Industrial Incidents Caused by Communication Failure¶
Communication failures — between shifts, between contractors and facility staff, between field operators and control room, or between management layers — have repeatedly allowed hazardous conditions to persist or escalate. These CSB investigations document specific communication breakdowns and the systemic factors — lack of written handover, language barriers, unclear roles — that made them possible.
49 investigations
Industries: Chemical Manufacturing, Petroleum Refining, Oil And Gas Production
Years: 1998–2024
Incidents (49)¶
| Incident | Date | Location | Key Hazards |
|---|---|---|---|
| T2 Laboratories Inc. Reactive Chemical Explosion | 12/19/2007 | Jacksonville, FL | Runaway Reaction, Thermal Runaway |
| Environmental Enterprises Hydrogen Sulfide Release | 12/11/2002 | Cincinnati, OH | Hydrogen Sulfide Release, Toxic Release |
| Optima Belle Explosion and Fire | 12/08/2020 | Belle, WV | Explosion, Fire |
| Marathon Martinez Renewable Fuels Fire | 11/19/2023 | Martinez, CA | Fire, Chemical Release |
| DPC Enterprises Glendale Chlorine Release | 11/17/2003 | Glendale, AZ | Toxic Release, Chemical Release |
| DuPont La Porte Facility Toxic Chemical Release | 11/15/2014 | La Porte, TX | Toxic Release, Chemical Release |
| Wacker Polysilicon Chemical Release | 11/13/2020 | Charleston, TN | Chemical Release, Toxic Release |
| Valero Delaware City Refinery Asphyxiation Incident | 11/05/2005 | Delaware City, DE | Asphyxiation |
| Aghorn Operating Inc. Waterflood Station Hydrogen Sulfide Release | 10/26/2019 | Odessa, TX | Hydrogen Sulfide Release, Toxic Release |
| First Chemical Corp. Reactive Chemical Explosion | 10/13/2002 | Pascgoula, MS | Runaway Reaction, Explosion |
| PEMEX Deer Park Chemical Release | 10/10/2024 | Deer Park, TX | Hydrogen Sulfide Release, Toxic Release |
| EQ Hazardous Waste Plant Explosions and Fire | 10/05/2006 | Apex, NC | Fire, Explosion |
| Xcel Energy Company Hydroelectric Tunnel Fire | 10/02/2007 | Georgetown, CO | Fire, Flash Fire |
| Evergreen Packaging Paper Mill - Fire During Hot Work | 09/21/2020 | Canton, NC | Fire |
| BP - Husky Oregon Chemical Release and Fire | 09/20/2022 | Oregon, OH | Chemical Release, Fire |
| Bayer CropScience Pesticide Waste Tank Explosion | 08/28/2008 | Institute, WV | Runaway Reaction, Explosion |
| DPC Enterprises Festus Chlorine Release | 08/14/2002 | Festus, MO | Chemical Release, Toxic Release |
| Barton Solvents Explosions and Fire | 07/17/2007 | Valley Center, KS | Explosion, Fire |
| Enterprise Pascagoula Gas Plant Explosion and Fire | 06/27/2016 | Moss Point, MS | Chemical Release, Explosion |
| Philadelphia Energy Solutions (PES) Refinery Fire and Explosions | 06/21/2019 | Philadelphia, PA | Chemical Release, Explosion |
| Goodyear Heat Exchanger Rupture | 06/11/2008 | Houston, TX | Overpressure, Chemical Release |
| ConAgra Natural Gas Explosion and Ammonia Release | 06/09/2009 | Garner, NC | Explosion, Ammonia Release |
| Didion Milling Company Explosion and Fire | 05/31/2017 | Cambria, WI | Dust Explosion, Explosion |
| TS USA Molten Salt Eruption | 05/30/2024 | — | Explosion, Overpressure |
| Kaltech Industries Waste Mixing Explosion | 04/25/2002 | New York , NY | Runaway Reaction, Explosion |
| Formosa Plastics Vinyl Chloride Explosion | 04/23/2004 | Illiopolis, IL | Explosion, Fire |
| Macondo Blowout and Explosion | 04/20/2010 | — | Explosion, Fire |
| MFG Chemical Inc. Toxic Gas Release | 04/12/2004 | Dalton, GA | Runaway Reaction, Toxic Release |
| Morton International Inc. Runaway Chemical Reaction | 04/08/1998 | Patterson, NJ | Runaway Reaction, Thermal Runaway |
| Union Carbide Corp. Nitrogen Asphyxiation Incident | 03/27/1998 | Hahnville, LA | Asphyxiation, Toxic Release |
| BP America (Texas City) Refinery Explosion | 03/23/2005 | Texas City, TX | Explosion, Fire |
| Carbide Industries Fire and Explosion | 03/21/2011 | Louisville, KY | Explosion, Overpressure |
| CTA Acoustics Dust Explosion and Fire | 02/20/2003 | Corbin, KY | Dust Explosion, Fire |
| Concept Sciences Hydroxylamine Explosion | 02/19/1999 | Allentown, PA | Explosion, Chemical Release |
| Tesoro Martinez Sulfuric Acid Spill | 02/12/2014 | Martinez, CA | Chemical Release, Toxic Release |
| Packaging Corporation of America Hot Work Explosion | 02/08/2017 | Deridder, LA | Explosion, Fire |
| Kleen Energy Natural Gas Explosion | 02/07/2010 | Middletown, CT | Explosion, Chemical Release |
| Technic Inc. Ventilation System Explosion | 02/07/2003 | Cranston, RI | Explosion, Fire |
| Bethlehem Steel Corporation Gas Condensate Fire | 02/02/2001 | Chesterton, IN | Fire, Explosion |
| West Pharmaceutical Services Dust Explosion and Fire | 01/29/2003 | Kinston, NC | Dust Explosion, Explosion |
| Foundation Food Group Fatal Chemical Release | 01/28/2021 | Gainesville , GA | Chemical Release, Asphyxiation |
| Honeywell Geismar Chlorine and Hydrogen Fluoride Releases | 01/23/2023 | Geismar, LA | Chemical Release, Explosion |
| DuPont Belle Toxic Chemical Releases | 01/23/2010 | Belle, WV | Toxic Release, Chemical Release |
| Pryor Trust Fatal Gas Well Blowout and Fire | 01/22/2018 | Pittsburg County, OK | Explosion, Fire |
| BLSR Operating Ltd. Vapor Cloud Fire | 01/13/2003 | Rosharon, TX | Vapor Cloud Explosion, Flash Fire |
| Bethune Point Wastewater Plant Explosion | 01/11/2006 | Daytona Beach, FL | Explosion, Fire |
| Freedom Industries Chemical Release | 01/09/2014 | Charleston, WV | Chemical Release, Toxic Release |
| Texas Tech University Chemistry Lab Explosion | 01/07/2010 | Lubbock, TX | Explosion, Runaway Reaction |
| Sierra Chemical Co. High Explosives Accident | 01/07/1998 | Mustang, NV | Explosion, Fire |
Common Patterns¶
Across these 49 investigations, the CSB consistently found communication failure alongside these co-occurring failure modes, industries, and hazard types:
Co-occurring failure modes: Procedural Failure · Design Deficiency · Training Deficiency · Management of Change Failure · Human / Operator Error
Primary industries: Chemical Manufacturing, Petroleum Refining, Oil And Gas Production
Associated hazard types: Chemical Release · Explosion · Fire · Toxic Release
Data sourced from CSB.gov public investigation reports. This site is an independent project not affiliated with the U.S. CSB.