This document contains summaries of hazardous materials incidents from 1991 to 2014. It notes key details from each incident such as location, materials involved, cause of ignition, and consequences. Minimum training standards and good engineering practices are also referenced to help prevent future incidents.

1. Subpart H Hazardous Materials
John Newquist
Draft 5 5 2018

2. Mar 2018
• December 24, 1991 interpretation
• Hence, the Incident Commander
will require more than 24 hours of
total training. The training hours
suggested in the standard are
minimums; we often find that
people developing training
programs must go over the
minimum 8, 24, or 40 hours to
properly instruct employees on all
of the required subjects.

3. Nov 2017
• Orange County CA
• Static Electricity from Splash Filling
• The MIE of hexamethyldisiloxane is less than 1 mJ
so it does not take much static - in fact, we would
not even feel or see a static discharge of 1 mJ.
• Hexamethyldisiloxane is Category 2 Flammable
liquid which carries the following GHS
Precautionary statements for good reason:
• P241 Use explosion-proof electrical/ ventilating/
lighting/ equipment.
• P242 Use only non-sparking tools.
• P243 Take precautionary measures against static
discharge.

4. Nov 2015
• Ohio
• The vents are not adequately
protected by the bollards.
• The second vent from the left
is capped off.
• The baseplate of the lamp post
base is not grouted, so rain
water and condensation gets in
the conduit and wiring.
• Vent discharges too close to an
ignition source (the light)

5. May 2014
• Hartford CT
• A workbench in the finishing room
of the facility caught fire on May
19, 2014, while an employee
cleaned titanium aircraft parts.
• The room's dust collection system
lacked adequate fire and explosion
controls.
• Flammable titanium dust had also
settled on electrical equipment.
Titanium Dust Collector fire photo

6. March 2014
• Two separate fires brought
responders to a downtown Erie
plant on Tuesday.
The first one started around 1pm
at Fralo Industries Metal
Fabricators and left one worker in
critical condition after he suffered
severe burns to his body from a
combustible dust fire ignited by a
bearing/
Then a second, unrelated fire
sparked just before 6pm. This time
the fire was on the shop floor.

7. January 2014
• According to OSHA records, it was
first shift workers acting under
supervision, who loaded the fateful
batch of carbon and graphite parts,
coated in a highly flammable
alcohol and iodine solution.
• The oven, unequipped to handle
combustibles, exploded roughly 15
minutes later.
• OSHA said the force ripped the
oven’s door from its hinges,
causing the heavy metal object to
strike a group of three workers on
a tour of the facility, 15 to 20 feet
away.
• The result is listed as “death and
broken bones.”
The “event” oven – a
Despatch-brand electric oven
— had reportedly been
purchased by the company to
cure water-based calcium
treatments roughly four years
earlier.

8. Dec 2010
• New Cumberland WV
• At about 1:30 p.m. on Dec. 9,
2010, Jeffrey Scott Fish, James
Eugene Fish and Steven Swain
were at work at AL Solutions, a
small metals recycling plant
along the Ohio River in New
Cumberland.
• Outside the Hancock County
facility, witnesses heard a loud
thud and metal hitting the floor.
• An explosion ripped through the
building. Flames shot in all
directions.
• Hydrogen gas during titanium
and zirconium processing.
The two Fish brothers, 39 and 38 years old, died
inside from heat and smoke inside the building.
Swain, 27, made it out, but suffered burns over most
of his body. He died four days later.

9. Texas City
• April 16, 1947
• Cargo Ship of
Ammonium Nitrate
Exploded
• Neighboring
Monsanto plant
caught fire
• 561 died

10. West Fertilizer
• Smoke first in 911 call.
• No Sprinklers
• Ammonium-nitrate fire
code, NFPA 490
• West Fertilizer had
anhydrous ammonia, but
investigators say it was
not involved in the fire
or explosion.

11. West Fertilizer
West firefighters were dispatched to the
plant earlier in the evening after an earlier
fire rekindled.
Something started a blaze in the seed room
of the company’s fertilizer and seed
building, a 13,000-square-foot structure by
the spur rail on the northeast side of town

12. West Fertilizer
$100 million in damage.
14 died

13. $14 million award to workers
• Investigators determined
that workers installing a
water heater at the plant
released natural gas
inside the building as
they purged a line, and a
spark from nearby
machinery caused the
blast.
Three workers and a contractor were
killed in the June 9, 2009, explosion,
and dozens of others were injured

14. 51
59
63
64
130
119(d)(3)(ii)
107(b)(5)(i)
106(e)(6)(ii)
107(g)(2)
101(b)
Hazardous Materials [1910.101 –
.126]
14
COMPRESSED GASES – HANDLING STORAGE AND USE
SPRAY BOOTH – AIR VELOCITY
CLASS I LIQUIDS – DISPENSING
SUBPARTH
SPRAY AREAS – CLEANING WITH NON-SPARKING TOOLS
DOCUMENTATION OF EQUIPMENT WITH GOOD ENGINEERING PRACTICES

15. 1910.101(b)
• "Compressed gases." The in-
plant handling, storage, and
utilization of all compressed
gases in cylinders, portable
tanks, rail tank cars, or motor
vehicle cargo tanks shall be
in accordance with
Compressed Gas Association
Pamphlet P-1-1965, which is
incorporated by reference as
specified in Sec. 1910.6.

20. Issue?
Photo: Bryan Haywood

21. 1910.107(g)(2)
• Cleaning.
• All spraying areas shall
be kept as free from the
accumulation of deposits
of combustible residues
as practical, with
cleaning conducted daily
if necessary.
• Scrapers, spuds, or other
such tools used for
cleaning purposes shall
be of nonsparking
material.
What could be the weaknesses
in citing this?

22. 1910.106(e)(2)(iv)(d)
• Flammable liquids shall be drawn
from or transferred into vessels,
containers, or portable tanks
within a building only through a
closed piping system, from safety
cans, by means of a device drawing
through the top, or from a
container or portable tanks by
gravity through an approved self-
closing valve.
• Transferring by means of air
pressure on the container or
portable tanks shall be prohibited.

23. September 2014

24. Ether accident
• Drop filling
• Worker sees sparks in
funnel
• Next thing he knows
he is on fire with
invisible flames

25. Self-Closing Safety Faucet
• Bonding wire
between drum and
container
• Grounding wire
between drum and
ground
• Safety vent in drum

26. Aug 2013
• Bruce Hall, 44, died early Tuesday
at Harborview Medical Center in
Seattle from burns suffered when
static electricity caused lacquer
fumes to ignite in an enclosed area
in the back of the shop.
• Hall was pouring the lacquer from
a barrel to a smaller container
through a funnel when the fumes
exploded, Missoula Fire Marshal
Gordy Hughes said.

27. Safety Pump
• Faster and safer than using a
faucet
• Spills less likely
• No separate safety vents in
drum required
• Installed directly in drum
bung opening
• Some pump hoses have
integral bonding wires

28. 1910.107(b)(5)(i)
• The spraying operations
except electrostatic spraying
operations shall be so
designed, installed and
maintained that the average
air velocity over the open
face of the booth (or booth
cross section during spraying
operations) shall be not less
than 100 linear feet per
minute.

29. 1910.119(d)(3)(ii)
• The employer shall
document that
equipment complies
with recognized and
generally accepted
good engineering
practices.

30. 1910.119(d)(3)(ii)
• OSHA considered, but
rejected, publishing a list of
RAGAGEP providers
• The employer (not OSHA!)
selects the applicable and
protective RAGAGEP it will
use / comply with!

31. Ammonia - IIAR (International
Institute of Ammonia
Refrigeration)
Bulletin 107 - Guidelines for: Suggested
Safety and Operating Procedures when
Making Refrigeration Plant Tie-Ins
Bulletin 108 - Guidelines for: Water
Contamination in Ammonia
Refrigeration System
Bulletin 109 - Guidelines for: IIAR
Minimum Safety Criteria for a Safe
Ammonia Refrigeration System
Bulletin 110 - Guidelines for: Start-Up,
Inspection and Maintenance of
Ammonia Mechanical Refrigerating
Systems
Potential Sources of RAGAGEP

32. Ammonia - IIAR
Bulletin 111 - Guidelines for:
Ammonia Machinery Room
Ventilation
Bulletin 112 - Guidelines for:
Ammonia Machinery Room
Design
Bulletin 114 - Guidelines for:
Identification of Ammonia
Refrigeration Piping and
System Components
Bulletin 116 - Guidelines for:
Avoiding Component Failure in
Industrial Refrigeration
Systems Caused by Abnormal
Pressure or Shock
Potential Sources of RAGAGEP

33. The Chlorine Institute
Numerous Standards for:
Chlorine
Sodium hypochlorite
Hydrogen Chloride
Hydrochloric Acid
Many pamphlets
available for free
download
– www.chlorineinstitute.org
Potential Sources of RAGAGEP

35. API – American Petroleum Institute
ASME – American Society of
Mechanical Engineers
NBIC – National Board Inspection
Code, The National Board of Boiler
and Pressure Vessel Inspectors
CCPS – American Institute of
Chemical Engineers, Center for
Chemical Process Safety
NFPA – National Fire Protection
Association
Potential Sources of RAGAGEP
Boiler leak

36. ANSI – American National
Standards Institute
NIOSH – National Institute for
Occupational Safety and Health
ASNT – American Society for
Non-Destructive Testing
ISA – International Society of
Automation
ISA-TR84.00.04 – Safety
Instrumented Systems
EPRI – Electric Power and
Research Institute
Potential Sources of RAGAGEP

37. Definitions
• Class I are areas where
flammable gases may be
present in sufficient
quantities to produce
explosive or flammable
mixtures.
• Class II locations can be
described as hazardous
because of the presence of
combustible dust.
• Class III locations contain
easily ignitable fibers A flammable painting room would be
Class I

38. Definitions
• Flammable liquid means
any liquid having a
flashpoint at or below
199.4 °F (93 °C).
Flammable liquids are
divided into four
categories as follows:
• Category 1 shall include
liquids having flashpoints
below 73.4 °F (23 °C) and
having a boiling point at
or below 95 °F (35 °C).
NFPA 30 3.3.33.2* Flammable
Liquid. Any liquid that has a
closed cup flash point below
100°F (37.8°C)
Class IA Liquid — Any liquid
that has a flash point below 73°F
(22.8°C) and a boiling point
below 100°F (37.8°C)

39. Definitions
• Category 2 shall include
liquids having flashpoints
below 73.4 °F (23 °C) and
having a boiling point
above 95 °F (35 °C).
Many flammable paints
and inks are Class 1B
Class IB Liquid — Any
liquid that has a flash point
below 73°F (22.8°C) and a
boiling point at or above
100°F (37.8°C)

40. Definitions
• Category 3 shall include
liquids having flashpoints
at or above 73.4 °F (23
°C) and at or below 140
°F (60 °C). When a
Category 3 liquid with a
flashpoint at or above
100 °F (37.8 °C) is heated
for use to within 30 °F
(16.7 °C) of its flashpoint,
it shall be handled in
accordance with the
requirements for a
Category 3 liquid with a
flashpoint below 100 °F
(37.8 °C)
Class IC Liquid — Any liquid that
has a flash point at or above 73°F
(22.8°C), but below 100°F (37.8°C)

41. Definitions• Category 4 shall include
liquids having flashpoints
above 140 °F (60 °C) and
at or below 199.4 °F (93
°C). When a Category 4
flammable liquid is
heated for use to within
30 °F (16.7 °C) of its
flashpoint, it shall be
handled in accordance
with the requirements
for a Category 3 liquid
with a flashpoint at or
above 100 °F (37.8 °C).
Class II Liquid — Any liquid
that has a flash point at or
above 100°F (37.8°C) and
below 140°F (60°C) (2) Class
III Liquid — Any liquid that
has a flash point at or above
140°F (60°C)
(a) Class IIIA Liquid — Any
liquid that has a flash point
at or above 140°F (60°C),
but below 200°F (93°C)
(b) (b) Class IIIB Liquid —
Any liquid that has a flash
point at or above 200°F
(93°C)

42. Flammable Liquid Storage
1910.106(e)(2)(ii)(b)
The quantity of liquid that may be
located outside of an inside
storage room or storage cabinet in
a building or in any one fire area of
a building shall not exceed:
25 gallons of Category 1 flammable
liquids in containers
120 gallons of Category 2, 3, or 4
flammable liquids in containers

43. Let’s count
• Cabinet or no
cabinet?

44. Inside Storage Room Requirements
• Fire resistant
construction
• Sprinklers
• Raised sills or
trench
• Fire doors
• Liquid tight (floor
to wall)
• Windows
• Capacity ratings
• Electrical
• Ventilation
• Storage
requirements
• Egress
• Leak procedures
• 29 CFR 1910.106(d)(4)

45. Fire Resistive Construction
• Walls per NFPA 251
• 29 CFR 1910.106(e)(3)(iii),
Flammable and Combustible
Liquids; Industrial Plants;
Unit Physical Operations;
Chemical Processes;
establishes that a firewall
may have a 2-hour fire
resistance rating.

46. Openings – Flammable Storage
• Non-combustible, liquid-
tight sills or ramps – 4”
• Open-grated trench in
alternative
• Storage area floor 4”
below surrounding floor,
in alternative

47. Flammable Storage Rooms
• Self closing fire door, per
NFPA 80-1968
• Floor to wall
construction shall be
liquid-tight

48. Flammable Storage
• Where other portions of
the building, or other
properties are involved,
protected windows are
required per NFPA 80-
1968
Flammable Storage rooms should
never have normal windows.

49. Other Acceptable Methods
• One inch nominal
thickness of wood is
acceptable for use in
shelves, racks, floor
overlays, etc

50. Storage Room Capacity
• Reference Table H-13 in
1910.106(d)(4)
• Capacity is dependent
on:
- room size
- fire resistant rating
- if fire protection is
available
(gals/cubic feet/floor area)
Electrical lighting of this type and
windows not allowed

51. Electrical
• Electrical installations
(lighting, receptacles,
etc) for Class I liquids
must meet Class I,
Division 2 Hazardous
location requirements in
Subpart S
• Electrical for Class II and
III is approved for
general use

52. Ventilation
• Gravity or mechanical
• Six air changes/hour
• Locate switch outside of
room – wired with
lighting

53. Inside Storage Rooms
• Minimum 3’ wide aisles
• No stacking of containers
over 30 gal
• Approved pump or self-
closing faucet for
dispensing

54. Leaking Containers
• Move leaking containers
either to storage room
or outside building to
transfer into intact
containers

55. Bonding and Grounding
• Many flash fires
from dispensing
flammables
from one
container to
another.

56. 2013
• State fire investigators think a
sparking forklift ignited a cloud of
propane in a storage yard about 10
p.m. July 29, touching off a blast
felt a mile away.
• Five employees were hospitalized
for months with severe burns. One
of the workers awoke from a coma
a month after the accident

57. Propane Storage
• NFPA 58
• The storage of propane in buildings
is limited:
• Buildings frequented by the public
are limited to cylinders with a
propane capacity of 1 pound.
• The total quantity stored is limited
to 200 pounds of propane.
• Buildings not frequented by the
public are limited to a maximum
quantity of 300 pounds of
propane.
• The cylinder size is not restricted.

58. PPE
• Hazard Assessment
required under
1910.132
• Fire Resistant
Clothing?

59. Paint Spray Booths
• A spray application
is also particularly
hazardous because
it creates fine
droplets of the
fluid, making the
fluid more ignitable
than when it is
applied with a
brush.

60. Effect of Lighting………
• Proper lighting (bright &
fluorescent) along with
light color painted walls
in the Spray Paint room
so that
workers/students can
see better when spray
painting.

61. Selection of Respirators
Employer must select and provide an
appropriate respirator based on the respiratory
hazards to which the worker is exposed and the
factors that affect respirator performance and
reliability.

62. A pressure gauge that indicates airflow outside the booth
will make it easier for instructors to determine when to
replace the booths air filters.

63. CLEAN FILTERS
• Replacing clogged air filters
keeps the paint booth’s
ventilation system working
efficiently to remove paint and
solvent mists, protecting the
painter and others from
overexposure to potentially
hazardous substances and
decreasing the risk of fire due to
flammable vapors.

64. FOLLOW GOOD HOUSEKEEPING
• Combustible
cardboard boxes
should not be
stored in the
booth and filters
are not stored
properly.

65. STORED CHEMICALS
• Store only the required
amount(s) of flammable liquid
for one classes usage at the
spraying area.

66. ERGONOMICS IN THE BOOTH

67. CHECK POINTS
• Are fire extinguishers installed near
all spraying areas? Ref:
1910.107(f)(4)

68. CHECK POINTS
• Are No smoking signs
conspicuously posted. Ref:
1910.107(g)(7)

69. CHECK POINTS
• Is all residue, scrapings, and debris
contaminated with residue
immediately removed from the
premises and properly disposed of?
Ref:1910.107(g)(3)

70. CHECK POINTS
• Are automatic sprinkler heads
located so as to provide water
distribution throughout the spray
booth? Ref: 1910.107(f)(1)

71. CHECK POINTS
• Is the electrical equipment in an
electrostatic hand spraying area
interlocked with the ventilation
system so that it cannot be turned
on unless the ventilation fans are
operating? Ref: 1910.107(I)(8)

72. CHECK POINTS
• Are approved metal waste cans
provided whenever rags or waste
are impregnated with finishing
material and are rags and waste
deposit in them immediately after
use? Ref:1910.107(g)(3)

73. CHECK POINTS
• Does the quantity of flammable or
combustible liquids that are kept in
the vicinity of spraying operations
exceed a supply needed for one
shift? Ref: 1910.107(e)(2)

74. CHECK POINTS
• Is a visible gauge, audible alarm, or
pressure-activated device installed
to ensure that the required air
velocity is maintained?
Ref:1910.107(b)(5)(i)

75. CHECK POINTS
• Are only fixed lighting units used as
a source of illumination? Ref:
1910.107(b)(10)

76. AVOIDANCE OF AIRBORNE
CONTAMINENTS
A properly working
ventilation system will
allow the avoidance of
time it takes to put on the
full body protection &
respirators. Ventilation
will prevent skin
absorption of hazardous
substances and inhalation
of fumes, mists or vapors
from paints or solvents.

77. NFPA 33
• Classified locations.

78. Open Spraying Locations

79. Some specific new NFPA 30
requirements.

80. Oxidizers
• 25 foot separation
from flammable and
combustible liquids

81. Detached Unprotected Buildings
• 1000 ft. separation
from most
occupancies. (Except
business, industrial,
mercantile, and
storage.)
• Want to avoid
assembly and health
care being too close.

82. Outdoor Storage
• Kept free of weeds,
debris and other
combustible material
within 10 feet

83. Processing Facilities
• Drainage to a safe
location to prevent
liquids accumulating
under vessel or load
bearing support

84. Flammable Liquid Use
• Flammable liquids
shall be kept in closed
tanks or containers
when not in use

85. Underground Storage Tanks
• Overfill prevention
equipment installed
to alert the transfer
operator that tank is
no more than 90%
full.

86. NFPA Read only access
• www.nfpa.org
• Set up alerts