Abstract: On December 6, 2002, the drive belt for an off-bearing conveyor broke down on an aluminum crusher at a die cast foundry, causing aluminum to back up against the crusher head of a hammer mill. The heat resulting from the continual action of the crusher head upon the backed up aluminum, combining with residual cutting oils on the metal and aluminum shavings, caused a fire and explosion when the jam was beginning to clear, presumably exposing the combustible materials to adequate oxygen. The explosion blew the crusher door open, burning a nearby Employee #1. Employee #2 was injured when he suddenly stood up, hit his head on machinery, and fell 4.5-feet into a nearby pit surrounding the machine. The burned Employee #1 received first-, second- and some third-degree burns to his upper body, face and arms. He was hospitalized, and received ongoing burn treatment. Employee #2 injured his neck and shoulders and was treated at the hospital and released.