Accident: Hayes Lemmerz Dust Explosions and Fire
Location: Location: Huntington, IN
Accident Occurred On: 10/29/2003 | Final Report Released On: 09/27/2005
Accident Type: Combustible Dust Explosion and Fire
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.
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.
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.
Communicate the findings and recommendations of this report to your members
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.
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.
Communicate the findings and recommendations of this report to the work force at Hayes and other HLI facilities with similar operations.
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.
Implement a program to provide regular training for all facility employees on the fire and explosion hazards of aluminum dust.
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.
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.
Develop and implement written operating procedures for chip processing and train all affected employees. Ensure that procedures address maintenance and housekeeping.
Provide training for fire inspectors in Indiana jurisdictions on the recognition and prevention of aluminum dust explosion hazards.
Develop and distribute an educational bulletin on the prevention of metal dust explosions.
Communicate findings, recommendations and sections applicable to fire codes and standards to your membership.
Communicate the findings and recommendations of this report to your membership who work in facilities with similar combustible dust hazards.
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.