The Aluminium Association’s Molten Metal Incident Reporting program
has three classifications of molten metal explosions (Force 1, Force 2, and
Force 3). Some in our industry call Force 1 explosions “pops”. We find that
term to be inappropriate to use. Why? Because in our industry there are
countless workers who have scars from molten metal that burned their skin.
There have been incidents where Force 1 explosions where workers succumbed to
their burns. We feel the term “pop” has a humorous, or comical tone to it.
There is nothing humorous or comical about molten metal burns. In addition the
term “pop” seems to lessen the importance of them. Every explosion no matter
the size should be investigated for the root cause. Here is a recent story
about a molten metal explosion.
At least two
people were injured by a steam explosion at an aluminum processing plant in Japan
one day during the week of January 21, 2016, police said.
One of the
injured people sustained burns to his entire body in the accident that occurred
around 1 p.m., according to the police.
The steam is
believed to have blasted out during the process of aluminum casting at the
plant, the police said, adding they are investigating details.
No fire has
been reported after the accident.
This aluminium
company's plant produces aluminum sheet products.
The Aluminium
Plant Safety Blog prays for both injured workers. We pray that they recover
fully from their physical injuries and any metal injuries they may suffered in
this explosion. We acknowledge that molten metal burns may leave physical
scars. Overtime those physical scar may fade, but the mental scars do not. We
hope that the aluminium company will offer counseling to the workers.
Regarding the
Aluminium Association’s Molten Metal Incident Reporting Program:
The Aluminum
Association’s 2015 Molten Metal Incident Report covering calendar year 2014
incidents is now available for download via the following link -
http://www.aluminum.org/2015-molten-metal-incident-report. Significant consulting support for its
development was provided by Ray Richter of Aluminum Cast Shop Consultants, LLC.
This report, while not a statistical representation of the industry due to its
reliance on voluntary self-reporting, once again highlights the predominant
hazards that result in explosions during molten aluminum management.
The Molten
Metal Incident Reporting Program is worldwide and incorporates roughly 300
aluminum plants in 20 countries. This reporting program started in 1980 and the
2015 report indicates that 107 incidents were reported, one fatality was
reported, and the number of reported Force 2 and Force 3 incidents continues
its downward trend. Overall, incident severity and frequency trends continue to
decline and this portends well for the future as well.
For the 2015
report, the format continues to include presentation of the information in a
more visual format including extensive use of charts and graphs as compared to
the prior tabular format and the report itself is now being distributed
primarily in electronic format.
The
Association continues to use the Molten Metal Incident Report as a primary
means of steering its efforts to address safety for the Aluminum industry and
would like to thank all the companies who take part in the program and for
their continued participation in the future.
A copy of the
reporting form for your use as needed is included at the back of the Molten
Metal Incident Report, and is also available as a stand alone document via the
linked website above.
The Molten Metal
Incident Reporting Program has been a great tool and has saved countless lives
by quantifying some incidents. This particular incident and many others that
the APSB post may not be included in the MMIRP. Why, because the APSB editors
do not report incidents to this program. Why? Well our concern (shared by AA)
is that our knowledge would skew the data that is gathered.
If your plant
handles molten metal, you should contact the Aluminium Association about
becoming a participant.
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