In a cast iron foundry that alternates the use of two cupola furnaces every other day, an explosion occurred at 6.30 pm during furnace unloading (carried out via hatches placed underneath the furnace) of meltdown products into a tub. Coke, cast iron and slag were all strewn throughout the building and 30 m² of roof were destroyed. Emergency services were notified and all company personnel had to be evacuated. Positioned 10 m from the cupola furnace and equipped with a powerful hose to spray these products with water should a fire break out, an employee suffered burns to the face and arms and required 4 days of hospitalisation; a second employee went into shock and received treatment from fire-fighters at the scene.

According to the operator, a water / molten metal reaction would have caused the accident. The refractory cement enclosing the recovery tub had been set up the very same morning; moreover, the cement drying time was insufficient. The cost of material damage was estimated at 10,000 euros. A number of technical and organisational measures were adopted to limit the risk of a repeat accident: acquisition of 3 new tubs to ensure better alternation of equipment with adequate drying time for the refractory cement (36 hours); storage of tub contents in a zone protected from water; drying, by use of a gas burner, of the tub designated to receive the day’s furnace drop; installation of a sound alarm intended to warn personnel during the time of manipulation; updating of the list of individual protective gear (sorted by either specialisation or workstation); layout of an identifiable protection zone; and assignment of a staff member to unload the furnace as well as rewrite the procedure.

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