BioLab Fire Exposes Preventable Hazards in Conyers

A massive chemical fire at the BioLab facility in Conyers, Georgia, on September 29, 2024, released toxic plumes that forced thousands to evacuate and shelter in place, stemming from a sprinkler malfunction that mixed water with reactive substances. Now, one year later, former employees reveal ignored warnings about corrosion and improper storage, while ongoing probes highlight systemic failures that could have been avoided.

Incident Details and Immediate Aftermath

The blaze started when a faulty sprinkler head allowed water to contact water-reactive chemicals like trichloroisocyanuric acid and others stored in a warehouse. This reaction produced heat, toxic vapors, and fires that sent plumes of chlorine and hazardous smoke across metro Atlanta.

Evacuations affected 17,000 residents, with shelter-in-place orders for 90,000 more. Firefighters battled the flames for days, and air quality concerns lingered as the smoke spread.

Recent updates show the fire connected to Hurricane Helene’s heavy rains, which may have exacerbated equipment issues. Local officials noted multiple prior small incidents at the site, raising questions about long-term oversight.

Former Workers Reveal Safety Lapses

Interviews with ex-employees paint a picture of neglected maintenance and risky practices. One former engineer described replacing dozens of corroded sprinkler heads in the months before the fire, questioning the use of water-based systems for chemicals that react violently with moisture.

Workers reported storage beyond approved limits, with over seven million pounds of reactive materials on site, far exceeding what county records indicated. They also mentioned emergency repairs weeks prior, ignored despite clear hazards.

These accounts align with federal findings of improper chemical handling, including materials stacked outside designated areas and a lack of proper firewalls.

• Common issues cited by staff: Leaky pipes, outdated equipment, and insufficient training on hazardous materials.
• Overlooked warnings: Reports of small “smoker” events in the past that went unaddressed.
• Storage concerns: Inventory levels that violated safety protocols, increasing fire risks.

Investigations Uncover Broader Failures

The U.S. Chemical Safety Board continues its probe, releasing updates that criticize BioLab for inadequate safety protocols and excessive chemical stockpiles. Their May 2025 report detailed how the reaction involved multiple substances, leading to offsite impacts.

OSHA issued citations in April 2025 for hazardous storage, proposing penalties after the incident hospitalized several people. These findings echo patterns from BioLab’s history of fires at other locations.

Experts link the event to broader industry problems, such as cost-cutting measures that prioritize profits over safety. A similar chemical plant incident in Texas last year highlighted the need for stricter federal regulations.

Residents still demand transparency on contaminants like polycyclic aromatic hydrocarbons found in soil and water samples.

Health and Environmental Concerns Persist

Neighbors report ongoing health issues, including headaches, respiratory problems, and hoarse voices, a year after the fire. Independent tests detected harmful substances in yards, gardens, and retention ponds near the site.

Children and adults face potential long-term risks, with some studies showing links to increased cancer rates from similar exposures. Local health officials advise monitoring symptoms and avoiding affected areas.

Environmental cleanup efforts continue, but questions remain about lingering toxins in water sources. Recent sampling near a dead frog in a nearby pond revealed baseline chemicals from the fire, underscoring the spread.

BioLab’s Response and Future Outlook

BioLab announced in May 2025 it would not resume manufacturing in Conyers, opting instead to use the site for distribution only. This decision brings relief to some, but worries persist about ongoing storage of hazardous materials.

The company faces lawsuits from affected residents and scrutiny over past incidents. Federal oversight may lead to new rules for chemical facilities, especially those near populated areas.

This table shows the progression from incident to current status.

As investigations wrap up, communities push for better protections to prevent future disasters. Share your thoughts on chemical plant safety or experiences with similar events, and spread this article to raise awareness.