A manufacturer of military explosives has been fined £670,000 after an employee was killed and another seriously injured in an explosion at its factory near Salisbury.

The two men were working on the production of MTV – an explosive substance used in military flares.

They were cleaning a vessel used in the production and were removing residual explosive material in preparation for the next day’s shift.

Piotr Zukowski, 29 of Southampton was partially inside the vessel when the remaining material exploded, killing him instantly.

An investigation by the Health and Safety Executive (HSE) found that Chemring Countermeasures Limited of Romsey, Hampshire, had failed to carry out a suitable and sufficient risk assessment. They had also failed to identify that explosive material was building up within work equipment, or to identify the sensitiveness of these explosives and had not put in place controls to ensure that this build-up of material did not present a serious risk to workers. Furthermore, workers were poorly supervised, allowing routine non-compliance with process instructions to take place.

The company holds an explosive licence, granted by HSE, which permits the manufacture and storage of explosives. Activities carried out in the corridor compromised the route of access and egress from the building and were contrary to the conditions of the licence. It was also custom and practice to have the doors to all of the bays in the building open during the working day, also contrary to the conditions of the licence.

Applications of explosives in manufacturing
A licence is required for most manufacturing activities. Manufacturing includes processes where explosive articles or explosive substances are made or assembled, or unmade or disassembled. For example, gunpowder manufacture, filling or fusing of fireworks, assembling fireworks displays from components, breaking down jet perforating guns, removing fuses from artillery shells and filling shotgun cartridges and other cartridges for small arms).

The controlled use of explosives is essential for efficiency and effectiveness in these industries. However, due to their inherently hazardous nature, the use of explosives is stringently regulated to ensure safety and compliance.

1.Mining and quarrying

• Blasting operations: Explosives are widely used in mining and quarrying to break rock and extract valuable minerals. Techniques such as bench blasting and controlled blasting help achieve precise fragmentation, enhancing the efficiency of resource extraction.
• Tunnel construction: In the construction of tunnels for transportation or mining, explosives facilitate the excavation process by breaking through rock layers, allowing for quicker and more efficient tunnelling.

2.Construction industry

• Demolition: Controlled demolition of buildings and structures often involves the use of explosives. This method is efficient for bringing down large structures safely and quickly.
• Road construction: Explosives are used in road construction for removing rock obstacles and levelling the ground, particularly in hilly or mountainous areas.

3.Pyrotechnics and entertainment

• Fireworks: The manufacturing of fireworks involves the use of various explosive compounds to create controlled explosions for entertainment purposes. Fireworks displays are a common feature of celebrations and public events.
• Special effects: In the film and entertainment industry, explosives are used to create realistic special effects, such as explosions and pyrotechnic displays.

Regulatory framework
The use of explosives in the UK is governed by stringent regulations to ensure public safety, security, and environmental protection. Key regulatory bodies and regulations include:
1. Health and Safety Executive (HSE)
The HSE oversees the licensing and regulation of explosives in the workplace. It ensures that manufacturers comply with safety standards and procedures to prevent accidents and injuries.
2. Explosives Regulations 2014 (ER 2014)
ER 2014 sets out comprehensive guidelines for the manufacture, storage, transportation, and use of explosives. The regulations cover licensing requirements, risk assessments, and safety measures to mitigate hazards.
3. Police licensing
Local police authorities are involved in issuing licences for the storage and use of explosives. They conduct inspections and ensure that licensees adhere to legal requirements.

Licensing requirements
Manufacturers and users of explosives in the UK must obtain appropriate licences, depending on the nature and scale of their operations. Key licensing requirements include:
1.Manufacturing licence
Required for any entity involved in the production, processing, or handling of explosive substances. The licence ensures that manufacturers follow stringent safety protocols.
2. Storage licence
Necessary for storing explosives above specified quantities. Storage facilities must meet safety standards to prevent accidental detonation and unauthorised access.
3. Transport licence
Required for transporting explosives, particularly in large quantities. The licence ensures that transport vehicles and personnel adhere to safety regulations.
4. Sales and distribution licence
Businesses involved in the sale and distribution of explosives, such as fireworks retailers, must obtain a licence to ensure that products are sold and handled safely.
Safety measures

Ensuring safety in the use of explosives is paramount. Key safety measures include:
1. Risk assessments
Comprehensive risk assessments are conducted to identify potential hazards and implement measures to mitigate risks. This includes evaluating the suitability of storage facilities and transportation routes.
2. Training and competence
Personnel involved in the handling and use of explosives must undergo rigorous training to ensure they are competent and aware of safety procedures. Regular refresher courses are also mandated.
3. Protective equipment
The use of personal protective equipment (PPE), such as helmets, gloves, and safety goggles, is mandatory for individuals handling explosives.
4. Security measures
Strict security protocols are in place to prevent unauthorised access to explosives. This includes secure storage facilities, surveillance systems, and controlled access.
5. Emergency preparedness
Emergency response plans are developed to address potential incidents involving explosives. This includes coordination with emergency services and regular drills to ensure preparedness.

Conclusion
The use of explosives in manufacturing is integral to various industries in the UK, offering efficiency and effectiveness in processes such as mining, construction, and entertainment. However, due to the inherent risks associated with explosives, their use is subject to stringent regulations and safety measures. Compliance with regulatory frameworks, obtaining necessary licences, and adhering to safety protocols are essential to ensure the safe and responsible use of explosives in manufacturing.
Further HSE guidance on explosives is available here