Explosion Results in Workers Clothes Set On Fire...

This photo is not meant to make fun of this incident, but to reinforce what you should do if your clothes catch on fire!

There was a time, when workers wore t-shirts and jeans in many of our plants in the aluminium industry. No longer should that be the case, too many incidents have shown that the secondary clothing is very important in protecting the worker from burns. Is the fabric resistant to molten aluminium, molten bath, fire retardant, etc.  Our industry has been proactive regarding workers clothing and their fabric. Here is a story that reinforces the need for appropriate clothing and fabric.

Aluminium powder reacted with water in an industrial vacuum cleaner to create hydrogen gas that exploded and burned a worker, a court heard.

A Staffordshire research and development company was prosecuted by the Health and Safety Executive (HSE) following the incident at its site on 6 February 2012.

The workers clothes and face mask were set alight when the vacuum exploded as he tried to remove powder from a floor at the company. The 27 year-old employee suffered burns to the top of his body and was in hospital for two weeks. The worker suffered burns to his face, neck, shoulder and arm. The worker was off work and needed three months off work following the incident and has been left with a permanent burn scar to his left hand. Stafford Magistrates' Court heard the specialist vac had been used to clean up aluminium powder before being left to stand over a weekend. The powder reacted with water used in the machine to create hydrogen gas that exploded when the unassuming worker switched it on.

An HSE investigation found that had company undertaken a proper risk assessment it would have identified that a reaction could be caused by mixing metal powder with the water inside the cleaner. Health and Safety Inspector told Stafford Magistrates' Court yesterday: "The day before the accident another employee used the vacuum to clean up aluminium powder which had been spilt from a faulty valve on a sieving machine. It was then put to one side and the vacuumed aluminium started to react with water in the vacuum and started to produce hydrogen gas.

"The following day the employee took the vacuum to the sieving room, plugged it in and then it exploded. The motor part was blown clean off the drum and Mr Poor was lucky it did not hit his head. His clothing and face mask was on fire and several workers ran to his aid."

Speaking after the hearing, HSE inspector said: "This type of vacuum was not suitable for use with aluminium powder. Had the company paid attention to the instructions for working with this metal powder, or indeed the machine itself, then the incident could have been prevented.

"It must have been a very frightening experience for the worker, who suffered painful injuries.

"Aluminium powder mixed with water can create highly explosive gas and a suitable and sufficient risk assessment would have shown that they should not have been mixed."

The magistrate said: "It is quite clear that the employee could have been much more seriously injured, or even killed, but we are pleased to see that the worker is well on the way to recovery. We would like to commend the prompt action taken by the company following this incident."

The company was fined £7,000 and ordered to pay £6,397 in costs after pleading guilty to breaching Regulation 5 (1) of the Dangerous Substances and Explosive Atmospheres Regulations 2002.

The Aluminium Association (AA) has been at the forefront in clothing/fabric testing. They have done extensive testing. The report is available through AA's bookstore. The report is titled "Resistance of Protective Fabrics to Molten Aluminium and Bath". It can be found here. 

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