Rome 23 November 2016 ing. Domenico CONTICCHIO INAIL Con.T.A.R.P.

Fireworks industry: critical issues and risk management

Symposium 2- Diversification of use of explosives and ammunition «Explosive safety management and risk analysis» Caserma E. Rosso della Città Militare della Cecchignola

Fireworks industry

The fireworks industry represents , and it is largely characterized by a scarce number of both factories and workers. Nevertheless in Italy - it is one of the most hazardous working environment, especially due to the seriousness of recorded accidents.

It is a productive sector regulated by a manifold and uncoordinated regulatory framework, with a 1930 Law about Public Security, which coexists with other more recent ones on safety at work. Firms are largely made up of small family-run business, sometimes characterized by a working risk underestimation and by an inadequate knowledge about safety legislation and procedures.

Fireworks industry: critical issue and risk management 23/11/2016 2 EXSPLOSING Factories 24 JULY 2015: ten deaths in Modugno (Puglia) 13 MAY 2015: four deaths in Qualiano (Campania) 28 FEBRUARY 2015: one death in Belmonte in Sabina (Lazio) 9 JULY 2014: Three deaths in Tagliacozzo (Abruzzo) 25 JULY 2013: five deaths in Città S. Angelo (Abruzzo) 12 SEPTEMBER 2011: six deaths in Arpino (Lazio) 2 FEBRUARY 2011: one death in Ceppaloni (Campania) 10 JANUARY 2011: two deaths in Santa Venerina (Sicilia) 6 FEBRUARY 2008: four deaths in Orvieto (Umbria) 11 MAY 2007: one death in Fermo (Marche) 23 APRIL 2007: Three deaths in Gragnano (Campania) 24 MAY 2006: two deaths in Mercato San Severino (Campania) 6 August 2005: three deaths in Ottaviano (Campania) 19 July 2005: two deaths in Teggiano (Campania) 5 July 2004: Five deaths in Giugliano (Campania) 30 August 2002: Three deaths in Visciano (Campania) 2 MAY 2002: three deaths in Terzigno (Campania)

Fireworks industry: critical issue and risk management 23/11/2016 3

Modugno (Bari) 24th July 2015, 12.30 p.m. A sequence of explosions in a factory causes 10 deaths. Possible causes of the accident are going to became clear. The explosion would have been happened inside the factory. A van had just unloaded material for fireworks production, that would have been used during a summer local festival. The blast ran over the people standing inside and outside the factory. Four labs were burned to the ground.

Fireworks industry: critical issue and risk management 23/11/2016 4 EXPLOSING Factories Bari considerations

Investigations on the accident occurred in Bari, July 2015, are still in progress.

The most accredited hypothesis make us lean towards a set of causal linked factors, among which: Human error in manipulation loading- unloading of materials. Simultaneous presence of lots of people inside labs. Frantic pace due to the overlap of orders in a narrow period. Quantity of explosive material higher than the allowed limits. Shortage of passive protection measures to oppose the domino effect.

Fireworks industry: critical issue and risk management 23/11/2016 5

INAIL Study

INAIL Having regard to the seriousness of the accidents and conscious of the CONTARP Puglia Ardito Vincenzo need of proposing prevention solutions and more effective protection, CONTARP Puglia Conticchio Domenico CONTARP Centrale Frusteri Liliana INAIL has set up a study concerning companies of the field included in the CONTARP Centrale Incocciati Emma CONTARP Centrale Marra Francesco rate subset Production of fireworks, arranging and conducting CONTARP Centrale Zarrelli Giambattista CSA Bucci Giuseppe fireworks shows, both for industrial and handicraft field. CSA RomualdiGina DITSIPIA BragattoPaolo Angelo The study is carried on by INAIL facilities (Technical Advice for Risk and DITSIPIA Pirone Annalisa DITSIPIA Vallerotonda M. Rosaria Prevention Verification, Statistical and Actuarial Advise, Technological

Innovations Department), in cooperation with the Central Management Central Management for Prevention and Technical Security of the Fire Fighters for Prevention and Technical Security of the Fire Fighters Department, of Department, of Public Aid and Civil Defence Public Aid and Civil Defence. Mazzaro Michele Imbrisco Marcella De Rosa Armando Emmanuele Roberto

Fireworks industry: critical issue and risk management 23/11/2016 6 Study Purposes

Risks analysis and Industrial Accident in favour of:

Employers and H&S Manager Employees

Support tools for risk Information sheets assessment and management (data sheets, check-lists, technical, organisational and procedural solutions)

Fireworks industry: critical issue and risk management 23/11/2016 7

Study Activities

1. Regulatory framework

2. Statistical survey: factories, workers, accidents

3. Accidental causes analysis

4. Critical issues analysis

5. Support tools for risk assessment

6.Information sheets for employees

Fireworks industry: critical issue and risk management 23/11/2016 8 Regulatory Framework

Reference standards for the production and storage of fireworks manufacturing products: Consolidated Law on Safety in working Environments Laws on Fire Prevention Laws on public security: particularly the Consolidated act of public security laws [TULPS] and its Implementing Regulation [RETULPS] Legislation on Relevant Risk of Accident activities: Legislative Decree n. 105/2015 (Seveso ter Directive)

Numerousness and complexity

Fireworks industry: critical issue and risk management 23/11/2016 9

Regulatory Framework

Factories and stores of explosives produce, hold and handle explosive material and must be designed and practiced in compliance with safety criteria established by the Implementing Regulation of the Consolidated act of Public Security Laws (RE.T.U.L.P.S.). In terms of the amount of present dangerous substances, some of the factories are also subject to regulations of Seveso III Directive, incorporated into national legislation by the Legislative Decree n. 105/2015.

Fireworks industry: critical issue and risk management 23/11/2016 10 Regulatory Framework Seveso Directive

The Legislative Decree n. 105/2015 provides for the introduction of a Safety Management System and, in that factories, the presentation of a Safety Report (design, construction, practice and maintenance of building must guarantee safety for employees, population and surrounding). analysis of relevant accidents must be carried out and a plan for the emergencies management must be determined.

Need of integration of TULPS requirements with Seveso Directive elements: reading and integrated implementation

Fireworks industry: critical issue and risk management 23/11/2016 11

Comparison between TULPS and SMS* requirements: example of integration/improvement 1/3

Critical issues: Explosive materials compatibility and stability Quality control, purity Packaging and traceability criteria

*Safety Management System

Fireworks industry: critical issue and risk management 23/11/2016 12 TULPS requirements: 2/3 Measures for: incompatibles segregation safe storage of explosive materials workplaces ventilation damaged products removal package piles arrangement criteria inside labs opening procedure of containers whithin explosive materials

Critical issues: in-out flow of materials regulation just for quantity control but not for stability lack of recommendation on walking spaces inside the storage areas lack of recommendation on microclimatic parameters (T, RU) inside the storage areas lack of references of explosive materials to MSDS* *Material Safety Data Sheet

Fireworks industry: critical issue and risk management 23/11/2016 13

SMS requirements in addition to TULPS: 3/3

Stability control of explosive materials by tests (if not provided by MSDS) Raw material quality control Suitable management storage (avoiding stability loss and/or substances decomposition) Materials in-out flow management in storage areas (avoiding explosives stockpile and long time parking) Microclimatic parameters maintenance in storage areas according to the MSDS data End products arrangement in limited height piles Suitable storage of end products with walking spaces width conformed to D. Lgs. 81/2008 requirements. Written operating procedures and workers training.

Fireworks industry: critical issue and risk management 23/11/2016 14 Statistical Survey Data sources used

In order to make a deep analysis about the accidents phenomena in the field (number of workers, factory sizes, etc.), the following statistical sources were consulted: Statistical database of INAIL e-MARS (Major accidents reporting system) Infor.MO (national supervision system of accidents at work) BARPI-ARIA (Bureau for Analysis of industrial risks and pollutions) Post-accidental inspections inside fireworks factories, carried out by INAIL staff (DIT researchers) involved into the relevant accident control activity (Seveso Directive).

Atti IX Convegno Contarp, Genova 5-7 ottobre 2016 «Reti, sinergie, appropriatezza, innovazione: professioni tecniche verso il futuro della salute e sicurezza sul lavoro», V. Ardito, P.A. Bragatto, G. Bucci, D. Conticchio, L. Frusteri, E. Incocciati, F. Marra, A. Pirone, G. Romualdi, M.R. Vallerotonda, G. Zarrelli: Analisi del fenomeno infortunistico nel settore pirotecnico, pag. 203 - 210

Fireworks industry: critical issue and risk management 23/11/2016 15

Table 1. Inail insured Policy (PAT) and workers in factory size Pyrotechnics field event years 2010-2014 (Source : INAIL CSA* - Statistics Database updated to 31.10.2015)

Tariff Firm PAT Number PAT Employees Number management size 2010 2011 2012 2013 2014 2010 2011 2012 2013 2014 From 1 to 9 41 44 43 39 39 60 61 57 45 52 employees Industry From 10 to 5 5 5 6 6 43 43 39 50 52 49 empl. From 1 to 9 252 256 253 249 254 383 380 385 364 352 employees Handicraft From 10 to 4 3 2 3 3 36 28 29 37 26 49 empl. From 1 to 9 293 300 296 288 293 443 441 442 409 405 employees Total From 10 to 9 8 7 9 9 79 71 68 88 78 49 empl.

*Actuarial Statistic Advice

Fireworks industry: critical issue and risk management 23/11/2016 16 Table 2. Inail insured Policy (PAT) and workers in geographical distribution event years 2010-2014 (Source: INAIL CSA - Statistics Database updated to 31.10.2015)

PAT Number PAT Employees Number Geographical distribution 2010 2011 2012 2013 2014 2010 2011 2012 2013 2014

North-West 14 15 16 20 20 51 51 48 51 45 North-East 35 32 23 25 26 85 77 76 77 79 Central 35 36 32 32 33 52 52 47 45 43 South 166 169 174 163 166 261 257 267 253 244 Islands 52 56 58 57 57 73 75 71 71 70 Italy 302 308 303 297 302 522 512 510 497 483

Fireworks industry: critical issue and risk management 23/11/2016 17

Examined case studies

In INAIL study, besides statistical office data, other different data sources [eMARS- Infor.MO BARPI_ARIA INAIL verifications] have been used. Overall, 41 cases were examined, among which:

4 from field experience of INAIL staff, Seveso 10 cases from eMARS 9 cases from Infor.MO 18 from BARPI_ARIA

Through accidents analysis the most recurring risk factors have been highlighted.

Fireworks industry: critical issue and risk management 23/11/2016 18 The main risk factors: INAIL study evidence

Organizational factors: missed quality control, lack or not application of procedures, lack of cleaning, lack of personal protective equipement, inadequate plants layout, hurry, illegal activities. Chemical factors: Inadequate raw material quality, inadequate additives, spontaneous combustion, production discards, storage incompatibility Mechanical factors: Impacts, falls, tool manufacturing/ inadequate equipment, malfunctioning/equipment flaws, accidents with inadequate means of transport Thermal factors: Overheating, ventilation Electrical factors: Electrostatic discharge, overcurrent, faulty contacts, devices breakdown, etc grindstone Natural factors: Storm/flood, heat and humidity wave, fulmination

Fireworks industry: critical issue and risk management 23/11/2016 19

Main risk factors Classified by statistical sources

Data Meeting VGR 2016 Assessment and Management of Risk in civilian and industrial areas - VIII edition «Insegnamenti appresi da incidenti recenti avvenuti in stabilimenti pirotecnici», Annalisa Pirone, Maria R. Vallerotonda, Paolo A. Bragatto, INAIL-DIT

Fireworks industry: critical issue and risk management 23/11/2016 20 Organizational/management factors

The results show that the main cause of accidents is connected with organizational and management factors, among which, the most relevant are: Missing knowledge/ fulfillment of operative safety procedures; Low cultural level on safety at work and human factor; Factory lay-out, that is operating area disposition and building distribution.

organizational/management factors

use of material locked in judicial warehouse 1,6% hurry/lack of workers 1,6% missing quality control 1,6% illegal activities 3,2% Personal Protective Equipement lack 6,5% other factors 9,7% layout 11,3% a not appliance of well-known safety procedures 29,0% ignorance/lack of procedures 35,5%

Fireworks industry: critical issue and risk management 23/11/2016 21

Organizational/management factors Factory lay-out Drying process in open The minimal configuration of labs, as provided by 1940 laws, should be updated, in order to make safer some of the manufacturing cycle phases. For instance:

It is necessary to provide a separated space for drying process of component. A not perfectly dry product, after the ignition of the fuse, could deform and explode inside the mortar.

The planning of Component store within elementary components of fireworks, avoids the wrong storing of the all material inside the ended products store, risking accidental primers.

Fireworks industry: critical issue and risk management 23/11/2016 22 Passive protection considerations Passive protection in buildings construction, particularly concerns the roofs containing explosives. INADEQUATE asbestos cement covering leaning to: on wooden girders be the smallest obstacle to the devastating power of explosions have lightness properties offer the best protection from water seepage guarantee good thermal insulation features.

A good building solution is represented by self- supporting roof panels with polyurethane foam insulation, which offers a sufficient opposition against the breach from the outside to the inside area, in case of burning bodies projection coming from explosions of different places (domino effect of explosions).

Fireworks industry: critical issue and risk management 23/11/2016 23

Main risk factors analysis Chemical factors The most critical are: Employment of low quality raw material; A scarce cleaning of working spaces.

CHEMICAL FACTORS 30,0% 26,3%

25,0% 21,1% 21,0% 20,0% 15,8% 15,0% 10,5% 10,0% 5,3% 5,0%

0,0% missing cleaning inadequate quality of incompatibility other chemical inadequate additives scrap og raw materials among materials factors manufacturing

Fireworks industry: critical issue and risk management 23/11/2016 24 Critical issues and proposals

CONCLUSIONS

Arising from the document of the Permanent Advisory Committee

th 2013) and from first results emerged from Inail study about pyrotechnics field,

Fireworks industry: critical issue and risk management 23/11/2016 25

It is necessary to operate mainly on: Regulatory simplification and coordination, specific for production of fireworks articles. Dissimilarity in verification methods of technical abilities of civilian personnel as regards to the education provided for the sappers of the Armed Forces. Inadequate knowledge and education of employees. Compulsory professional and updating educational career. I Review of factory lay-out in modern terms and promulgation of guidelines for a safe construction of pyrotechnics labs. Quality controls of raw material and incoming components. Use of machineries and tools appropriate to the risks. Choice of personal protective equipement appropriate to the risk and training course for their right use. Quality of the inspection activities and implementation of stricter and deeper periodic supervisions inside factories.

To support factories to take advantages of economical subsidies that Inail proclaims each year, in order to improve safety conditions in working environments.

Fireworks industry: critical issue and risk management 23/11/2016 26