Metal and Steel Safety & Security
The steel industry is home to some of the most complex and high-risk manufacturing operations in the world. For example, from blast furnaces and electric arc furnaces to rolling mills and coke ovens, steelmaking demands precision in environments characterized by extreme temperatures, high pressures, flammable gases, combustible dust, complex material handling, and massive machinery in a fast-paced production environment. Without robust process safety management (PSM) systems, even a single breakdown, whether due to equipment failure, procedural lapse, or inadequate hazard controls, can trigger catastrophic events such as fires, explosions, toxic releases, or structural failures.
In light of these risks, process safety is far more than a regulatory obligation, it is a strategic necessity. Robust process safety management protects lives, prevents costly unplanned outages, ensures environmental compliance, and preserves corporate reputation. By systematically identifying hazards, evaluating risks, and applying effective safeguards, steel producers can significantly lower the risk of major incidents, enhance operational reliability, and maintain productivity in an industry where safety and performance go hand in hand. A strong process safety culture protects workers, ensures compliance, safeguards business continuity, and maintains community trust.
With this in mind, AcuTech partners with steel manufacturers worldwide to embed these principles into daily operations, ensuring alignment with global standards, improving plant reliability, and protecting people, assets, and the environment.
- Process Safety Management Implementation and Auditing
- Process Hazard Analyses (HAZOP, LOPA)
- Dust Hazard Analyses
- Quantitative Risk Assessments
- Fire Risk Assessments
- Asset Integrity & Risk-Based Inspection
- Crisis Management Planning
- Incident Investigation & Root Cause Analysis
- Emergency Preparedness & Crisis Management
- Security Risk & Vulnerability Assessments
AcuTech’s consultants are well versed in codes and standards and will refer to these as well as each client’s local jurisdiction codes and standards.
- OSHA 29 CFR 1910.119: Process Safety Management (PSM). This OSHA regulation establishes requirements for managing hazards associated with processes using highly hazardous chemicals, which may apply to steel facilities handling ammonia, hydrogen, or chlorine above threshold quantities.
- OSHA 29 CFR 1910.147: Control of Hazardous Energy (Lockout/Tagout). This standard requires procedures to control hazardous energy during servicing of equipment such as rolling mills, conveyors, and cranes.
- OSHA 29 CFR 1910.146: Permit-Required Confined Spaces. This standard governs safe entry into confined spaces such as furnaces, pits, and tanks for inspection or maintenance.
- OSHA 29 CFR 1910 Subpart L: Fire Protection. This section establishes requirements for fire prevention, suppression systems, and portable extinguishers in molten metal, casting, and dust collection areas.
- EPA 40 CFR Part 68: Risk Management Program (RMP). This regulation requires hazard analysis and prevention programs for facilities storing or using certain toxic or flammable chemicals above threshold quantities.
- EPA 40 CFR Part 112: Spill Prevention, Control, and Countermeasure (SPCC) Rule. This rule mandates spill prevention and secondary containment measures for oil, fuel, and hydraulic fluid storage.
- NFPA 484: Standard for Combustible Metals. This standard provides requirements for the safe processing, handling, and storage of combustible metals like aluminum and magnesium used or produced in steel facilities.
- NFPA 652: Standard on the Fundamentals of Combustible Dust. This standard establishes the baseline requirements for identifying and managing combustible dust hazards, including dust hazard analysis (DHA).
- NFPA 654: Standard for the Prevention of Fire and Dust Explosions from the Manufacturing, Processing, and Handling of Combustible Particulate Solids. This standard addresses design, housekeeping, and explosion protection measures for facilities handling combustible particulate solids.
- Chemical Facility Anti-Terrorism Standards (CFATS). This DHS program requires facilities with certain chemicals of interest above thresholds to implement security vulnerability assessments and site security plans.
- NIST Cybersecurity Framework. This voluntary framework provides guidance for protecting industrial control systems and operational technology from cyber-physical threats.
- State OSHA Programs. State-run occupational safety programs may impose stricter exposure limits or additional process safety requirements beyond federal OSHA rules.
- Seveso III Directive (EU). This directive requires major accident prevention and emergency planning for facilities handling large quantities of dangerous substances.