Federal investigation finds safety failures fueled catastrophic BioLab fire in Conyers

A federal investigation has concluded that long-standing maintenance failures and unsafe chemical storage practices led to the massive BioLab fire that blanketed parts of Rockdale County in toxic smoke nearly two years ago.

The final report from the U.S. Chemical Safety and Hazard Investigation Board found the Conyers facility was storing approximately 14 million pounds of reactive pool treatment chemicals, more than double the amount originally anticipated for the warehouse. Investigators said the volume of chemicals, combined with deteriorating fire suppression equipment, created conditions that allowed a small equipment failure to escalate into a major industrial disaster.

According to the board, chlorine gases released by the stored chemicals gradually corroded the warehouse’s sprinkler system over several years. Moisture in the building reacted with the fumes to form hydrochloric acid, damaging metal components designed to control fires.

A routine inspection in late 2023 documented more than 1,100 corroded sprinkler heads, but the system remained in service.

When a corroded sprinkler fitting failed on Sept. 29, 2024, water reached incompatible chemicals, triggering a powerful chemical reaction. The resulting fire released toxic gases and thick orange-and-black smoke, forcing thousands of residents to shelter in place as emergency crews worked to contain the blaze.

Chemical Safety Board Chair Steve Owens said the warehouse lacked adequate safeguards for the amount of hazardous material being stored. He also said the way the chemical bags were stacked limited firefighters’ ability to stop the incident before it spread throughout the facility.

The board is urging federal regulators to expand oversight of reactive pool chemicals to help prevent similar incidents.

BioLab, a manufacturer of pool and spa treatment products and a subsidiary of KIK Consumer Products, said it is reviewing the investigation’s findings. The company said it fully cooperated with investigators, has completed cleanup of the property, and established programs to assist nearby residents and businesses affected by the fire.

The company previously announced it would not reopen the Conyers plant. Separate from the federal investigation, the U.S. Department of Labor cited BioLab for six workplace safety violations and proposed more than $60,000 in penalties.