Friday, May 10, 2013

Small Molten Metal Explosions Can Lead To Large Fires (video added)

The APSB appologizes for deleting the earlier post, there was an update of this story, so instead of a second post they were combined.

In our industry small molten metal explosions are sometimes called "pops".

Whomever termed "pops" made a serious mistake in choosing a word that sounded comical. In root cause analysis it is common to find that large explosions were preceded by smaller explosions. Unfortunately, the smaller explosions were never considered serious, or explored on exactly why they occurred.

Over the past 12 months the APSB has posted story after story of small explosions that had serious consequences. Some of the stories resulted in injuries and deaths. Fortunately, for all the workers and firemen involved in this incident there were no injuries. Here is the followup story.


Firefighters in Harrison, Arkansas have been battling a blaze at Pace Industries. Boone County Emergency Services Director says the fire was reported about 9:20 a.m. Sunday, during the week of April 21, 2013. Boone County Emergency Services Director says there were 30 to 35 employees in the building at the time — but no injuries are reported and there is and no hazardous materials at the plant. 

Pace's website describes the plant as a small die casting facility that opened in Harrison in 1970.
Smoke from the fire led officials to briefly shut down the Arkansas Highway 62/65 Bypass.
Smithyman says it appears the fire was started when a small aluminum die malfunctioned



Unfortunately, accidents occur at a such a pace that the APSB cannot post quick enough. This update shows a little publicized side effect of accidents in our industry. Potential layoffs after an accident.

Hundreds of people may be forced to the unemployment line after a fire scorched a factory.  The blaze started just before 10 a.m. Sunday at the Harrison branch of Pace Industries.

Monday morning, fire tape blocked the entrances as pieces of debris continued to fall from the sky.  Workers paced around the building and peeked into smashed out windows.  Many wondered if their jobs are safe.

"All the roof is melted and all the rafters are bent. It got really hot in there.  All the doors on the machines are warped," said current employee, as he took pictures on his phone.  "Our dock spray holders are melted; our forklifts are melted to the floor.  It got real hot."

For the past six months, the worker found the job at Pace fun.  The pictures he took were of the machines he used to run, now melted on the charred floor.

"It's pretty much the heartbeat of Harrison, where we make our money, so, got to support myself and my family," he said.

His once secure job is as uncertain as the plant's future.

"It smells bad too," the worker said, thrusting his body through the open area.

Drivers could see the Sunday morning smoke for miles.  The fire not only scorched equipment, it also incinerated paychecks.

"I don't think I'm going to get another paycheck," said the worker.  "I get a paycheck for the next week.  But, as of now, I won't be working for now.  So, until I hear anything,
I won't be getting paid."

The worker supports his disabled mother with the pay that he gets working the die casting machines at Pace.  His mother said, without the steady paycheck, the worker will have to forfeit his car.  It's one of the many causalities of fire.

Another worker also peeked inside the smashed windows.

"Man," he said with a sigh.  "I see a lot of charred stuff around here."

In a month, that worker will turn 41.  He has a daughter, and he lives with his fiancĂ©e and her child.  He's been with the company since 1995.

"I hope to get back to work as soon as possible.  It pays the bills.  That's the main thing," he said matter-of-factly.

The Harrison branch of Pace Industries fits about 500 workers inside and is as big as six football fields.  Those on shift at the time of the fire made it out of the building safely.  Firefighters and employees said emergency drills prepared staff.

"There's a lot of good guys that work up here," he said. "Everybody was fine. Drill went according to plan basically and everybody's fine. So it's always a good thing."

The first echoed his co-worker's sentiments.

"It is a real scary thought.  I'm glad nobody got hurt and everybody got out in time," he said.

Investigators with the company will be on site to help determine the cause of the fire.  They plan to meet with Harrison fire investigators later in the week.

While workers wait and see about money, they said they would keep doing what they can to make it.

"Devastated and sad because I like my job a lot and it's a good place to work," said the first worker.  "I really wanted to help out and make sure everything was okay so we could keep going.  Of course, we are down here to help, support, and do all we can and try to get us back on our feet again.  That's about all we can do, really."



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