This news article featured in issue no.13 in CHSP’s April 2022 newsletter
In a tragic incident on 21st September 2020, two contract workers at Evergreen Packaging Mill lost their lives due to a fire caused by the use of an electric heat gun on flammable resin. This accident underscores the critical need for rigorous risk assessments and adherence to hot works procedures in hazardous work environments, particularly confined spaces.
Incident Overview
Two blast core workers were refinishing a vessel’s interior surface at Evergreen Packaging. Working in cooler temperatures, they noticed the resin they were applying was not setting properly, so they attempted to warm it using an electric heat gun. This improvised method was neither planned nor approved in advance, which left other workers in a connected vessel unaware of the potential risks. At around 5:15 a.m., the heat gun accidentally fell into the bucket of flammable resin, igniting a fire that tragically led to the death of two workers who inhaled smoke while attempting to evacuate.
Key Safety Measures to Prevent Similar Tragedies
Risk Assessment for Variations: Any changes in work activities, especially those involving flammable materials or confined spaces, should be preceded by a risk assessment and training. This review might have highlighted a safer alternative non/ less flammable resin to be used, or a safer method of warming resin, potentially outside the confined area.
Strict Hot Works Procedures: The incident could have been mitigated by a hot works procedure to address the use of ignition sources like heat guns. An alternative, such as a space heater located outside the space with a duct blowing into the area, providing a remote heat source or an infrared heater, may have been a more feasible solution with due thought on the length of time used and how and where it is located so as not to cause obstruction or be obstructed. Monitoring of temperature to ensure the flashpoint isn’t reached.
Clear Communication: Involving all workers and consulting with Evergreen Packaging could have ensured everyone was informed about the hazards in the vessel, including the flammable materials and the use of a heat gun, which is an ignition source even without a visible flame.
Confined Space Rescue Plans: Rescue provisions specifically designed for confined spaces could have provided immediate response options and ensured rescuers were on standby for emergencies.
COSHH Assessment: Proper assessment would have identified the resin’s flashpoint, underscoring the fire risks involved with heating the substance.
Lesson for All Industries
Heatco, the contractor involved, may have overlooked the potential of a heat gun as an ignition source simply because it doesn’t produce a visible spark. This serves as a critical reminder that all work equipment should be thoroughly assessed for hazards, even when non-sparking.
Safety Message
Review hazardous chemicals and equipment used in the workplace, from industrial to everyday cleaning supplies. Conduct risk assessments and consult workers on potential hazards to ensure everyone’s safety—prevention starts with planning.
What safety risks are associated with using a heat gun near flammable resin?
Using a heat gun near flammable resin can cause ignition if the gun overheats or comes into direct contact with the resin. This can result in rapid fire spread, especially in confined spaces where heat and fumes can quickly build up, endangering workers’ lives.
How can risk assessments prevent accidents in hazardous work environments?
Conducting a risk assessment prior to starting or altering any work activity can identify potential hazards, such as ignition risks when using equipment like heat guns. These assessments help in planning safer alternatives, such as warming resin outside confined spaces and using safer heat sources.
What are ‘hot works procedures’ and why are they important?
Hot works procedures are safety protocols for activities involving heat sources or potential ignition sources. They are crucial in identifying safe practices, such as proper equipment and safe locations, to prevent fires in environments with flammable materials.
Why is a confined space rescue plan essential?
A confined space rescue plan is essential as it ensures there is an immediate, well-coordinated response if an emergency occurs. In high-risk environments, a dedicated rescue plan with standby rescuers can be lifesaving during accidents like fires or toxic fume exposure.
How can clear communication improve safety in shared work environments?
Clear communication between all workers and management ensures everyone is aware of ongoing activities and hazards. In environments with flammable materials, communication is vital for coordinated safety and for preventing incidents that could impact others working nearby.