Pollution
Humain
Environnement
Economique

Fire and explosions broke out on site manufacturing polyurethane resins for car seat cushions; the site is a lower tier seveso establishment due to a bulk storage of toluene diisocyanate (TDI).

During factory shut down, contractors were removing redundant pipework in factory area using oxy-acetylene torch. Sparks from hot work ignited combustible material. The contractors noticed flames at 09:15 and sounded the alarm at 09:17. All on site personnel were evacuated to the car park. A gas cylinder exploded at 09:20 and flames shot through the roof of the building. Services suspended traffic for 24 hours on the local railway line. The local population was advised to stay indoors and keep windows closed as a precautionary measure.

No sprinkler system was installed, the main factory unit was destroyed, including the loss of 0.5 t of TDI in day tanks in the process area. The costs were estimated at 2 M euros. The main road alongside the factory was closed for approximately 2 weeks following the incident, and subsequently 4 weeks to allow demolition work to take place.

Neither on-site casualties nor off-site effects were reported, even if some firewater run off into nearby river. The integrity of the TDI bulk storage was maintained by cooling the tanks; the storage were unaffected.

Inadequacies within the permit to work system allowed hot work to be carried out in area from which combustible materials had not been excluded. The operator will revise its safety procedures (including hot work permits).