Adhesive use inside ductwork causes a fatal Hot Work fire ($156K)

At 10:00 a.m. on November 13, 2024, Employee #1 (23) was inside a large section of HVAC duct applying Design Polymerics DP 2590 Duct Liner Spray Adhesive to repair sagging insulation. After completing the adhesive application, Employee #1 used a pin welder to secure the insulation. While using the welder, a spark ignited flammable vapors from the adhesive, causing a flash fire inside the duct.

Employee #1, who was engulfed in flames, exited the duct. Coworkers used a fire extinguisher to put out the flames. A coworker working in the opposite corner also jumped out to safety. Employee #1 sustained burns to over 80% of his body and later died from complications related to the injuries.

Violations/PenaltiesSeriousWillfulRepeatOtherUnclassTotal
Initial Violations1010
Current Violations1010
Initial Penalty$156,043$0$0$0$0$156,043
Current Penalty$156,043$0$0$0$0$156,043
FTA Penalty$0$0$0$0$0$0
#Citation IDCitaton TypeStandard CitedIssuance DateAbatement Due DateCurrent PenaltyInitial PenaltyFTA PenaltyContestLatest EventNote
1.01001ASerious19100132 D0103/14/202504/03/2025$16,550$16,550$004/10/2025C – Contested 
2.01001BSerious19100252 B0303/14/202504/03/2025$0$0$004/10/2025C – Contested 
3.01002ASerious19100134 C02 II03/14/202504/03/2025$7,093$7,093$004/10/2025C – Contested 
4.01002BSerious19101052 D0203/14/202504/03/2025$0$0$004/10/2025C – Contested 
5.01003Serious19100146 C0103/14/202504/03/2025$16,550$16,550$004/10/2025C – Contested 
6.01004ASerious19100146 C0403/14/202504/03/2025$16,550$16,550$004/10/2025C – Contested 
7.01004BSerious19100252 A02 XIII A03/14/202504/03/2025$0$0$004/10/2025C – Contested 
8.01005ASerious19100146 D0203/14/202504/03/2025$16,550$16,550$004/10/2025C – Contested 
9.01005BSerious19100146 D03 VI03/14/202504/03/2025$0$0$004/10/2025C – Contested 
10.01005CSerious19100146 D04 I03/14/202504/03/2025$0$0$004/10/2025C – Contested 
11.01005DSerious19100146 D05 I03/14/202504/03/2025$0$0$004/10/2025C – Contested 
12.01005ESerious19100146 D05 II03/14/202504/03/2025$0$0$004/10/2025C – Contested 
13.01005FSerious19100252 A02 XIV B03/14/202504/03/2025$0$0$004/10/2025C – Contested 
14.01006ASerious19100146 D03 IV03/14/202504/03/2025$16,550$16,550$004/10/2025C – Contested 
15.01006BSerious19100146 D04 II03/14/202504/03/2025$0$0$004/10/2025C – Contested 
16.01007ASerious19100146 E0103/14/202504/03/2025$16,550$16,550$004/10/2025C – Contested 
17.01007BSerious19100252 A02 IV03/14/202504/03/2025$0$0$004/10/2025C – Contested 
18.01007CSerious19100252 A02 XIII B03/14/202504/03/2025$0$0$004/10/2025C – Contested 
19.01007DSerious19100252 A02 XIV D03/14/202504/03/2025$0$0$004/10/2025C – Contested 
20.01007ESerious19100252 A02 XIV E03/14/202504/03/2025$0$0$004/10/2025C – Contested 
21.01008ASerious19100146 G0103/14/202504/03/2025$16,550$16,550$004/10/2025C – Contested 
22.01008BSerious19100252 A02 XIII C03/14/202504/03/2025$0$0$004/10/2025C – Contested 
23.01008CSerious19100255 A0303/14/202504/03/2025$0$0$004/10/2025C – Contested 
24.01009Serious19100252 A02 VI C03/14/202504/03/2025$16,550$16,550$004/10/2025C – Contested 
25.01010Serious19101200 H0103/14/202504/03/2025$16,550$16,550$004/10/2025C – Contested 

Source: https://www.osha.gov/ords/imis/establishment.inspection_detail?id=1787826.015

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