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The CSB investigated an incident involving a series of explosions at the Hayes Lemmerz manufacturing plant in Huntington, Indiana. The explosions were likely the result of a dust explosion in the dust collector system for the aluminum scrap processing area. No review was performed to address why the chip system was releasing excess dust, and the hazards of aluminum dust were neither identified nor addressed. Contributing causes include inadequate housekeeping in the foundry area and insufficient maintenance of the chip feed ducts that lead to the dust accumulation and fueled the secondary deflagration. The CSB issued safety recommendations based on these root and contributing causes.
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