS HAD BEEN ID LE SINCE FEBRUARY OF 1985. THIS ACCIDENT COULD HAVE BEEN AVOIDED IF THE EMPLOYER HAD ESTABLISHED A SAFE STANDARD OPERATING PROCEDURE. ONE THAT, FOR EXAMPLE, REQ UIRED THE TANK OPERATOR TO MEASURE THE TEMPERATURE OF THE MOLTEN SALTS WITH A PY ROMETER TO COMPARE WITH THE TEMPERATURE RECORDED BY THE AUTOMATIC EQUIPMENT. THE N, IF THE TEMPERATURE REACHED 970 DEGREES FAHRENHEIT AND THE AUTOMATIC EQUIPMENT FAILED TO SHUT OFF THE BURNERS, THE OPERATOR COULD HAVE SHUT THEM OFF HIMSELF. RATE, USED IN HEAT TREATING ALUMINUM RODS, EXPLODED. EMPLOYEES #1, 2 AND 3 WERE KILLED. EMPLOYEES #13,14 AND 18 WERE SEVERELY BURNED AND REQUIRED HOSPITALIZATIO N. EMPLOYEES #4,5,6,7,8,9,10,11,12,15,16,17,19 AND 20 WERE TREATED FOR BRUISES, CONTUSIONS, AND ABRASIONS AND WERE RELEASED. THE AREAS AFFECTED BY THE EXPLOSION INCLUDED THE ENTIRE HEAT TREAT DEPARTMENT, THE SCREW MACHINE DEPARTMENT, SIX EL ECTRIC FURNACES, THE ENGINE ROOM, THE SHIPPING DEPARTMENT, AND PART OF THE MAINT ENANCE AREA. AN INVESTIGATION REVEALED THAT THE AUTOMATIC TEMPERATURE CONTROL EQ UIPMENT DID NOT FUNCTION TO SHUT DOWN THE HEATING SOURCE AS IT SHOULD WHEN A TEM

Victims (20)

  1. #1 Fatality Age 57 M

    Nature of injury
    12
    Part of body
    4
    Event type
    14
    Source
    16
    Occupation code
    999
    Human factor
    9
    Environmental factor
    9
    Task assigned
    1

  2. #10 Hospitalized Age 60 M

    Nature of injury
    3
    Part of body
    4
    Event type
    14
    Source
    16
    Occupation code
    999
    Human factor
    9
    Environmental factor
    9
    Task assigned
    1

  3. #11 Hospitalized Age 54 F

    Nature of injury
    3
    Part of body
    4
    Event type
    14
    Source
    16
    Occupation code
    999
    Human factor
    9
    Environmental factor
    9
    Task assigned
    1

  4. #12 Hospitalized Age 36 M

    Nature of injury
    3
    Part of body
    4
    Event type
    14
    Source
    16
    Occupation code
    999
    Human factor
    9
    Environmental factor
    9
    Task assigned
    1

  5. #13 Hospitalized Age 44 M

    Nature of injury
    5
    Part of body
    4
    Event type
    14
    Source
    16
    Occupation code
    999
    Human factor
    9
    Environmental factor
    9
    Task assigned
    1

  6. #14 Hospitalized Age 32 M

    Nature of injury
    5
    Part of body
    12
    Event type
    14
    Source
    16
    Occupation code
    999
    Human factor
    9
    Environmental factor
    9
    Task assigned
    1

  7. #15 Hospitalized Age 45 M

    Nature of injury
    3
    Part of body
    4
    Event type
    14
    Source
    16
    Occupation code
    999
    Human factor
    9
    Environmental factor
    9
    Task assigned
    1

  8. #16 Hospitalized Age 55 M

    Nature of injury
    3
    Part of body
    4
    Event type
    14
    Source
    16
    Occupation code
    999
    Human factor
    9
    Environmental factor
    9
    Task assigned
    1

  9. #17 Hospitalized Age 56 F

    Nature of injury
    3
    Part of body
    4
    Event type
    14
    Source
    16
    Occupation code
    999
    Human factor
    9
    Environmental factor
    9
    Task assigned
    1

  10. #18 Hospitalized Age 35 M

    Nature of injury
    5
    Part of body
    2
    Event type
    14
    Source
    16
    Occupation code
    999
    Human factor
    9
    Environmental factor
    9
    Task assigned
    1

  11. #19 Hospitalized Age 31 M

    Nature of injury
    3
    Part of body
    4
    Event type
    14
    Source
    16
    Occupation code
    999
    Human factor
    9
    Environmental factor
    9
    Task assigned
    1

  12. #2 Fatality Age 45 M

    Nature of injury
    12
    Part of body
    4
    Event type
    14
    Source
    16
    Occupation code
    999
    Human factor
    9
    Environmental factor
    9
    Task assigned
    1

  13. #20 Hospitalized Age 53 F

    Nature of injury
    3
    Part of body
    4
    Event type
    14
    Source
    16
    Occupation code
    999
    Human factor
    9
    Environmental factor
    9
    Task assigned
    1

  14. #3 Fatality Age 45 M

    Nature of injury
    12
    Part of body
    4
    Event type
    14
    Source
    16
    Occupation code
    999
    Human factor
    9
    Environmental factor
    9
    Task assigned
    1

  15. #4 Hospitalized Age 44 M

    Nature of injury
    3
    Part of body
    4
    Event type
    14
    Source
    16
    Occupation code
    999
    Human factor
    9
    Environmental factor
    9
    Task assigned
    1

  16. #5 Hospitalized Age 40 M

    Nature of injury
    3
    Part of body
    4
    Event type
    14
    Source
    16
    Occupation code
    999
    Human factor
    9
    Environmental factor
    9
    Task assigned
    1

  17. #6 Hospitalized Age 48 M

    Nature of injury
    3
    Part of body
    4
    Event type
    14
    Source
    16
    Occupation code
    999
    Human factor
    9
    Environmental factor
    9
    Task assigned
    1

  18. #7 Hospitalized Age 51 M

    Nature of injury
    3
    Part of body
    4
    Event type
    14
    Source
    16
    Occupation code
    999
    Human factor
    9
    Environmental factor
    9
    Task assigned
    1

  19. #8 Hospitalized Age 49 M

    Nature of injury
    3
    Part of body
    4
    Event type
    14
    Source
    16
    Occupation code
    999
    Human factor
    9
    Environmental factor
    9
    Task assigned
    1

  20. #9 Hospitalized Age 50 M

    Nature of injury
    3
    Part of body
    4
    Event type
    14
    Source
    16
    Occupation code
    999
    Human factor
    9
    Environmental factor
    9
    Task assigned
    1

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