ALUMINUM ASSOCIATION

MOLTEN METAL INCIDENT REPORT

Date of Incident: / Predominant Plant Activity: / SELECT ONE:ReductionRecyclingRollingExtrusionOther - please specify
(month/year)
Explosion Force – Mark One: / Force 1Characterization:Property Damage - NoneLight - MinimalSound - Short CrackingVibration - Short SharpMetal Dispersion - <15' (4.5m) Radius / Force 2Characterization:Property Damage - MinorLight - FlashSound - Loud ReportVibration - Brief RollingMetal Dispersion - 15-50' (4.5 - 15 m) Radius / Force 3Characterization:Property Damage - ConsiderableLight - IntenseSound - PainfulVibration - Massive StructuralMetal Dispersion - >50' (15 m) Radius
For definition of force, click arrow to see a description
Alloy / Metal Temperature / °F °C / Approximate Amount of Metal Involved / lbs kilograms

OPERATION:

Charging / Melting / Type of Furnace / SELECT ONE:ReverbTopchargingSide Bay ChargingInductionOther - please specify
Furnace Capacity / lbs mt / % Full
Materials Charged
Outside Storage? / Yes / No / Preheat? / Yes / No / Preheat Time/Temp: / hrs / °F °C
Transfer Type / SELECT ONE:CrucibleDrain PanTroughOther - Please List
Casting Type / SELECT ONE:D.C.HorizontalContinuous StripPermanent MoldSandOther - please speficy Type of Product being Cast: SELECT ONE:Billet/Round IngotSheet IngotT-BarCast Shape1-30kg Sow30-300 kg Sow> 300 kg Sow
Stage of Operation: / SELECT ONE:Start-UpTerminationSteady State
Other Describe
Number of Injuries by Type: Minor Severe Fatal
Provide a brief description of the incident and its root cause(s):
.
______
If Charging/Melting Incident, please select appropriate Primary and Secondary cause(s):
PRIMARY CAUSE:Wet Scrap or DrossContaminated Scrap with oils, plastics, flammablesFertilizer or other oxidizerWet Primary Metal RSI or Alloying MaterialContainer with liquidSolid with trapped liquidWet Salt FluxAluminum FinesAmmunition or other explosiveWet Skim Tools - Large Fork TrucksWet Charging EquipmentWet FloorWet Sample LadleWet Skimming / Stirring ToolTime Constraints / RushingOther
SECONDARY CAUSE:Wet Scrap or DrossContaminated Scrap with oils, plastics, flammablesFertilizer or other oxidizerWet Primary Metal, RSI or Alloying MaterialContainer with liquidSolid with trapped liquidWet Salt FluxAluminum FinesAmmunition or other explosiveWet Skim Tools - Large Fork TrucksWet Charging EquipmentWet FloorWet Sample LadleWet Hand Skimming / Stirring ToolTime Constraints / RushingOther
If Contaminations (other than moisture) was selected, please specify:
SELECT ONE:Aersol CanClosed ContainerPlasticsFertilizerOrdinanceExplosivesOther / If Transfer Incident, please select appropriate Primary and Secondary cause(s):
PRIMARY CAUSE:Wet or Rusty Drain PanWet Trough/LaunderWet Hand ToolWet MoldWet Fluxing RotorWet Skim Tools - Large Fork TruckWet Alloying Material in TroughWet SiphonWet FloorWet SpoutExcessive Cl2Time Constraints / RushingOther
SECONDARY CAUSE:Wet or Rusty Drain PanWet Trough/LaunderWet Hand ToolWet MoldWet Fluxing RotorWet Skim Tools - Large Fork TruckWet Alloying Material in TroughWet SiphonWet FloorWet SpoutExcessive Cl2Time Constraints / RushingOther / If Casting Incident, please select appropriate Primary and Secondary cause(s):
PRIMARY CAUSE:Bleed-out or Bleed-overIngot Head Became Submerged in WaterIngot Hung-up in MoldExcess Butt CurlButt Curl Control Equipment ProblemWater Control ProblemMetal Level Control ProblemMetal Temperature ControlWater on Bottom BlockEquipment Not Preheated SufficientlyEquipment Set-up Not ProperEquipment FailureWet Mold RefractoryMold Oil FailureProcedures Not FollowedCast Rate Not Controlled ProperlyInadequate Water Level in PitPoor Protective Coating On Equipment or Pit WallsTime Constraints / RushingOtherCorrect Cast Recipe Not InstalledCast Recipe not Designed Properly
SECONDARY CAUSE:Bleed-out or Bleed-overIngot Head Became Submerged in WaterIngot Hung-up in MoldExcess Butt CurlButt Curl Control Equipment ProblemWater Control ProblemMetal Level Control ProblemMetal Temperature ControlWater on Bottom BlockEquipment Not Preheated SufficientlyEquipment Set-up Not ProperEquipment FailureWet Mold RefractoryMold Oil FailureProcedures Not FollowedCast Rate Not Controlled ProperlyInadequate Water Level in PitPoor Protective Coating On Equipment or Pit WallsTime Constraints / RushingOtherCorrect Cast Recipe Not InstalledCast Recipe not Designed Properly
If Bleed-out/Bleed-over is selected above, describe reason for Bleed-out or BleedOver:
If Explosion due to Bleed-out/Bleed-over was selected above, where was the location of Explosions:
SELECT ONE:Water Trapped on Bottom BlockWater Trapped on Bottom Block BaseIngot HeadCasting Pit WallsBottom of Casting PitOther
If Metal Level Control Problem was selected above, please specify location of problem:
SELECT ONE:Ingot HeadTrough/LaunderOther

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Please return to:
Curt Wells
Director, Regulatory Affairs
The Aluminum Association.
1400 Crystal Drive, Suite 430
Arlington, VA 22202
When you have completed the form please send it as an attachment or fax the form to 703-358-2961.

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