Industrial Incidents Caused by Design Deficiency¶
Design deficiencies are engineering flaws — in process design, equipment selection, layout, or relief system sizing — that created a fundamentally unsafe condition that operations and maintenance could not compensate for. CSB investigations in this category often find that the hazardous design was known or knowable before the accident, and that process hazard analyses failed to identify or adequately address it.
103 investigations
Industries: Chemical Manufacturing, Petroleum Refining, Plastics
Years: 1998–2024
Incidents (103)¶
| 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 |
| AL Solutions Fatal Dust Explosion | 12/09/2010 | New Cumberland, WV | Dust Explosion, Fire |
| Optima Belle Explosion and Fire | 12/08/2020 | Belle, WV | Explosion, Fire |
| NDK Crystal Inc. Explosion with Offsite Fatality | 12/07/2009 | Belvidere, IL | Explosion, Overpressure |
| Marcus Oil and Chemical Tank Explosion | 12/03/2004 | Houston, TX | Explosion, Fire |
| Delaware City Refining Company | 11/29/2015 | Delaware City, DE | Flash Fire, Fire |
| TPC Port Neches Explosions and Fire | 11/27/2019 | Port Neches, TX | Chemical Release, Explosion |
| ExxonMobil Baton Rouge Refinery Chemical Release and Fire | 11/22/2016 | Baton Rouge, LA | Chemical Release, Fire |
| CAI / Arnel Chemical Plant Explosion | 11/22/2006 | Danvers, MA | 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 |
| Allied Terminals Fertilizer Tank Collapse | 11/11/2008 | Chesapeake, VA | Chemical Release, Structural Failure |
| E. I. DuPont De Nemours Co. Fatal Hotwork Explosion | 11/09/2010 | Buffalo, NY | Explosion, Fire |
| Barton Solvents Flammable Liquid Explosion and Fire | 10/29/2007 | Des Moines, IA | Fire, Explosion |
| Hayes Lemmerz Dust Explosions and Fire | 10/29/2003 | Huntington, IN | Dust Explosion, Fire |
| Aghorn Operating Inc. Waterflood Station Hydrogen Sulfide Release | 10/26/2019 | Odessa, TX | Hydrogen Sulfide Release, Toxic Release |
| Caribbean Petroleum Corporation (CAPECO) Refinery Tank Explosion and Fire | 10/23/2009 | Bayamón, PR | Chemical Release, Explosion |
| First Chemical Corp. Reactive Chemical Explosion | 10/13/2002 | Pascgoula, MS | Runaway Reaction, Explosion |
| INDSPEC Chemical Corporation Oleum Release | 10/11/2008 | Petrolia, PA | Chemical Release, Toxic Release |
| US Ink Fire | 10/09/2012 | East Rutherford , NJ | Dust Explosion, Flash Fire |
| Formosa Plastics Propylene Explosion | 10/06/2005 | Point Comfort, TX | Chemical Release, Explosion |
| EQ Hazardous Waste Plant Explosions and Fire | 10/05/2006 | Apex, NC | Fire, Explosion |
| Isotec/Sigma Aldrich Nitric Oxide Explosion | 09/21/2003 | Miami Township, OH | Explosion, Chemical Release |
| BP - Husky Oregon Chemical Release and Fire | 09/20/2022 | Oregon, OH | Chemical Release, Fire |
| Bio Lab Conyers Chemical Release | 09/14/2020 | Conyers, GA | Thermal Runaway, Toxic Release |
| Arkema Inc. Chemical Plant Fire | 08/29/2017 | Crosby, TX | Fire, Chemical Release |
| AirGas Facility Fatal Explosion | 08/28/2016 | Pensacola, FL | Explosion, Runaway Reaction |
| Bayer CropScience Pesticide Waste Tank Explosion | 08/28/2008 | Institute, WV | Runaway Reaction, Explosion |
| Bio-Lab Lake Charles Chemical Fire and Release | 08/27/2020 | Lake Charles, LA | Runaway Reaction, Toxic Release |
| Millard Refrigerated Services Ammonia Release | 08/23/2010 | Theodore, AL | Ammonia Release, Chemical Release |
| Sterigenics Ethylene Oxide Explosion | 08/19/2004 | Ontario, CA | Explosion, Fire |
| DPC Enterprises Festus Chlorine Release | 08/14/2002 | Festus, MO | Chemical Release, Toxic Release |
| Chevron Richmond Refinery Pipe Rupture and Fire | 08/06/2012 | Richmond, CA | Chemical Release, Fire |
| Cuisine Solutions Ammonia Release | 07/31/2024 | Sterling, VA | Ammonia Release, Toxic Release |
| LyondellBasell La Porte Fatal Chemical Release | 07/27/2021 | La Porte, TX | Chemical Release, Toxic Release |
| Horsehead Holding Company Fatal Explosion and Fire | 07/22/2010 | Monaca, PA | Explosion, Fire |
| Honeywell Chemical Incidents | 07/20/2003 | Baton Rouge, LA | Chemical Release, Toxic Release |
| CITGO Refinery Hydrofluoric Acid Release and Fire | 07/19/2009 | Corpus Christi, TX | Fire, Chemical Release |
| Barton Solvents Explosions and Fire | 07/17/2007 | Valley Center, KS | Explosion, Fire |
| Motiva Enterprises Sulfuric Acid Tank Explosion | 07/17/2001 | Delaware City, DE | Explosion, Fire |
| Dow Louisiana Operations Explosions | 07/14/2023 | Plaquemine, LA | Explosion, Fire |
| Enterprise Pascagoula Gas Plant Explosion and Fire | 06/27/2016 | Moss Point, MS | Chemical Release, Explosion |
| Praxair Flammable Gas Cylinder Fire | 06/24/2005 | St. Louis, MO | Fire, Explosion |
| Philadelphia Energy Solutions (PES) Refinery Fire and Explosions | 06/21/2019 | Philadelphia, PA | Chemical Release, Explosion |
| Universal Form Clamp Co. Explosion and Fire | 06/14/2006 | Bellwood, IL | Vapor Cloud Explosion, Fire |
| Williams Olefins Plant Explosion and Fire | 06/13/2013 | Geismar, LA | Bleve, 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 |
| Midland Resource Recovery Explosion | 05/24/2017 | Barbour County, WV | Explosion, Runaway Reaction |
| Kuraray Pasadena Release and Fire | 05/19/2018 | Pasadena, TX | Chemical Release, Fire |
| Veolia Environmental Services Flammable Vapor Explosion and Fire | 05/04/2009 | West Carrollton, OH | Explosion, Fire |
| AB Specialty Silicones, LLC | 05/03/2019 | Waukegan, IL | Chemical Release, Explosion |
| Third Coast Industries Petroleum Products Facility Fire | 05/01/2002 | Brazoria County, TX | Fire, Pool Fire |
| Husky Energy Superior Refinery Explosion and Fire | 04/26/2018 | Superior, WI | Explosion, Fire |
| 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 |
| West Fertilizer Explosion and Fire | 04/17/2013 | West, TX | Fire, Explosion |
| MFG Chemical Inc. Toxic Gas Release | 04/12/2004 | Dalton, GA | Runaway Reaction, Toxic Release |
| D.D. Williamson & Co. Catastrophic Vessel Failure | 04/11/2003 | Louisville, KY | Overpressure, Explosion |
| Herrig Brothers Farm Propane Tank Explosion | 04/09/1998 | Albert City, IA | Bleve, Explosion |
| Yenkin-Majestic Resin Plant Vapor Cloud Explosion and Fire | 04/08/2021 | Columbus, OH | Vapor Cloud Explosion, Explosion |
| Giant Industries Refinery Explosions and Fire | 04/08/2004 | Gallup, NM | Chemical Release, Explosion |
| Morton International Inc. Runaway Chemical Reaction | 04/08/1998 | Patterson, NJ | Runaway Reaction, Thermal Runaway |
| Loy Lange Box Company Pressure Vessel Explosion | 04/03/2017 | St. Louis , MO | Explosion, Overpressure |
| KMCO LLC Fatal Fire and Explosion | 04/02/2019 | Crosby, TX | Vapor Cloud Explosion, Flash Fire |
| Tesoro Anacortes Refinery Fatal Explosion and Fire | 04/02/2010 | Anacortes, WA | Explosion, Fire |
| 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 |
| Intercontinental Terminals Company (ITC) Tank Fire | 03/17/2019 | Deer Park , TX | Fire, Pool Fire |
| BP Amoco Thermal Decomposition Incident | 03/13/2001 | Augusta, GA | Chemical Release, Explosion |
| Sonat Exploration Co. Catastrophic Vessel Overpressurization | 03/04/1998 | Pitkin, LA | Overpressure, Fire |
| 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 |
| ExxonMobil Torrance Refinery Explosion | 02/18/2015 | Torrance, CA | Explosion, Fire |
| Valero McKee Refinery Propane Fire | 02/16/2007 | Sunray, TX | Fire, Flash Fire |
| 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 |
| Imperial Sugar Company Dust Explosion and Fire | 02/07/2008 | Port Wentworth, GA | Dust Explosion, Explosion |
| 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 |
| Hoeganaes Corporation Fatal Flash Fires | 01/31/2011 | Gallatin, TN | Flash Fire, Dust Explosion |
| Synthron Chemical Explosion | 01/31/2006 | Morganton, NC | Runaway Reaction, Vapor Cloud Explosion |
| Little General Store Propane Explosion | 01/30/2007 | Ghent, WV | Chemical Release, Vapor Cloud Explosion |
| Wendland 1H Well Fatal Explosion | 01/29/2020 | Burleson County , TX | Explosion, Fire |
| 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 |
| Watson Grinding Fatal Explosion and Fire | 01/24/2020 | Houston, TX | Chemical Release, Explosion |
| 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 |
| Georgia-Pacific Corp. Hydrogen Sulfide Poisoning | 01/16/2002 | Pennington, AL | Hydrogen Sulfide Release, Toxic Release |
| BLSR Operating Ltd. Vapor Cloud Fire | 01/13/2003 | Rosharon, TX | Vapor Cloud Explosion, Flash Fire |
| Silver Eagle Refinery Flash Fire and Explosion and Catastrophic Pipe Explosion | 01/12/2009 | Woods Cross, UT | Flash Fire, Explosion |
| 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 |
| Sierra Chemical Co. High Explosives Accident | 01/07/1998 | Mustang, NV | Explosion, Fire |
| Catalyst Systems Inc. Reactive Chemical Explosion | 01/02/2003 | Gnadenhutten, OH | Explosion, Fire |
Common Patterns¶
Across these 103 investigations, the CSB consistently found design deficiency alongside these co-occurring failure modes, industries, and hazard types:
Co-occurring failure modes: Procedural Failure · Training Deficiency · Management of Change Failure · Human / Operator Error · Communication Failure
Primary industries: Chemical Manufacturing, Petroleum Refining, Plastics
Associated hazard types: Chemical Release · Fire · Explosion · Structural Failure
Data sourced from CSB.gov public investigation reports. This site is an independent project not affiliated with the U.S. CSB.