Safex Newsletter No.82 May 2025

In alignment with our previous newsletters, we commence our articles with a safety message from Gilles de Preux, the CEO of the SEE Group, headquartered in Switzerland.

We are pleased to announce the introduction of a new member to our Board of Governors. Christo Peltz from AECI Mining will be succeeding Neil Franklin, who has stepped down due to work commitments.

Progress on our website is being prioritized under the leadership of Andy Begg, Paulo Siquera, and Ludovic Turlin. A Basis of Safety section is now operational, and significant advancements have been made on the Safety Management System. Articles regarding both initiatives are presented by Andy and Paulo.

Johanne dela Rovere from EPC presents an article on the reinforcement of windows to withstand overpressure. An assessment of the resistance of installations to blast waves typically indicates that glazed joinery and glazing are prevalent weak points in infrastructure.

Diane Ginnane elaborates on a Safety Management System developed by Dyno Nobel. Dyno Nobel has introduced an innovative Explosives Management System (ExMS) that emphasizes the identification and management of critical activities, while establishing standards and procedures that define minimum requirements for all operations related to explosives and the security of sensitive hazardous substances.

From South Africa, BME’s Dr. Ramesh Dhoorgapersadh addresses risk management in reactive ground. Reactive ground refers to soil containing high concentrations of sulfides (typically iron or copper) that have the potential to react exothermically with ammonium nitrate-based explosives.

Johanne recently delivered a presentation at a technical conference in Belgium focused on SAFEX and the associated database. In her preparation, she identified key areas for improvement, which were subsequently communicated to the webmaster.

NIXT, a Corporate Associate Member in South Africa, successfully hosted a conference in April, during which they agreed to feature two presentations in our Newsletter. One presentation will cover the Track and Trace of Explosives by Rob Penny from Synertech, while the other will discuss the application of fungi in environmental cleanup, presented by Northwest University in collaboration with Dyno Nobel and Sasol.

The current list of Board Initiatives is accessible on the homepage of the website. Should any member wish to contribute to these work groups, please feel free to reach out to me.

We are pleased to announce that our upcoming Newsletter will be published at the end of October 2025. A reminder will be distributed to solicit contributions from industry professionals.

Additionally, we would like to remind you of our triannual Congress taking place in Lisbon in April 2026. The organization of this significant event in our calendar is progressing well. We are currently seeking a few more papers on incidents for discussion during our Member Day. Please reach out to me if you are interested in representing your company.

Until we meet again, please remain vigilant and prioritize your safety.

Principles of Safe Operation

By Paulo Siqueira and Andy Begg - March 2025

The cardinal principle of safe operation is simple: expose the minimum number of people to the smallest quantity of explosives for the shortest time possible, consistent with the task at hand.

But how can we achieve this in practice?
Two essential concepts come into play: Inherent Safety and the Basis of Safety (BOS).
Inherent safety focuses on designing systems to eliminate hazards at their source, reducing the need for external protective measures.

Meanwhile, the Basis of Safety aims to minimize any factors that could trigger an initiation and mitigate the consequences if one occurs. Together, they form a powerful approach to safeguarding both people and processes.

To bring this safety framework to the daily activities in our plants, certain key principles should be followed rigorously. These principles are not just best practices; they are essential safeguards that reduce the likelihood and consequences of incidents. Keeping inventory low, using simple designs, reducing energy in all its forms, and minimizing the exposure of people to hazardous materials are just the start. By incorporating slow, gentle handling and using soft materials the operations can further lower risks. Application of the principles can be aided by considering a series of guidewords shown below.

Each of these principles plays an important role in maintaining a safe environment when dealing with explosive, pyrotechnics, chemical compositions or any sensitive materials.

1. Gentle

Careful handling of sensitive materials like explosives and fast pyrotechnics compositions is key to preventing accidental initiation. Gentle handling reduces impact forces and friction, both of which can serve as ignition sources. Proper training on handling techniques and the use of soft materials or cushioning can further reduce the likelihood of unintended initiation events. Personnel should perform their tasks with obvious respect for the material being handled.

2. Less Complex

A simpler system reduces the number of components or interactions that could fail or introduce errors, especially when dealing with explosives. Complex systems require more oversight, increasing the chances for errors in operation and maintenance. By simplifying processes, we reduce the risk of miscommunication and create fewer opportunities for accidental initiation through human error or equipment malfunction. Operating instructions and procedures should be written in simple terms and comprehensive but concise. Plant layout should be simple to aid movement of people and materials but also to keep escape routes clear.

3. Slow

Rushed operations often lead to mistakes, whether it's improper material handling, missed safety checks, or unintentional overloading of equipment. By slowing down the process, you reduce the chance of mistakes, allowing for more deliberate and cautious actions. Slow movement and gradual processes prevent sudden shocks, friction, or other stimuli that might initiate an explosive. There are many examples where we see evidence of jobs being done too quickly such as damage to the walls - particularly corners – caused by careless control of trolleys, forklift trucks etc.

4. Soft

Hard materials can generate sparks through friction or impact, which is dangerous when dealing with explosives and fast delay compositions. The energy released in an impact is also less when one or both of the surfaces is soft as the inert surface will absorb some of the energy thus there is less to transfer to any explosives present. Soft tools and non-sparking materials like bronze shall be used in operations where sparks may cause a fire or explosion. Additionally, conductive/dissipative rubber mats absorb impact of accidental drops on floors, workstations and can help prevent static buildup.

5. Lower

Processes conducted at lower pressures, temperatures, and speeds are inherently safer, as they reduce the chance of unexpected reactions. High pressures and temperatures can increase the volatility of materials, potential for decomposition, making them more likely to react violently if something goes wrong. Reducing these parameters also limits the strain on equipment, lowering the chance of equipment failure or leaks. Many processes require the use of stirrers, mixers, augers, crimping heads, presses and so on where there are close metal/metal contacts with explosives present. Reducing the operating speeds can significantly reduce the contact energy in fault conditions.

6. Minimum energy

Operating at lower energy levels, such as chemical reactivity, mechanical energy or reduced voltage, decreases the potential for accidental ignition. Processes with high energy input, such as those involving heat, pressure, or electric discharge, are more prone to spark ignition or runaway reactions. Minimizing energy input also lessens the severity of any incident by reducing the stored energy that could be released in case of an accident. This also applies to equipment that inputs energy into the process such as motors that drive mixers, stirrers, presses, pumps etc. where the power supplied should be limited to that required for the operation and no more.

7. Minimum quantity

Reducing the amount of hazardous material handled at any given time limits the scale of an incident if something goes wrong. Smaller quantities mean that any release of energy, will be limited in scope, making the situation easier to control and mitigate and help limit propagation to other explosives . By minimizing inventory of explosives and handling only the required amount of hazardous material, you ensure that any potential incidents are less severe.

8. Minimum height

Working at lower elevations minimizes potential energy and the risk of materials falling or dropping. This is especially relevant when dealing with sensitive products, as falling objects can create enough impact to initiate an explosion. Keeping operations, tools and materials at a lower height ensures that any accidental falls have less likelihood of ignition.

9. Minimum operations

Repetitive operations create a higher probability of human error through fatigue, loss of concentration, or complacency. Reducing manual handling, especially in hazardous environments, minimizes exposure to potential ignition sources and lowers the risk of mishaps caused by distractions or improper procedures. Many production processes involve multiple stages, and it is tempting to reduce costs by putting some or all of these into the same building. This can result in operators doing a low hazard activity being exposed to a higher hazard. It can also result in congestion in the working area with consequences in operational control.

10. Minimum weight

Handling lighter materials reduces the likelihood of dropping them, which could lead to accidental initiation in the case of sensitive products. It also minimizes the physical strain on workers, helping reduce fatigue and the risk of accidents. Using lightweight packaging and smaller containers can further enhance safety in operations involving explosives or chemicals.

11. Minimum people

Limiting the number of people involved in hazardous operations is crucial to minimize the exposure to risks and reduce the consequences of an accident. The number of workers shall be the minimum consistent with safe and efficient operation and nonessential personnel shall not be allowed in the hazardous area during operations. Visitor control must also be excercised.

12. Cool

Maintaining cooler operational conditions slows down reaction rates, making processes more stable and easier to control. Elevated temperatures can increase the volatility of materials, making them more prone to ignition or dangerous reactions. By controlling temperature, particularly during the processing of explosives and oxidizers, you reduce the risk of runaway reactions or thermal decomposition.

13. Remote

Remote handling of explosives materials reduces the need for human presence in dangerous zones, significantly lowering the risk of injury or exposure in the event of an accident. Automated systems and remotely operated equipment can safely manipulate hazardous products without placing operators directly in harm’s way, increasing overall operational safety.

14. Correct place

Keeping hazardous chemicals, raw materials and tools within designated places like pegboard hooks, together with the List of Permitted Articles they facilitate the control, prevent ingress in the wrong places and contribute to a safe working environment. The working floor area should be marked/identified for its use. Motto: A place for everything and everything in its place.

15. FISH control

Always maintain control over FISH.
Analyzing investigation reports, friction, impact, sparks or heat are most likely among the causes that gave rise to accidents with explosives. Therefore, the identification and control of ignition sources is essential for maintaining a safe work environment.

The Basis of Safety (BOS) and Inherent Safety begin at the design stage, grounded in a clear understanding of the process, yet this is not a task with an endpoint. It’s an ongoing effort, requiring constant attention to keep it alive.
The principle of minimizing both the likelihood of initiation and the consequences of any incidents must be well applied across all areas of the company—from plant design and manufacturing process to the application of explosives in blasting services.

While these safety principles may seem trivial or obvious, they serve as reminders. So, why not take a walk around the plant and check if these principles are actually being applied in day-to-day operations?