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Hayes Lemmerz Dust Explosions and Fire
FINAL REPORT: Final Investigation Report
Location: Huntington, IN
Accident Occurred On: 10/29/2003
Final Report Released On: 09/27/2005
Accident Type: Combustible Dust Explosion and Fire
Company Name: Hayes Lemmerz

statistics

Total # of Recommendations
20
Total # of Open Recommendations
0
Total # of Closed Recommendations
20
Total % of Open 0 vs. Closed 100

investigation information

Image
Accident Description
On the evening of October 29, 2003, a series of explosions severely burned two workers, injured a third, and caused property damage to the Hayes Lemmerz manufacturing plant in Huntington, Indiana. One of the severely burned men subsequently died. The Hayes Lemmerz plant manufactures cast aluminum automotive wheels, and the explosions were fueled by accumulated aluminum dust, a flammable byproduct of the wheel production process.
Investigation Status
The Board approved an investigation report on this investigation on September 27, 2005. A news conference was held in Fort Wayne, IN, on October 5, 2005.


 

Recommendations

Aluminum Association, Inc.
2004-1-I-IN-12

Conduct research into the feasibility and design of improved explosion protection for aluminum dust collector applications, including explosion venting, isolation and suppression systems. Coordinate this research activity with the Fire Protection Research Foundation.

Status: Closed - Unacceptable Action/No Response Received
Closed - Unacceptable Action/No Response Received (C - UA/NRR) - Recipient responds by expressing disagreement with the need outlined in the recommendation and the Board concludes that further correspondence on, or discussion of, the matter would not change the recipient?s position.
 

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2004-1-I-IN-13

Communicate the findings and recommendations of this report to your members

Status: Closed - Acceptable Action
Closed - Acceptable Action (C - AA) - The recipient has completed action on the recommendation. The action taken meets the objectives envisioned by the Board.
 

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Fire Protection Research Foundation
2004-1-I-IN-11

Conduct research into the feasibility and design of improved explosion protection for aluminum dust collector applications, including explosion venting, isolation and suppression systems. Coordinate this research activity with the Aluminum Association, Inc.

Status: Closed - Reconsidered/Superseded
Closed - Reconsidered/Superseded (C - R/S) - Recipient rejects the recommendation and also supports the rejection with a rationale with which the Board concurs. This designation may apply when later facts indicate that the concerns expressed in the recommendation were actually addressed prior to the incident, or when a recommendation is superseded by a new, more appropriate recommendation.
 

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Hayes-Lemmerz International (HLI)
2004-1-I-IN-6

Conduct regular audits of all North American facilities that produce, process, or handle aluminum chips or dust, in light of the findings of this report. Emphasize engineering, hazard, and MOC reviews and compliance with NFPA-484. Ensure that: audits are documented and contain findings and recommendations, audit findings are shared with the work force at the facility, and audit recommendations are tracked and implemented.

Status: Closed - No Longer Applicable
Closed - No Longer Applicable (C - NLA) - Due to subsequent events, the recommendation action no longer applies (e.g., the facility was destroyed or the company went out of business).
 

2004-1-I-IN-7

Communicate the findings and recommendations of this report to the work force at Hayes and other HLI facilities with similar operations.

Status: Closed - No Longer Applicable
Closed - No Longer Applicable (C - NLA) - Due to subsequent events, the recommendation action no longer applies (e.g., the facility was destroyed or the company went out of business).
 

Hayes-Lemmerz International- Huntington, Indiana
2004-1-I-IN-1

Develop and implement a means of handling and processing aluminum chips that minimizes the risk of dust explosions. Refer to: 1. The Aluminum Association Pamphlet F-1, Guidelines for Handling Aluminum Fines Generated During Various Aluminum Fabricating Operations. 2. NFPA 484, Standard for Combustible Metals, Metal Powders, and Metal Dusts.

Status: Closed - No Longer Applicable
Closed - No Longer Applicable (C - NLA) - Due to subsequent events, the recommendation action no longer applies (e.g., the facility was destroyed or the company went out of business).
 

2004-1-I-IN-2

Implement a program to provide regular training for all facility employees on the fire and explosion hazards of aluminum dust.

Status: Closed - No Longer Applicable
Closed - No Longer Applicable (C - NLA) - Due to subsequent events, the recommendation action no longer applies (e.g., the facility was destroyed or the company went out of business).
 

2004-1-I-IN-3

Develop and implement policies and procedures for conducting engineering, hazard, and management of change (MOC) reviews of plant projects and modifications to support systems such as chip processing. In particular, ensure that a hazard analysis is conducted during the design phase, as well as during the engineering and construction phases, and when changes are made to the system.

Status: Closed - No Longer Applicable
Closed - No Longer Applicable (C - NLA) - Due to subsequent events, the recommendation action no longer applies (e.g., the facility was destroyed or the company went out of business).
 

2004-1-I-IN-4

Implement a program to conduct management reviews of incidents and near-miss incidents, including duct fires and dust flashes. Apply this program to all plant areas, including support areas such as chip processing. Address the root causes of the incidents and near-misses and implement and track corrective measures.

Status: Closed - No Longer Applicable
Closed - No Longer Applicable (C - NLA) - Due to subsequent events, the recommendation action no longer applies (e.g., the facility was destroyed or the company went out of business).
 

2004-1-I-IN-5

Develop and implement written operating procedures for chip processing and train all affected employees. Ensure that procedures address maintenance and housekeeping.

Status: Closed - No Longer Applicable
Closed - No Longer Applicable (C - NLA) - Due to subsequent events, the recommendation action no longer applies (e.g., the facility was destroyed or the company went out of business).
 

Indiana Department of Homeland Security
2004-1-I-IN-10

Provide training for fire inspectors in Indiana jurisdictions on the recognition and prevention of aluminum dust explosion hazards.

Status: Closed - Unacceptable Action/No Response Received
Closed - Unacceptable Action/No Response Received (C - UA/NRR) - Recipient responds by expressing disagreement with the need outlined in the recommendation and the Board concludes that further correspondence on, or discussion of, the matter would not change the recipient?s position.
 

Indiana Occupational Safety and Health Administration
2004-1-I-IN-9

Develop and distribute an educational bulletin on the prevention of metal dust explosions.

Status: Closed - Acceptable Action
Closed - Acceptable Action (C - AA) - The recipient has completed action on the recommendation. The action taken meets the objectives envisioned by the Board.
 

International Code Council (ICC)
2004-1-I-IN-20

Communicate findings, recommendations and sections applicable to fire codes and standards to your membership.

Status: Closed - Acceptable Action
Closed - Acceptable Action (C - AA) - The recipient has completed action on the recommendation. The action taken meets the objectives envisioned by the Board.
 

International Union, United Automobile, Aerospace and Agricultural Implement
2004-1-I-IN-16

Communicate the findings and recommendations of this report to your membership who work in facilities with similar combustible dust hazards.

Status: Closed - Acceptable Action
Closed - Acceptable Action (C - AA) - The recipient has completed action on the recommendation. The action taken meets the objectives envisioned by the Board.
 

National Association of State Fire Marshals
2004-1-I-IN-18

Communicate findings, recommendations and sections applicable to fire codes and standards to your membership.

Status: Closed - Acceptable Action
Closed - Acceptable Action (C - AA) - The recipient has completed action on the recommendation. The action taken meets the objectives envisioned by the Board.
 

National Fire Protection Association (NFPA)
2004-1-I-IN-19

Communicate findings, recommendations and sections applicable to fire codes and standards to your membership.

Status: Closed - Acceptable Action
Closed - Acceptable Action (C - AA) - The recipient has completed action on the recommendation. The action taken meets the objectives envisioned by the Board.
 

North American Die Casting Association
2004-1-I-IN-15

Communicate the findings and recommendations of this report to your members

Status: Closed - Acceptable Action
Closed - Acceptable Action (C - AA) - The recipient has completed action on the recommendation. The action taken meets the objectives envisioned by the Board.
 

Premelt Systems
2004-1-I-IN-8

Communicate the findings and recommendations of this investigation to owners/operators of facilities to which Premelt supplies similar aluminum chip-melting systems. Include in your communication specific information that the chip drying process liberates small particles of aluminum, and that such particles may be explosive.

Status: Closed - Acceptable Action
Closed - Acceptable Action (C - AA) - The recipient has completed action on the recommendation. The action taken meets the objectives envisioned by the Board.
 

Risk and Insurance Management Society (RIMS)
2004-1-I-IN-14

Communicate the findings and recommendations of this report to your members

Status: Closed - Acceptable Action
Closed - Acceptable Action (C - AA) - The recipient has completed action on the recommendation. The action taken meets the objectives envisioned by the Board.
 

United Steelworkers of America (USWA)
2004-1-I-IN-17

Communicate the findings and recommendations of this report to your membership who work in facilities with similar combustible dust hazards.

Status: Closed - Acceptable Action
Closed - Acceptable Action (C - AA) - The recipient has completed action on the recommendation. The action taken meets the objectives envisioned by the Board.
 

 
 

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