Aluminum extrusion plants are essential to many industries, transforming raw aluminum into a wide range of products. However, the intense heat and complex machinery involved in the extrusion process pose significant risks to workers. One particularly dangerous event that can occur is a steam flash – a rapid vaporization of water that can result in severe burns and other injuries. When molten aluminum comes into contact with water, the resulting steam flash can lead to powerful explosions, putting workers’ lives at risk.
That is exactly what happened last week at Zarbana Aluminum Extrusion in Columbiana, Ohio. Officials are investigating a steam flash last week that injured three people.
In today’s blog, the workplace injury attorneys at Kherkher Garcia will explore how steam flashes occur, the hazards they present, and what legal recourse injured workers may have following such an incident at an aluminum extrusion plant.
Steam Flash Incident Details
The U.S. Department of Labor’s Occupational Safety and Health Administration (OSHA) is investigating an incident at Zarbana Aluminum Extrusion in Columbiana that injured three employees on Thursday night. According to Columbiana Fire Chief Jim Douglas, the incident was a “steam flash,” not an explosion. The workers were pouring molten aluminum, at around 800 degrees, into a container with a water jacket, which caused the overflow and subsequent steam flash.
The injured employees are being treated for burns, with two transported to local hospitals by ambulance and one taken by medical helicopter to a hospital in Pittsburgh. The incident occurred around 7:52 p.m., prompting a large response from firefighters, police, and EMS. The fire department confirmed minor damage to the building, and no information on the employees’ conditions has been released.
OSHA has six months to complete its investigation and determine whether any health or safety violations occurred, which could result in citations or penalties.
What is a Steam Flash?
A steam flash, also known as a flash steam event, occurs when water is rapidly heated to its boiling point and turns into steam in an almost instantaneous process. This can happen when hot liquids, such as molten metal, come into contact with cooler water. In this process, the intense heat causes the water to quickly vaporize, leading to a rapid expansion of steam. Since steam occupies much more space than water, this sudden expansion can create a violent release of pressure.
Risks of a Steam Flash:
- Burn Injuries: The rapid release of high-temperature steam can cause severe burns to anyone nearby. Steam carries more heat than boiling water and can cause deep tissue damage.
- Explosions: Though not technically an explosion, the rapid expansion of steam can result in a powerful blast-like force, causing projectiles or structural damage.
- Pressure Build-Up: If contained in a closed system, the sudden steam generation can cause dangerous pressure levels that may rupture equipment or cause additional damage.
- Chemical Reactions: In industrial settings, the combination of heat, metal, and water can trigger secondary chemical reactions, potentially leading to more hazards.
- Visibility Issues: The steam generated can create clouds that obscure vision, increasing the risk of further accidents.
Industries working with molten metals, like aluminum, are particularly susceptible to steam flash incidents, making safety protocols crucial.
What are the General Hazards of Working in Aluminum Extrusion?
Working in aluminum extrusion involves several hazards due to the high temperatures, heavy machinery, and specific materials used in the process. Here are some key hazards workers might encounter:
High Temperatures and Burn Risks
- Molten Aluminum: The extrusion process involves heating aluminum to extremely high temperatures (often over 900°F). Contact with molten aluminum or hot equipment can cause severe burns.
- Steam Flash: If molten aluminum comes into contact with water, a steam flash can occur, leading to explosions or burn injuries from the rapid vaporization of water.
Mechanical Hazards
- Pinch Points and Crush Injuries: Extrusion presses and heavy machinery pose the risk of pinch points, which can trap body parts, leading to crush injuries or amputations.
- Conveyor Systems: Conveyor belts and rollers used to transport aluminum can also create hazards, such as entanglement or getting caught between moving parts.
- Shearing and Cutting: Cutting tools used to trim the extruded aluminum may cause lacerations or sever limbs if proper safeguards are not in place.
Exposure to Toxic Fumes
- Metal Fumes: The heating of aluminum can release harmful fumes, including oxides and gases. Prolonged exposure without proper ventilation or respiratory protection can lead to respiratory issues like metal fume fever or long-term lung damage.
- Hydraulic Fluids and Lubricants: Workers may also be exposed to fumes from the lubricants and hydraulic fluids used in the machinery, which can cause health issues if inhaled in large quantities.
Physical Strain
- Heavy Lifting: Workers are often required to lift and move heavy materials, increasing the risk of musculoskeletal injuries like back strain.
- Repetitive Motion Injuries: Repeated movements over time can lead to repetitive strain injuries (RSIs), including carpal tunnel syndrome or tendonitis.
Noise Exposure
- The extrusion process involves loud machinery, and prolonged exposure to high noise levels without hearing protection can cause permanent hearing loss.
Fire and Explosion Hazards
- The aluminum dust created during cutting and finishing processes is highly flammable. Inadequate dust control can lead to fires or even dust explosions.
Electrical Hazards
- Extrusion plants often use high-powered machinery that poses electrical hazards if wiring is faulty, equipment is damaged, or safety procedures are not followed.
Slip, Trip, and Fall Hazards
- Spilled lubricants, hydraulic fluids, or debris on the floor can cause workers to slip, trip, or fall, potentially leading to serious injuries.
Proper safety training, personal protective equipment (PPE), regular maintenance, and emergency protocols are essential to mitigate these risks in aluminum extrusion environments.
What Legal Recourse do Victims of a Steam Flash Have?
Victims of a steam flash incident at an aluminum extrusion plant have several potential avenues for legal recourse depending on the circumstances of the incident and the nature of their injuries. These include:
Workers’ Compensation
- Automatic Coverage: In most states, workers’ compensation laws require employers to provide benefits to employees who are injured on the job, regardless of fault. This typically covers medical expenses, lost wages, and disability benefits.
- Limited Damages: While workers’ compensation is relatively straightforward to claim, it often limits the types of damages a worker can recover. Pain and suffering are generally not covered under workers’ compensation.
Personal Injury Lawsuit
- Third-Party Claims: If a party other than the employer was responsible for the steam flash, such as a contractor, equipment manufacturer, or maintenance company, the injured worker may file a personal injury lawsuit. For example, if faulty equipment caused the steam flash, the manufacturer may be liable under product liability law.
- Negligence: If it can be proven that the employer or a third party was negligent in maintaining equipment, training workers, or providing safety measures, the victim may pursue compensation through a personal injury lawsuit. In such cases, the injured worker could recover damages for pain and suffering, emotional distress, and loss of quality of life in addition to medical expenses and lost wages.
Wrongful Death Lawsuit
- If a worker dies as a result of a steam flash, their surviving family members may file a wrongful death lawsuit. This type of claim allows family members to seek compensation for the loss of income, funeral expenses, and the emotional pain of losing a loved one.
OSHA Violations and Legal Implications
- If an investigation by the OSHA uncovers safety violations that contributed to the steam flash, the injured worker may have a stronger case for pursuing legal action. An OSHA investigation could also lead to fines or penalties against the employer, further supporting the worker’s legal claim.
Product Liability Claims
- If the steam flash was caused by faulty machinery, defective equipment, or unsafe working conditions due to improper design, a product liability lawsuit could be filed. Manufacturers or suppliers of faulty equipment may be held liable if their products are deemed dangerous or fail to function as intended.
Negligence of Employer
- In rare cases, if an employer was grossly negligent or intentionally disregarded known safety risks, workers may be able to bypass the workers’ compensation system and file a lawsuit directly against the employer. This would allow them to pursue additional damages beyond what workers’ compensation provides.
Victims of a steam flash should consult with an experienced workplace injury attorney to understand their rights and the best course of legal action. An attorney can help identify potential defendants, gather evidence, and pursue the maximum compensation allowed under the law.
Get Help after a Workplace Injury
If you have been injured on the job, you may be entitled to compensation for your medical bills, lost wages, and pain and suffering. At Kherkher Garcia, our experienced workplace injury attorneys are here to help you navigate the complex legal process and fight for your rights. Whether your injury was caused by unsafe working conditions, equipment failure, or employer negligence, we will work tirelessly to get you the compensation you deserve.
If you have questions about a workplace injury or illness, contact Kherkher Garcia today for a free consultation. Let us help you secure your future after a workplace injury. Call 713-333-1030, or complete our online contact form to get started.
Image by onlyyouqj on Freepik
