Steel Plant Explosion in Pennsylvania Leaves 2 Dead, 10 Injured & 1 Missing

At least two people have died, 10 more were injured, and one is missing after a massive blast at a steel plant located about 15 miles outside Pittsburgh, Pennsylvania. Five of the injured workers were treated and released from nearby hospitals, while five others remain in critical—but stable—condition.

Just before 11 a.m. on Monday, August 11, a large explosion was reported at the U.S. Steel Clairton Coke Works plant in Clairton, Pennsylvania. The initial blast was followed by “multiple secondary explosions,” according to Allegheny County officials, prompting an emergency rescue as workers became trapped beneath rubble.

A construction worker who was working nearby said the explosion “sounded like thunder… It shook my chest. It shook the building, then we saw the dark smoke rising from the steel mill.”

Officials reported that 14 local fire departments and 20 EMS agencies rushed to the scene to aid in the initial search and rescue operation. One of the 10 injured workers—who was originally reported missing—was pulled from beneath the rubble after hours of being trapped and transported to an area hospital.

What Caused the Blast?

While the plant is now considered stable, the cause of the explosion remains under investigation. The president and CEO of U.S. Steel, David B. Burritt, released a statement saying, “Our top priority is the safety and well-being of our employees and the environment. We are working closely with relevant authorities to investigate the cause of the incident.”

The Fire Marshall is currently investigating the incident.

Impact on the Environment

The impact of the explosion on the local environment is not yet known. At a news conference held shortly after the blast, Allegheny County Executive Sara Innamorato stated, “Out of an abundance of caution, we advise residents within one mile of the plant to remain indoors, close all windows and doors, set HVAC systems to recirculate, and avoid activities that draw in outside air, such as exhaust fans.”

However, there was no detectable rise in fine inhalable particles, such as soot, and sulfur dioxide levels did not exceed federal standards following the explosion. The health advisory was lifted later on Monday and residents were informed that they could resume normal activities.

U.S. Steel’s Clairton Coke Works Plant: A History of Safety Issues

This is not the first explosion to occur at the U.S. Steel Clairton Coke Works plant. An explosion in September 2009 killed a maintenance worker at the plant, and another blast less than a year later injured 20 people. After this second explosion, the Occupational Safety and Health Administration (OSHA) fined U.S. Steel and a subcontractor $175,000 for various safety violations.

In 2014, OSHA records show that a worker at the plant died after falling into a trench and sustaining significant burns, according to CNN. This was the last reported death at the plant until this week.

Earlier this year, officials reported a “buildup of combustible material” at the plant due to an issue with a battery. This material ignited, leading to a loud “boom.” No serious injuries were reported, but two workers did receive on-site treatment.

Coking Plant Environmental Concerns

The plant has also come under fire for environmental concerns.

Located on the Monongahela River about 20 miles south of Pittsburgh, the plant’s primary operation is converting coal to coke, a permeable, high-carbon material often used as fuel, for physical support, or as a reducing agent or carbon source in steelmaking. The process of creating coke involves baking coal at extremely high temperatures in specialized ovens to remove volatile impurities, such as gas and tar, which can reduce the steel’s strength. This process creates a byproduct commonly referred to as “coke gas,” a harmful combination of carbon dioxide, carbon monoxide, and methane.

Over the years, Clairton Coke Works has faced several lawsuits alleging environmental harm.

In 2017, the company was hit with a lawsuit that it later agreed to settle for $8.5 million, with the condition that $6.5 million would be used to decrease both noxious odors and soot emissions at the plant. After a fire at the facility in December 2018, which resulted in damage to controls that helped curb sulfur pollution, a lawsuit accused the Clairton plant of violating clean air laws.

Worker Safety Is Not Optional

Industrial workers contend with some of the most dangerous conditions and daily hazards of any worker in any occupation. But this does not mean that disasters like the U.S. Steel Clairton Coke Works plant explosion are inevitable or acceptable.

With greater risk to workers comes a higher responsibility from employers to ensure on-the-job safety. Industrial employees must receive adequate training, including safety training, as well as well-maintained personal protective equipment (PPE) and safe working conditions to limit hazards and reduce the risk of serious injury and death.

At Arnold & Itkin, our thoughts are with all those affected by the tragic explosion at the Clairton plant.