When explosives are improperly stored in the workplace, all it takes is a single spark to turn a normal day into a disaster zone. But, when proper safety protocols are followed, you can avoid these sorts of situations.
Explosives are essential in industries like mining, construction, and demolition. However, improper storage and handling can lead to catastrophic accidents.
Recent news from the U.S. Department of Labor has cast a spotlight on workplace safety, particularly concerning the handling of hazardous materials.
The case of an Orlando aerospace facility, now facing $262,451 in proposed penalties following a December 2024 fire that hospitalized employees, highlights the severe consequences of failing to adhere to OSHA standards regarding the storage and use of explosives.
Here, we’ll break down what happened at the facility, and OSHA’s requirements for safe explosives storage, handling, and transportation, along with best practices to prevent workplace disasters.
Related Article: 7 Key Steps to Prevent Workplace Chemical Fires.
Related Article: 7 Steps to Keeping Fireworks Industry Workers Safe.
OSHA Cites Orlando Aerospace Facility
The U.S. Department of Labor has cited an aerospace facility in Orlando for multiple safety and health violations following a fire that injured several workers.
Workers were subjected to fire, burning, and inhalation risks when working on missile parts. Two employees were severely burned, while a third suffered burns and smoke inhalation. Additionally, OSHA found that improper handling and storage of explosives put numerous others at risk, as well as failure to properly label hazardous materials.
Ultimately, the company received citations for one willful and six serious violations, resulting in over $262K in penalties.
The company has 15 business days from receipt of the citations and penalties to comply, request an informal conference with OSHA, or contest the findings before the independent Occupational Safety and Health Review Commission.
This highlights the potentially devastating human cost of neglecting safety processes and protocols.
Why Proper Handling of Explosives Is Essential
Explosives are inherently dangerous. They can cause havoc such as explosions, fires, leakage of dangerous chemicals and even permanent health complications for workers when handled or stored improperly.
Dangers of Improper Explosives Handling Include:
– Fire and Explosion: All it takes is one slip-up to cause fires, explosions, and create rampaging blazes too fierce to control, placing all nearby workers at immediate risk.
– Toxic Exposures: Most explosives produce toxic fumes, leading to acute or long-term respiratory and systemic health effects.
– Physical Injuries: In addition to burns, explosions may lead to flying objects and loss in hearing, as well as injuries due to crushes.
– Environmental Hazards: Improper storage can lead to leaks or contamination, thus extending harm to outside communities and life.
See OSHA’s Guideline on Process Safety Management for Explosives and Pyrotechnics Manufacturing.
OSHA Standards on Explosives and Hazardous Materials
Workplace safety regulations for explosives are among the most strictly enforced due to their inherently high risks.
Key OSHA standards and guidelines include:
- Explosives and Blasting Agents – 29 CFR 1910.109
This core standard covers:
– Storage: Requirements for separate, secure storage magazines (e.g. buildings or containers) in terms of distance to an occupied space. Proper storage requirements also cover strict controls over temperature, humidity, and ventilation.
– Handling: Safe procedures of movement, inspection, and accounting of explosives in day-to-day work.
– Labeling: Mandates clear, uniform labels on every piece of storage and handling equipment.
– Training: Employers are required to train every employee that deals with explosives in safe procedures, identification of hazards, and emergency action.
- Hazard Communication (HazCom) Standard – 29 CFR 1910.1200
Employers must:
– Categorize the risks of all chemicals used or stored in the workplace.
– Make sure that chemicals, such as explosives, are branded with hazard warnings.
– Make Safety Data Sheets (SDS) available to employees.
– Conduct regular training and briefing on recent updates to chemical hazard and safe practices.
- Process Safety Management (PSM) – 29 CFR 1910.119
For high-risk operations, PSM requires:
– Full risk-assessments.
– Operating procedures that are written.
– Programs ensuring mechanical integrity.
– Emergency preparedness and response programs.
– All incidents and near-misses to be investigated and causes eliminated.
Steps to Ensure Explosive Safety at Worksites
The established OSHA standards provide the safest workspace possible when dealing with explosives.
To comply with these rules:
- Conduct Hazard Evaluations: Monitor each stage of storage, handling and usage regularly to identify the risks.
- Install Controls and Safeguards: Put in fire suppression systems, install emergency alarms, and maintain clearly marked escape routes that are well lit.
- Train Your Team: Use constant and comprehensive training on how to handle explosives safely, as well as steps to take during an emergency.
- Store and Label Properly: Use appropriate containers and maintain secure, clearly marked storage areas.
- Documented and Review Procedures: Maintain updated safety plans and accident records. Review them regularly to enhance safety.
See HAZWOPER/OSHA Guidelines on Types of Chemical Hazards & How to Manage Them.
The Cost of Non-Compliance
Besides significant OSHA penalties, as seen in the Orlando Aerospace Facility case, the cost of improper handling of explosives is too often paid in workplace injuries, loss of life, and damage to business reputation.
Every employer must recognize the enormous responsibility (and legal mandate) to protect workers from explosive and chemical hazards.
Key Takeaways
Explosives safety isn’t just about avoiding OSHA fines—it’s about protecting lives. Recent enforcement cases prove that neglecting proper storage distances, employee training, or magazine specifications can have devastating consequences.
By using approved storage facilities to maintaining strict detonator separation—employers transform compliance into a lifesaving practice. Remember: In high-risk industries, there’s no room for shortcuts. Invest in training, enforce safety protocols relentlessly, and make ‘zero incidents’ an achievable standard rather than an aspiration.
Remember: when working with explosives, the margin for error is zero.
Stay In Compliance With Worksite Medical
In most cases, OSHA requires medical surveillance testing, and at no cost to employees.
Worksite Medical makes that program easier with mobile medical testing.
We conduct silica exam physicals, on-site respirator fit tests (including N95 masks), audiometric exams, pulmonary function tests, heavy metal lab work, and much more, right on your job site.
We also keep accurate, easy-to-access medical records for your convenience. You’ll keep your employees at work, and stay ahead of OSHA inspections.
With Worksite Medical, a mobile medical testing unit — we can bring all the resources of a lab to you. Our certified lab technicians can perform both qualitative and quantitative respirator tests to ensure a perfect fit.
You’ll keep your employees at work, and stay ahead of OSHA and MSHA inspections.
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Give us a call at 1-844-622-8633, or complete the form below to schedule an on-site visit or to get your free quote.
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