Chemical Manufacturer to Pay $1.3M for Fatal ExplosionChemical Manufacturer to Pay $1.3M for Fatal Explosion
The 2019 explosion killed four workers and caused extensive damage to nearby businesses. See what transpired in this video.

AB Specialty Silicones LLC, a chemical manufacturer, must pay $1.3 million in penalties after an explosion and fire at its Waukegan, IL, plant in May 2019 claimed the lives of four workers, destroyed the company's production building, and caused extensive damage to nearby businesses.
The company manufactures silicone products used in applications such as personal care and roof coatings.
The Occupational Safety and Health Administration (OSHA) reached a settlement agreement with the company after an investigation revealed AB Specialty Silicones failed to ensure electrical equipment complied with OSHA standards. The company also used propane-powered forklifts to transport flammable liquids in areas where employees handled flammable liquids and gases.
As part of the agreement, the company has temporarily ceased production and use of silicon-hydride emulsions at all facilities until a new process area for production is designed by an engineering firm. The company has also agreed to do the following:
Develop a company-wide safety and health management system, implement an emergency action plan and conduct evacuation drills.
Provide safety training to employees and offer it in all languages understood by employees.
Require specialty training for management on handling flammable materials.
Purchase industrial trucks properly rated for handling flammable materials for all facilities.
Perform comprehensive audits of its occupational health and safety management system certification and maintain at all facilities.
Hire third-party consultants to assist with the analysis of electrical classification and hazards for any future or rebuilt facilities and audit those facilities six months after the start of operations.
Allow OSHA to periodically inspect facilities without requiring a warrant.
On May 3, 2019, the massive explosion and fire at the AB Specialty Silicones facility were caused by a mix-up of chemicals in a tank in the production building, causing a hydrogen gas release.
According to the US Chemical Safety and Hazard Investigation Board's 73-page final investigation report in Sept. 2021 on the event. The organization stated that AB Specialty Silicones workers were performing a batch operation that involved manually adding and mixing chemicals in a tank inside the production building. During the operation, an operator pumped an incorrect chemical into the tank, which was incompatible with another chemical that was added to the tank. The incorrect, incompatible chemical was stored in an identical drum to one of the correct chemicals, the only differentiating markings being small labels on the drums, and bung caps.
After the incompatible chemicals were mixed, the tank contents underwent a chemical reaction, causing a process upset in which the tank contents foamed and overflowed from the tank’s top opening. A fog also formed. The CSB determined that the process upset produced hydrogen gas, which released inside the manufacturing facility’s production building. Soon after the hydrogen gas release started, it ignited, causing the massive explosion and fire.
The CSB also found these safety issues by AB Specialty Silicones:
Mixing of Incompatible Materials
Hazard Analysis Program
Storage and Handling of Incompatible Materials
Batch Equipment and Ventilation System Design
Gas Detection System
Emergency Preparedness
Double Initial Procedure Program
Process Safety Culture
Safety Management System that Addresses Process Safety
Regulatory Coverage of Reactive Hazards
The following video by the CSB reveals the steps that were taken during the day of the fatal event.
About the Author
You May Also Like