A massive chemical tank at a Southern California aerospace plant is threatening to explode in what officials are calling an unprecedented industrial disaster.
Evacuation orders were issued for 40,000 people in Orange County on Friday as emergency crews warn the situation is spiraling toward catastrophe.
The 34,000-gallon tank containing highly volatile methyl methacrylate (MMA) cannot be secured and is threatening to 'spill or explode,' according to officials at the GKN Aerospace facility.
The terrifying warning sent panic rippling across the city of Garden Grove as neighboring communities were ordered to evacuate immediately over fears the giant tank could either rupture or meltdown in a devastating explosion capable of triggering a toxic chain reaction.
'This thing is going to fail. We don't know when,' Orange County Fire Authority Division Chief Craig Covey warned during a tense emergency briefing Friday.
Officials said there are now only two possible outcomes remaining.
'One, it fails and cracks and all the product leaks out onto the ground,' Covey said. 'The other option that was told to us is that it blows up.'
MMA is an industrial compound used in plastics and aerospace manufacturing.
Around 40,000 residents across parts of Garden Grove in Orange County, California were ordered to evacuate as officials warned a massive chemical tank could explode or rupture
Orange County Fire Authority Division Chief Craig Covey said the compromised tank is 'actively in crisis' and warned: 'This thing is going to fail. We don't know when.'
A drone photo shows a blocked off road as a chemical incident involving a failing tank of flammable liquid called methyl methacrylate forced an evacuation in surrounding areas
'This is highly volatile, it's highly toxic, it's highly flammable,' Covey said while urging residents to obey evacuation orders.
'This is not precautionary,' he added. 'This is gonna happen unless some brilliant guy behind me here figures out how we can mitigate this incident.'
Orange County health officials also cautioned that exposure to MMA vapors can cause severe respiratory distress, dizziness, nausea and irritation to the eyes and lungs.
'At very high levels, it can really cause severe respiratory distress and hospitalization,' Orange County Health Officer Dr Regina Chinsio-Kwong warned.
The crisis unfolded at GKN Aerospace, a major manufacturer that produces engine structures and aerospace components for commercial and military aircraft.
Firefighters first responded on Thursday after vapors began escaping from the massive storage tank at the company's Garden Grove facility.
Officials said the tank's temperature had increased, activating a relief valve designed to release pressure safely.
At first, crews believed they had stabilized the emergency after deploying cooling measures and using water systems to reduce the tank's temperature.
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Firefighters responded to a leak at an aerospace manufacturing company in Garden Grove on Thursday, for vapor releasing from a 34,000-gallon tank containing methyl methacrylate
Neighborhoods close to the area where the tank is located were evacuated
Fire officials said the giant tank began overheating Thursday, causing vapor releases and forcing firefighters to launch emergency cooling operations at the GKN Aerospace facility
Evacuation orders issued on Thursday evening were briefly lifted after vapor conditions improved, but the situation dramatically deteriorated again overnight.
By early Friday morning, officials realized a damaged valve on the compromised tank had made it impossible to safely remove or neutralize the chemicals inside.
'We have determined that the tank that is in the biggest crisis is in fact unable to be secured and mitigated,' Covey said.
Authorities warned the tank could spill between 6,000 and 7,000 gallons of dangerous chemicals if it ruptures - or explode in what officials fear could ignite neighboring tanks containing fuel and additional hazardous substances.
Emergency crews scrambled throughout the day on Friday to prepare for the worst-case scenario.
Sand barriers and containment systems were erected around the facility in hopes of preventing chemicals from reaching storm drains, river channels and eventually the ocean if the tank bursts.
Drones were also deployed overhead to monitor the tank's temperature as hazmat crews searched desperately for a solution.
Covey said emergency officials had contacted specialists 'all over the state and country' looking for what he described as 'out of the box' ideas to prevent disaster.
'We've assembled a team to think outside the box,' he said.
Firefighters and hazmat crews worked through the night on Thursday and into Friday while drones monitored the tank’s temperature from above
Law enforcement officers block off a roadway as the chemical incident unfolded
More than a dozen schools closed or canceled outdoor activities as the hazmat crisis intensified across Orange County. Pictured, roads are seen being blocked off by police
At one point on Friday afternoon, officials offered a sliver of hope after announcing the tank's temperature appeared to have stabilized temporarily, but authorities stressed the danger was far from over.
'We are setting up these evacuations in preparation for these two options: It fails, or it blows up,' Covey said.
Police and firefighters expanded evacuation zones across parts of Garden Grove, Anaheim, Cypress, Stanton and Westminster as the crisis deepened.
Garden Grove Police Chief Amir El-Farra said community safety remained the top priority.
'We want to see this come to a successful resolution, but we need your help,' El-Farra said.
Garden Grove Mayor Stephanie Klopfenstein pleaded with residents not to ignore evacuation orders despite fears about abandoning homes, businesses and pets.
'We understand it is frightening people who are worried about their homes, their businesses, their pets and loved ones,' Klopfenstein said. 'But this is a serious situation, and now is not the time to wait.'
Some residents described frantically trying to decide what belongings they could carry with them while uncertain whether they would be allowed to return home anytime soon.
Firefighters deployed sprinkler systems and high-powered hoses to spray the overheating chemical tank in an attempt to lower its temperature and prevent a catastrophic explosion
About 15 percent of residents inside the evacuation area were still refusing to leave on Friday despite repeated warnings from police and firefighters
Westminster resident Britney Pham told the Orange County Register she struggled to decide whether to bring an urn containing her late sister's ashes.
'Should we be getting everything that we think is important, or do we just grab what's basically essential to live for the next couple of days?' she said.
Officials said about 15 percent of residents inside the evacuation zone were still refusing to leave Friday afternoon despite repeated warnings.
The crisis also forced widespread closures across the region.
More than a dozen schools shut down operations while others canceled outdoor activities 'out of an abundance of caution,' according to the Garden Grove Unified School District.