Home Foundry Steam Explosion - November 2022
Description of event:
The steam explosion shown was the result of molten bronze spilling onto damp concrete. A sheared hinge pin on the tongs being used caused the crucible to drop and spill nearly 19lbs of molten bronze. Superheating of the damp concrete caused the water trapped within the concrete to instantly turn to steam. With pressure exceeding the strength of the concrete, it exploded and sent approximately 4lbs of molten bronze airborne.
Aluminum Bronze:
https://www.ebay.com/itm/394229533249
Injuries:
The injuries included 1st and 2nd degree burns to my chest, abdomen, both arms, and thighs to a lesser extent. The largest 2nd degree burn was on my right flank and about the size of a credit card. As of today (45 days later), everything is scared over except one small spot on my right arm that refuses to heal (possibly 3rd degree says the Doc). Luckily, my face and the "famly jewels" were completely untouched.
Property damage:
Overall, the truck wasn't damaged too bad. The plastic trim at the top of the tailgate has a few burn marks. One piece of bronze managed to burn through the plastic, leaving a small hole. The back window has a graze mark that scoured the surface of the glass. Luckily, the truck was mostly covered with snow, which saved the paint.
A few things I've learned:
- Welding gloves provide less protection than I thought. (Open cuff and temp rating)
- Cotton burns like tissue paper
- Never melt on damp concrete
New safety equipment and protocols:
- Tongs inspected and pins replaced with Grade 8 (Class 10.9 metric) bolts.
- Plywood sheets cover the concrete in the work area
- Propane tanks moved to the opposite side of the furnaces and out of the work area. The hoses are elevated and covered with Nomex split sleeve wrap.
- Pyramex steel mesh face shield (blocks a lot of heat and doesn't fog up)
- CarbonX Balaclava
- CarbonX Level 10 gloves
- CarbonX long underwear
- CarbonX turtle neck undershirt
I'm surely forgetting a few things, but I'd highly recommend looking into CarbonX safety apparel. It's the new age apparel used in professional motorsports. 'Sheds molten metal' is stated on the tag. Unlike leather, it won't burn, char, or shrink and is rated up to 2600°F. I would order a size larger than you normally wear.
The steam explosion shown was the result of molten bronze spilling onto damp concrete. A sheared hinge pin on the tongs being used caused the crucible to drop and spill nearly 19lbs of molten bronze. Superheating of the damp concrete caused the water trapped within the concrete to instantly turn to steam. With pressure exceeding the strength of the concrete, it exploded and sent approximately 4lbs of molten bronze airborne.
Aluminum Bronze:
https://www.ebay.com/itm/394229533249
Injuries:
The injuries included 1st and 2nd degree burns to my chest, abdomen, both arms, and thighs to a lesser extent. The largest 2nd degree burn was on my right flank and about the size of a credit card. As of today (45 days later), everything is scared over except one small spot on my right arm that refuses to heal (possibly 3rd degree says the Doc). Luckily, my face and the "famly jewels" were completely untouched.
Property damage:
Overall, the truck wasn't damaged too bad. The plastic trim at the top of the tailgate has a few burn marks. One piece of bronze managed to burn through the plastic, leaving a small hole. The back window has a graze mark that scoured the surface of the glass. Luckily, the truck was mostly covered with snow, which saved the paint.
A few things I've learned:
- Welding gloves provide less protection than I thought. (Open cuff and temp rating)
- Cotton burns like tissue paper
- Never melt on damp concrete
New safety equipment and protocols:
- Tongs inspected and pins replaced with Grade 8 (Class 10.9 metric) bolts.
- Plywood sheets cover the concrete in the work area
- Propane tanks moved to the opposite side of the furnaces and out of the work area. The hoses are elevated and covered with Nomex split sleeve wrap.
- Pyramex steel mesh face shield (blocks a lot of heat and doesn't fog up)
- CarbonX Balaclava
- CarbonX Level 10 gloves
- CarbonX long underwear
- CarbonX turtle neck undershirt
I'm surely forgetting a few things, but I'd highly recommend looking into CarbonX safety apparel. It's the new age apparel used in professional motorsports. 'Sheds molten metal' is stated on the tag. Unlike leather, it won't burn, char, or shrink and is rated up to 2600°F. I would order a size larger than you normally wear.
