A tragic accident at a metal-treating plant in Chattanooga, Tennessee, has raised serious concerns about workplace safety. The explosion, which occurred in 2024, claimed the life of one worker and left three others injured. The U.S. Chemical Safety and Hazard Investigation Board (CSB) released a report detailing the incident and highlighting significant safety failures at the plant, owned by the French company HEF Groupe.
The TS USA facility specializes in hardening metals through a process called nitriding. The explosion happened when a drain hole in a roller cylinder became clogged while submerged in a molten salt bath. This blockage caused the unit to erupt, resulting in severe burns to a worker who later died. The explosion also sparked multiple fires and caused an estimated $1.3 million in damages, leading to an eight-month shutdown of the facility.
The CSB’s investigation revealed that TS USA had not implemented effective safety management systems or learned from previous incidents. In fact, there had been at least three similar accidents at other HEF Groupe facilities, including one at the Chattanooga plant just a year earlier. Despite these incidents, the parent company did not share vital safety information across its operations.
CSB Chairperson Steve Owens emphasized the importance of a robust safety management system in preventing such tragedies. He noted that the lack of strong safety protocols put workers at significant risk, culminating in this heartbreaking loss.
Following the investigation, the Tennessee Occupational Safety and Health Administration imposed a minor penalty of $6,600 on the company. However, the CSB did not recommend any fines or penalties. Instead, it outlined several recommendations to enhance safety at the plant. These include installing physical barriers to protect employees from molten salt spills, developing a comprehensive safety management system, and ensuring effective communication of safety information across all HEF Groupe facilities.
The CSB also shared key lessons for the metal-treating industry. It urged companies to adopt safety management systems even without regulatory requirements, incorporate safer design concepts into hazard analyses, and establish incident investigation programs that communicate findings across all levels of the organization.
This incident serves as a stark reminder of the critical need for safety in industrial settings. The full report from the CSB is available for those interested in a deeper understanding of the events and recommendations.