Hazardous Materials Accident Report
Rupture of a Railroad Tank Car
Containing Hazardous Waste
Near Clymers, Indiana
February 18, 1999

NTSB Number HZM-01/01
NTIS Number PB2001-917002
PDF Document(1.4M) 

Abstract: About 12:05a.m. on February18, 1999, railroad tank car UTLX643593, which was on the west unloading rack at the Essroc Cement Corporation (Essroc) Logansport cement plant near Clymers, Indiana, sustained a sudden and catastrophic rupture that propelled the tank of the tank car an estimated 750 feet and over multistory storage tanks. The 20,000-gallon tank car initially contained about 161,700pounds (14,185gallons) of a toxic and flammable hazardous waste that was used as a fuel for the plant’s kilns. There were no injuries or fatalities. Total damages, including property damage and costs from lost production, were estimated at nearly $8.2million.

The National Transportation Safety Board determines that the probable cause of the accident was the failure of Essroc Cement Corporation and CP Recycling of Indiana management to develop and implement safe procedures for offloading toluene diisocyanate matter wastes, resulting in the overpressurization of the tank car from chemical self-reaction and expansion of the toluene diisocyanate matter wastes.

This report discusses the following safety issues:

• Sufficiency of safety requirements addressing the procedures used for loading and offloading railroad tank cars and other bulk containers used to transport hazardous materials;
• Adequacy of inspection and testing requirements for pressure relief devices on railroad tank cars;
• Adequacy of provisions addressing changes in product service for railroad tank cars; and
• Adequacy of the U.S. Department of Transportation Hazardous Materials Regulations pertaining to the notification and reporting of hazardous materials incidents.

As a result of its investigation of this accident, the Safety Board makes recommendations to the Federal Railroad Administration, the Research and Special Programs Administration, the Association of American Railroads, the Railway Progress Institute, the Lyondell Chemical Company, the Olin Corporation, the Essroc Cement Corporation, and CP Recycling, Inc., and Affiliated Companies. The Safety Board also reiterates one recommendation to the Research and Special Programs Administration.