Investigators are exploring a forklift fire and propane-tank explosion in the Kutztown plant of thermoplastic sheet extruder Palram Americas Inc.

The Weisenberg Volunteer Fire Department responded to the call and is pursuing the causes along with the unidentified forklift manufacturer, propane tank supplier, insurance carrier and Palram, a division of Israel-based Palram Industries Ltd.

According to a preliminary report, "the fire started in the (forklift) engine compartment and was fed by the LP fuel line," fire department Chief Scott Freeman says. "The fire consumed the majority of the operator's compartment."

Fire fighters encountered "a fully involved propane forklift fire", Freeman reports. Before units arrived, the fire had compromised the attached 80-pound (36kg) capacity propane cylinder and caused a boiling liquid expanding vapour explosion (BLEVE).

"The BLEVE occurred approximately five minutes from the time the fire started," Freeman says. "The building's sprinkler system (was) activated and suppressed the fire. The operator of the forklift was transported to the hospital as a precaution and released. No other employees were injured," and all workers had exited the structure before the tank exploded.

Freeman observes that the propane cylinder appears to have been attached to the forklift properly when the BLEVE occurred. "The cylinder was torn clear of the hold-down straps and is thought to have hit numerous walls and the (industrial-height) ceiling before coming to rest approximately 35 feet (10.5 m) from the forklift," he says. The explosion damaged numerous light fixtures and sprinkler heads in the warehousing area for raw materials.

In the wake of the 2 March incident, Freeman suggests all companies should "implement and practise their emergency evacuation procedures. Numerous employees reported that smoke conditions became so severe within one minute that they had a hard time finding exit doors."

Freeman envisions what could have been a darker conclusion. "I have little doubt that anyone in close proximity (to the explosion) would not have survived without extreme injuries or fatality."

Freeman reports that Palram's co-ordinated company communication system and prompt leadership response "greatly assisted fire crews in clearing smoke from the building and limiting property damage from the sprinklers".

Palram Americas manufactures polycarbonate, polyvinyl chloride and acrylic sheet for digital and screen print markets and other end-uses. The Kutztown plant occupies 250,000 square feet (22,500 sqm).