Beirut case study points to the quiet danger present in every explosives store

Improper storage of industrial explosives led to the most powerful non-nuclear blast in history, resulting in a costly lesson for companies globally dealing in industrial-use explosives to learn from. This accident was the infamous Beirut explosion of 2020, in which a massive quantity of ammonium-nitrate detonated at the Port of Beirut in Lebanon, killing 218 people, injuring around 7,000, and depriving 300,000 residents of their homes.

Lebanese authorities later confirmed that for seven years, around 2,500 tonnes of ammonium nitrate had been stored in a waterfront warehouse that lacked dedicated fire-suppression or climate-control measures, despite repeated customs alerts. When a fire broke out near the storeroom, the fertiliser-grade oxidiser detonated, producing a pressure wave experienced as far as 200 km away in Cyprus.

The issue was not the ammonium nitrate in itself, but the way in which a hygroscopic, oxidising solid was left to cake, sweat, and release heat in a confined, un-ventilated shed. No matter what explosive is used – whether ANFO, dynamite, detonating cords, or emulsion pumped with sensitising microspheres – the potential failure risks remain broadly the same in these conditions. Elevated temperatures, uncontrolled contamination factors, mechanical impacts, and external detonation risks pose a threat to most explosives.

The amount of explosives used in mining, quarrying, and construction can vary significantly between smaller and larger operations, from dozens to thousands of tonnes per month. Safely transporting and storing these significant quantities of explosive material while adhering to strict local regulations is a notoriously complex logistical task, especially considering the additional requirement that materials must be easily accessible (under strict control standards) for daily operations.

To ensure that explosives are stored safely and accidental detonation risk is minimised, here are three disciplines considered non-negotiable across every class of explosive:

1.     Treat inventory as a live system

Static stock can create a false sense of security. Explosives are not a ‘set-it-and-forget-it’ material. A dedicated storage control team must ensure that:

·       Temperature within the storeroom and emulsion tanks themselves is closely monitored and adjusted;

·       Humidity levels are tightly regulated;

·       Regular inspections for signs of degradation, leaks, and damage are conducted;

·       Explosives past their shelf life are safely removed and disposed of;

·       Rooms are equipped with the proper fire detection and suppression systems;

·       Different classes of explosives and devices are separated;

·       Pest control measures are implemented;

·       Steps are taken to eliminate the risk of static buildup; and

·       Regular emergency response drills are practiced to ensure that staff can react to dangerous situations without hesitation or error.

By introducing proactive monitoring and routine interventions into daily operations, teams can identify issues before they escalate, respond with confidence under pressure, and uphold the highest standards of safety and compliance in even the most demanding environments.

2.     Build magazines that efficiently exhaust heat

Concrete blocks alone are insufficient if the roof traps and radiates heat. Roof vents or negative-pressure extractors need to pull warm air away from the stack apex. The addition of ridge vents will allow convective lift to continue even if the power goes out.

Adequate space between the tallest package and lowest structural element should be maintained to prevent hot spots forming during seasonal peaks. Floors must also be power-floated, sealed, and painted in a light colour so that leaked fuel, grease, or other ignitable materials are easily identified and cleaned.

3.     Design storage to account for human error

In the case of the Beirut incident, firefighters unfortunately walked into an explosives warehouse without knowing what lay behind the doors. First responders may not share a blaster’s familiarity with safety data sheets.

Every storage building must carry external signage visible through smoke. Signs must list the relevant UN numbers, where UN Number 1942 represents ammonium nitrate, and ammonium nitrate emulsions and gels are categorised as UN Number 3375, for example.

Moreover, lock cylinders must be colour-coded to match compatibility group letters to minimise delays in finding the correct keys and accessing units under pressure. Use high-contrast pictograms, reflective tape, and tactile indicators on doors, containers, and switches to support rapid recognition by diverse personnel, including in low visibility conditions like smoke or darkness.

Install emergency lighting and luminescent floor markings to guide responders and personnel safely through or out of a facility, even in the event of power failure or heavy smoke. Post laminated quick-reference guides near entrances that summarise response steps, contact numbers, and hazard types for on-site materials in plain language and clear visuals.

Finally, design storerooms with modular compartments that physically isolate compatibility groups. This reduces the impact of potential human mistakes in sorting or accessing materials, and prevents cascading failures.

MEA operates various licensed magazines ideally located at key locations across sub-Saharan Africa, moving detonators, boosters, ANFO, and emulsions through multiple ports and land borders as clients require.

Our system couples SANS-aligned construction with contemporary digital management technology. The result is minimised risk of material loss or accidental ignition. No MEA-managed facility has suffered an uncontrolled ignition since its founding, thanks to the relentless auditing culture that our teams enforce at every step of the transportation and storage process.