AB Specialty Silicones LLC agreed to pay a $1.3 million OSHA penalty and implement comprehensive safety reforms after a May 2019 explosion and fire at its Waukegan, Illinois plant killed four workers; settlement finalized in October 2024.

AB Specialty Silicones LLC — Four Workers Killed in Plant Explosion, $1.3M Settlement (2019–2024)

Outcome: Four workers died in a May 2019 explosion and fire at AB Specialty Silicones' Waukegan, Illinois plant; the company agreed in October 2024 to pay a $1.3 million federal penalty, cease silicon-hydride emulsion production until new engineered process areas are built, and implement company-wide safety reforms including third-party audits and multilingual training.

In May 2019, an explosion and fire destroyed part of AB Specialty Silicones LLC's chemical manufacturing plant in Waukegan, Illinois, killing four workers. OSHA's investigation found the company had failed to ensure that electrical equipment in areas where flammable liquids and gases were handled met required standards for hazardous locations, and had used propane-powered forklifts to transport flammable liquids through those same areas — creating a ready ignition source in a flammable atmosphere.

The enforcement case continued for five years. In October 2024, AB Specialty Silicones reached a settlement with the Department of Labor requiring the company to pay $1.3 million in federal penalties, the largest in the case history. The company also agreed to cease production of silicon-hydride emulsions until a new, purpose-engineered process area is completed; implement company-wide safety management systems; provide employee safety training in multiple languages; submit to third-party safety audits; and allow OSHA facility access without a warrant requirement.

Primary Source: AB Specialty Silicones must pay $1.3M federal penalty, implement comprehensive safety programs after 2019 Waukegan plant explosion