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Occupational Safety and Health Administration

Inspection Detail

Inspection: 306860461 - Hayes Lemmerz Intl.

Inspection Information - Office: Indiana

Nr: 306860461Report ID: 0551800Open Date: 10/30/2003

Hayes Lemmerz Intl.
1870 Riverfork Dr.
Huntington, IN 46750
Union Status: NonUnion
SIC: 3365/Aluminum Foundries
NAICS: 331524/Aluminum Foundries (except Die-Casting)

Inspection Type:Accident
Scope:Partial Advanced Notice:N
Ownership:Private
Safety/Health:Health Close Conference:02/26/2004
Planning Guide: Health-Manufacturing Close Case:10/07/2005

Related Activity:TypeIDSafetyHealth
 Accident362665101    

Violation Summary
Serious Willful Repeat Other Unclass Total
Initial Violations 6 6
Current Violations 6 6
Initial Penalty $42,000 $0 $0 $0 $0 $42,000
Current Penalty $42,000 $0 $0 $0 $0 $42,000
FTA Amount $0 $0 $0 $0 $0 $0

Violation Items
# ID Type Standard Issuance Abate Curr$ Init$ Fta$ Contest LastEvent
  1. 01001 Serious 2200080101 04/29/2004 05/18/2004 $7,000 $7,000 $0 -
  2. 01002 Serious 19100307 B02 II 04/29/2004 05/18/2004 $7,000 $7,000 $0 -
  3. 01003 Serious 19101200 H03 II 04/29/2004 05/18/2004 $7,000 $7,000 $0 -
  4. 01004 Serious 19100022 A01 04/29/2004 05/18/2004 $7,000 $7,000 $0 -
  5. 01005 Serious 19100132 A 04/29/2004 05/18/2004 $7,000 $7,000 $0 -
  6. 01006A Serious 19100252 A02 V 04/29/2004 05/18/2004 $7,000 $7,000 $0 -
  7. 01006B Serious 19100252 A02 VIC 04/29/2004 05/18/2004 $0 $0 $0 -

Accident Investigation Summary
Summary Nr: 170365944Event: 10/29/2003Aluminum Dust Explosion Injures Six Employees And Kills One
At approximately 8:30 p.m. on October 29, 2003, an explosion occurred at a Hayes Lemmerz International, Inc. plant that manufactured cast alloy aluminum wheels. On the day of the explosion, a fire occurred in the chip-melt exhaust duct of furnace #5. As is common practice in the plant, when an aluminum fire occurs in the exhaust duct, the ventilation system is turned off to allow the fire in the duct to self-extinguish. After the ductwork had cooled down the ventilation system was started up again, and a fireball and pressure wave came through the system ductwork and back into the building from the chip-melt area of furnace #5. The fire lofted and ignited additional aluminum dust that had accumulated on rafters and equipment in the plant. The fire spread throughout the plant. One employee was killed and six others were injured. Two of the six injured employees were hospitalized, and the other four employees were transported to an emergency care facility and released after treatment.
Keywords: burn, duct, aluminum dust, casting, fire, dust collector, explosion, combustible dust, housekeeping, pressure release
Inspection Degree Nature Occupation
1 306860461 Hospitalized injury Burn/Scald(Heat) Machinery maintenance occupations
2 306860461 Hospitalized injury Burn/Scald(Heat) Machinery maintenance occupations
3 306860461 Fatality Burn/Scald(Heat) Machinery maintenance occupations

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