How are fireworks made? How does safety work for technicians working in firework and firework manufacturing facilities?
On the eve of one of many holidays around the world that use fireworks to celebrate, this week’s newsletter is all about fireworks. We all know basic firework safety tips for setting them off at home, but what happens behind the scenes, before the fireworks are set off or even delivered to the site…
How are Fireworks Made?
Due to secrecy across the industry, not much is known about the details of manufacturing fireworks. They are comprised of fuel, oxidizer, and special chemicals or minerals to produce colors. Stars and special effects are made from paper, plastics, and different chemicals. It is then all packed into a shell or tube in an order that releases the effects at the right time. (1) (2)
Worker Safety in Firework Manufacturing Facilities
It is easy to imagine that with all of the combustible and flammable material necessary at firework manufacturing facilities, even a small flame can be devastating to the entire operation and its employees. (3)
Examples of incidents include:
In 2014 in China, a blast occurred from friction generated by an employee sweeping highly combustible rice hulls.
In 2022, workers in the Magic in the Sky warehouse in Orlando, Florida suffered from a preventable deadly fire and explosion in which 4 employees lost their lives and a fifth was hospitalized for months with near-fatal injuries. The accident happened in the storage facility as the team readied the fireworks for a show. (4)
In Thailand in January 2024, an explosion at a firework manufacturing facility took the lives of an estimated 20 workers and left the worksite completely demolished and hurting members of the surrounding community. (3)
Firework Manufacturing Safety Suggestions and Requirements
A 2023 study of over 100 firework manufacturing accidents in China revealed the biggest risk factors as safety education and training, worker physical and mental state/health, and workplace management. (3) The concept of robust safety education and training is something that can be applied to pyrotechnic manufacturing worldwide.
A main part of worker safety is making sure the facilities they are working in are safe and operating correctly. OSHA urges companies to build pyrotechnic facilities which:
are built to reduce the risks of fires and explosions
are one story in height without basements or other subfloors
contain a weak/breakaway wall facing away from other process or storage buildings to direct any explosions away from other explosive materials
contain smooth interior wall and ceiling surfaces with no cracks or crevices
contain interior finishes that are noncombustible or have limited combustibility
use heating provided by steam, hot water, or indirect hot air radiators
have no exposed nail heads
have proper ventilation
contain two exits in every area of undivided floor more than 100 square feet
Due to the explosive or pyrotechnic materials used to manufacture fireworks, OSHA’s safety regulations for employees include:
no use of stoves, exposed flame (including smoking), or electrical heaters in any building where fireworks or firework components are/may be present
wearing clothing (provided by the employer) that is made of cotton with nonferrous fasteners and conductive footwear to reduce the danger of generating static electricity – protective clothing to be worn in plant only
proper PPE, including respiratory protection, fire resistant clothing, safety goggles, gloves, and ear protection (6)
using nonsparking tools
abandoning firefighting efforts if the fire involves or could spread to explosive material – EVACUATE
good cleaning and housekeeping practices in the plant to avoid accumulation of dust and flammable/combustible waste
training provided by employer on safety practices in the plant
Firework Manufacturing Safety – Conclusion
Fireworks bring joy and are used to celebrate by many, but their creation involves significant risks and requires meticulous safety measures. The firework manufacturing process remains somewhat shrouded in secrecy, yet it is clear that the combination of combustible materials requires stringent safety protocols. Ensuring the safety of workers in pyrotechnic facilities is vital, necessitating complete safety education, proper facility design, and strict adherence to regulations.
By implementing these safety measures, the industry can continue to provide dazzling displays while protecting the lives of those who make it possible.
There are three basic electrical hazards that cause injury and death: shock, arc-flash, and arc-blast. Following these safety principles can result in a safer work environment and prevent injuries or even death.
There are three basic electrical hazards that cause injury and death: shock, arc-flash, and arc-blast. Following these safety principles can result in a safer work environment and prevent injuries or even death.
It's hard to imagine belt conveyors anywhere playing a more important role than at South Africa's Kendal Power Station. Here, the world's largest black-coal-fired electrical generating complex converts up to 1.4 million tons a month into more than 4100 megawatts, enough to supply three cities the size of nearby greater Johannesburg.
It's hard to imagine belt conveyors anywhere playing a more important role than at South Africa's Kendal Power Station. Here, the world's largest black-coal-fired electrical generating complex converts up to 1.4 million tons a month into more than 4100 megawatts, enough to supply three cities the size of nearby greater Johannesburg.
In 2001, close to 100,000 people were treated in U.S. Hospital emergency rooms for eye injuries related to the workplace, yet this figure actually only represents a small portion of the total number of injuries. According to the U.S. Bureau of Labor Statistics, each day, as many as 2,000 workers incur eye injuries related to their jobs. According to Prevent Blindness America (PBA), 90% of these injuries are preventable.
In 2001, close to 100,000 people were treated in U.S. Hospital emergency rooms for eye injuries related to the workplace, yet this figure actually only represents a small portion of the total number of injuries. According to the U.S. Bureau of Labor Statistics, each day, as many as 2,000 workers incur eye injuries related to their jobs. According to Prevent Blindness America (PBA), 90% of these injuries are preventable.
In this advisory, we are going to demonstrate how hazardous, documented, service, repair, and troubleshooting recommendations have proliferated the fluid power industry, leaving unsuspecting persons vulnerable to possible injury or death. Unsafe service, repair, and troubleshooting recommendations are running rampant throughout the fluid power industry - and there is no end in sight!
In this advisory, we are going to demonstrate how hazardous, documented, service, repair, and troubleshooting recommendations have proliferated the fluid power industry, leaving unsuspecting persons vulnerable to possible injury or death. Unsafe service, repair, and troubleshooting recommendations are running rampant throughout the fluid power industry - and there is no end in sight!
About 80 percent of maintenance mistakes involve human factors (HF), according to the Federal Aviation Administration. The maintenance world has unique HF issues that are more severe and longer lasting than elsewhere in aviation. Operators are looking at various techniques to combat HF challenges.
About 80 percent of maintenance mistakes involve human factors (HF), according to the Federal Aviation Administration. The maintenance world has unique HF issues that are more severe and longer lasting than elsewhere in aviation. Operators are looking at various techniques to combat HF challenges.
Hydraulic systems must store fluid under high pressure. Three kinds of hazards exist: burns from the hot, high pressure spray of fluid; bruises, cuts or abrasions from flailing hydraulic lines; and injection of fluid into the skin. Safe hydraulic system performance requires general maintenance. Proper coupling of high and low pressure hydraulic components and pressure relief valves are important safety measures.
Hydraulic systems must store fluid under high pressure. Three kinds of hazards exist: burns from the hot, high pressure spray of fluid; bruises, cuts or abrasions from flailing hydraulic lines; and injection of fluid into the skin. Safe hydraulic system performance requires general maintenance. Proper coupling of high and low pressure hydraulic components and pressure relief valves are important safety measures.
Hour after hour, in businesses of all sizes, these workhorses respond to the men and women who operate them – by pounding, cutting, crushing, welding, stitching or whatever other task they were designed for, to fashion the products that will be marketed to hungry consumers. But there is a fearful downside to this scenario: the machine cannot distinguish between a piece of wood, steel or fabric and the operator’s body.
Hour after hour, in businesses of all sizes, these workhorses respond to the men and women who operate them – by pounding, cutting, crushing, welding, stitching or whatever other task they were designed for, to fashion the products that will be marketed to hungry consumers. But there is a fearful downside to this scenario: the machine cannot distinguish between a piece of wood, steel or fabric and the operator’s body.
Because maintenance departments are often recognized as caretakers of company safety initiatives, they're inundated with all things safety: messages, procedures, meetings, checks, equipment, training and permits, etc. Despite their good intentions, however, some maintenance professionals still get hurt on the job. To understand why, we need only to draw a parallel with automobile accidents.
Because maintenance departments are often recognized as caretakers of company safety initiatives, they're inundated with all things safety: messages, procedures, meetings, checks, equipment, training and permits, etc. Despite their good intentions, however, some maintenance professionals still get hurt on the job. To understand why, we need only to draw a parallel with automobile accidents.
Work-related deaths at U.S. manufacturing plants declined 14.0 percent in 2007, marking a rebound from the 16.0 percent increase that occurred in 2006. This was among the findings of the new Census of Fatal Occupational Injuries report released recently by the U.S. Department of Labor's Bureau of Labor Statistics.
Work-related deaths at U.S. manufacturing plants declined 14.0 percent in 2007, marking a rebound from the 16.0 percent increase that occurred in 2006. This was among the findings of the new Census of Fatal Occupational Injuries report released recently by the U.S. Department of Labor's Bureau of Labor Statistics.
For management, new and untrained employees present a different set of costly challenges. For example, productivity will drop due to lost time, there may be overtime expenses, insurance costs will rise and there can be potential lost customer sales. Worker's compensation claims will also increase and lead to higher premiums. How can these problems be avoided? What are some steps that can be put in place to help alleviate these concerns for new and untrained workers already in the workforce? Ideally, health and safety programs that offer basic training will fit the bill quite nicely. New and untrained workers need to learn about personal protective equipment (PPE), back-injury prevention, health and safety regulations and hazard recognition.
For management, new and untrained employees present a different set of costly challenges. For example, productivity will drop due to lost time, there may be overtime expenses, insurance costs will rise and there can be potential lost customer sales. Worker's compensation claims will also increase and lead to higher premiums. How can these problems be avoided? What are some steps that can be put in place to help alleviate these concerns for new and untrained workers already in the workforce? Ideally, health and safety programs that offer basic training will fit the bill quite nicely. New and untrained workers need to learn about personal protective equipment (PPE), back-injury prevention, health and safety regulations and hazard recognition.
The challenge of managing the aspects of occupational health and safety (OH&S) in the workplace can often times feel overwhelming. There are many legal, moral and financial reasons for you to pay attention to OH&S obligations. With all of these challenges, it's important not to waste time, money or place efforts on things that simply don't work. In terms of successfully managing OH&S issues, the following Top 10 list includes some of the common errors that organizations make.
The challenge of managing the aspects of occupational health and safety (OH&S) in the workplace can often times feel overwhelming. There are many legal, moral and financial reasons for you to pay attention to OH&S obligations. With all of these challenges, it's important not to waste time, money or place efforts on things that simply don't work. In terms of successfully managing OH&S issues, the following Top 10 list includes some of the common errors that organizations make.
The issuance of safety eyewear to employees requires more than a handout. An important thing to remember when issuing safety eyewear is that in order to put your safety program into action, you need to communicate and educate your employees. Merely handing out free safety goggles and glasses and saying "wear these when you are working or else..." will only get you so far. Employees need to know why it is important to wear protective eyewear, and they need you to make it easy for them to do so effectively. It often helps to recite employee eye injury statistics to show workers the reality of the hazards around them, and give them a starting point for improvement.
The issuance of safety eyewear to employees requires more than a handout. An important thing to remember when issuing safety eyewear is that in order to put your safety program into action, you need to communicate and educate your employees. Merely handing out free safety goggles and glasses and saying "wear these when you are working or else..." will only get you so far. Employees need to know why it is important to wear protective eyewear, and they need you to make it easy for them to do so effectively. It often helps to recite employee eye injury statistics to show workers the reality of the hazards around them, and give them a starting point for improvement.
With literally thousands of dangerous materials being used/transported/discarded every day, the process of choosing protective clothing has become increasingly complex for today's safety and hygiene professional. It is important to understand the distinction between three broad types of protective garments used today. Generally classified as disposable, reusable, and limited-use garments, these three general categories provide a basic framework for clothing decisions.
With literally thousands of dangerous materials being used/transported/discarded every day, the process of choosing protective clothing has become increasingly complex for today's safety and hygiene professional. It is important to understand the distinction between three broad types of protective garments used today. Generally classified as disposable, reusable, and limited-use garments, these three general categories provide a basic framework for clothing decisions.
The notions "one tool does all" or "any tool will do" result in wasted effort, poor quality work, damage to the misused tool, and exposing the user to possible injury, according to the Hand Tools Institute, an association of American manufacturers of quality hand tools. As with hammers, pliers, wrenches and all other hand tools, design is a key element to the type of work a tool is intended to do properly and safely, says HTI. Clamps are no exception and should be selected to conform to the work they are to perform.
The notions "one tool does all" or "any tool will do" result in wasted effort, poor quality work, damage to the misused tool, and exposing the user to possible injury, according to the Hand Tools Institute, an association of American manufacturers of quality hand tools. As with hammers, pliers, wrenches and all other hand tools, design is a key element to the type of work a tool is intended to do properly and safely, says HTI. Clamps are no exception and should be selected to conform to the work they are to perform.
Reactive maintenance is here defined as all maintenance work that was scheduled less than 20 hours before it was executed. It makes sense that there is a strong correlation between safety incidents, injuries and reactive maintenance. In a reactive situation you might not take the time you should to plan and think before you take action. The urgency also call out the so common hero in maintenance crafts people and they take risks they should not take.
Reactive maintenance is here defined as all maintenance work that was scheduled less than 20 hours before it was executed. It makes sense that there is a strong correlation between safety incidents, injuries and reactive maintenance. In a reactive situation you might not take the time you should to plan and think before you take action. The urgency also call out the so common hero in maintenance crafts people and they take risks they should not take.
Life without standards would result in near chaos for both manufactures and consumers. Just think if you could not rely on the strength of a critical fastener in an aircraft fuselage, the quality of the glass in a high rise building, the voltage fluctuation of the electrical grid at a faraway vacation destination, a crucial replacement for an electrical motor, the purity of a critical medication or the mere annoyance of not finding a correct battery for that digital camera. In short, as consumers, we would soon notice the lack of standards when the safety, quality, fit, reliability and compatibility of the products we consume, purchase and rely on are compromised.
Life without standards would result in near chaos for both manufactures and consumers. Just think if you could not rely on the strength of a critical fastener in an aircraft fuselage, the quality of the glass in a high rise building, the voltage fluctuation of the electrical grid at a faraway vacation destination, a crucial replacement for an electrical motor, the purity of a critical medication or the mere annoyance of not finding a correct battery for that digital camera. In short, as consumers, we would soon notice the lack of standards when the safety, quality, fit, reliability and compatibility of the products we consume, purchase and rely on are compromised.
“Prevention is better than cure”, this proverb sounds rightly in case of maintenance also. If the maintenance is prevented, then the availability of the plant increases and the overall cost reduces. Every effort should be made to avoid maintenance, which can be achieved through continuous monitoring of equipment and upgrading the sophistication of the equipment through better design and process improvement.
“Prevention is better than cure”, this proverb sounds rightly in case of maintenance also. If the maintenance is prevented, then the availability of the plant increases and the overall cost reduces. Every effort should be made to avoid maintenance, which can be achieved through continuous monitoring of equipment and upgrading the sophistication of the equipment through better design and process improvement.
ISO 12100 is a fundamental safety standard being developed that will apply to a very broad array of machinery. There are many machines that have specific industry consensus standards that pertain to the particular equipment (e.g., power presses, robots, packaging machinery). There are many more machines for which no industry specific standard exists. In this case, the ISO “A level” standard ISO 12100 Safety of Machinery applies. Complying with the requirements of ISO 12100 is a critical first step in achieving mobility of equipment and consistent operations.
ISO 12100 is a fundamental safety standard being developed that will apply to a very broad array of machinery. There are many machines that have specific industry consensus standards that pertain to the particular equipment (e.g., power presses, robots, packaging machinery). There are many more machines for which no industry specific standard exists. In this case, the ISO “A level” standard ISO 12100 Safety of Machinery applies. Complying with the requirements of ISO 12100 is a critical first step in achieving mobility of equipment and consistent operations.
We as safety professionals aren't exempt. Have you seen this: Workers don't change their actions? Tell them again (with a why-didn't-you-listen undertone). Policies and procedures not followed? Write additional (and more detailed) rules. Training didn't change their behavior? Put them through the same training again and again (until they "get it"). Try, try, try again to solve safety problems, but don't confuse persistence with obstinancy.
We as safety professionals aren't exempt. Have you seen this: Workers don't change their actions? Tell them again (with a why-didn't-you-listen undertone). Policies and procedures not followed? Write additional (and more detailed) rules. Training didn't change their behavior? Put them through the same training again and again (until they "get it"). Try, try, try again to solve safety problems, but don't confuse persistence with obstinancy.
Certified mail has arrived. The letter carrier isn't Ed McMahon. Uh Oh! It's a citation package from the USDOL/OSHA. What do you do? You glance at the paperwork to be sure it really relates to an OSHA inspection at one of your sites. You notice some rather heavy penalties. You are shocked, irate and feel as if you've been branded "corporate slime." You try to convince yourself that you've been in lots of workplaces that are more dangerous than yours. You need this like a centipede needs sore feet. Options pop through you mind.
Certified mail has arrived. The letter carrier isn't Ed McMahon. Uh Oh! It's a citation package from the USDOL/OSHA. What do you do? You glance at the paperwork to be sure it really relates to an OSHA inspection at one of your sites. You notice some rather heavy penalties. You are shocked, irate and feel as if you've been branded "corporate slime." You try to convince yourself that you've been in lots of workplaces that are more dangerous than yours. You need this like a centipede needs sore feet. Options pop through you mind.
