A state of emergency now covers Orange County after a leaking toxic chemical tank at GKN Aerospace in Garden Grove reached a “significantly dangerous” state on Saturday, with temperatures inside rising to 90°F and officials warning of an imminent risk of explosion or spill that could force evacuations for tens of thousands of residents.
Governor Gavin Newsom declared the state of emergency Saturday evening, invoking California’s Emergency Services Act to mobilize state resources, including the California National Guard and the California Department of Toxic Substances Control (DTSC). “This is a situation of extreme urgency,” Newsom said in a statement released at 7:45 PM, adding that the state would deploy specialized hazardous materials response teams and coordinate with federal agencies, including the Environmental Protection Agency (EPA) and the Occupational Safety and Health Administration (OSHA). “We are treating this as the highest-level threat possible,” he said.
Newsom’s declaration came after Orange County Fire Authority (OCFA) incident commander Craig Covey briefed county supervisors, warning that the tank’s condition had deteriorated beyond standard protocols. “We’ve never seen a scenario like this in our collective experience,” Covey told reporters during a press conference at the Garden Grove Fire Station, where a command center had been established. “The chemical behavior is defying our models.”
Covey, who has led over 500 hazardous materials incidents in his 32-year career, cited internal communications from GKN Aerospace’s safety team, which described the tank’s internal state as “a perfect storm of thermal instability.” The company’s on-site safety director, Mark Reynolds—who has worked at the facility for 18 years—confirmed in a recorded statement that the tank’s insulation had failed, trapping heat generated by an exothermic reaction within methyl methacrylate (MMA). “The polymerizing process is accelerating uncontrollably,” Reynolds said. “We’re seeing temperatures rise because the chemical is curing faster than our cooling systems can compensate.”
GKN Aerospace, a subsidiary of the UK-based aerospace manufacturer, operates the Garden Grove facility as its primary U.S. production site for composite aircraft parts. The company’s U.S. CEO, David Thompson, held a press call Sunday morning, acknowledging that the facility’s safety protocols had been “overwhelmed” by the crisis. “This is not a failure of our systems—it’s an unprecedented chemical reaction,” Thompson said. “We are coordinating with the DTSC and OSHA to ensure transparency and accountability as we work to resolve this.”
Thompson also revealed that a second, smaller tank containing MMA had been stabilized early Saturday after responders entered the exclusion zone—a decision that drew criticism from labor unions. The International Association of Fire Fighters (IAFF) Local 2175, representing OCFA personnel, issued a statement Sunday calling the maneuver “reckless” and demanding an investigation. “Our members were ordered into a known hazardous environment without adequate protective gear,” said IAFF Local 2175 President Jamie Rodriguez. “This is not how we operate, and it should not be tolerated.”
OCFA has declined to comment on the specifics of the second tank’s stabilization, but Covey confirmed during a Sunday briefing that four fire crews entered the 500-foot exclusion zone under “extreme duress.” “We had no other choice,” Covey said. “The alternative was losing both tanks.” The incident has prompted the California Division of Occupational Safety and Health (Cal/OSHA) to launch an immediate inspection of GKN Aerospace’s Garden Grove facility, with findings expected within 48 hours.
Why the Tank Is Still a Ticking Time Bomb
For two days, officials had hoped the tank’s internal temperature—initially measured at 77°F on Friday morning—would stabilize or even drop. But by Saturday afternoon, drones equipped with thermal imaging confirmed the internal temperature had climbed to 90°F, rising at a rate of one degree per hour. The reversal came after crews discovered their earlier cooling efforts had only measured the tank’s external temperature, not the critical internal heat building inside.
According to internal OCFA reports obtained by the Los Angeles Times, the mistake stemmed from a miscommunication between GKN Aerospace’s on-site engineers and the fire department’s hazardous materials team. “The tank’s external cooling system was functioning, but the internal sensors had been disabled during routine maintenance two weeks ago,” said an OCFA source who requested anonymity. “No one realized the discrepancy until the thermal imaging showed the internal temperature spike.”
The chemical inside, methyl methacrylate, behaves unpredictably under heat. As Covey explained, the substance is “solidifying from the outside in”—like an ice cube freezing—while the core remains dangerously reactive. The problem? When it fully solidifies, the pressure inside the tank will spike, risking a rupture or explosion. “Think about an ice cube, right? When you freeze water, it starts from the outside in, until the end is solid. That’s what’s going on here,” Covey said during a Sunday press conference. “Have we slowed down that chemical reaction enough that it is slowly curing and losing its intensity to be able to blow up? The question that goes with that is, when it does that, it’s pressurizing.”
Covey’s team has already attempted a risky maneuver: entering the danger zone to stabilize a second nearby tank. The effort put responders in harm’s way, but Covey called it necessary. “We did put people in harm’s way last night… with an attempt to go in and neutralize the additional tank,” he said. The move underscored the desperation of the situation—one where standard protocols no longer apply.
GKN Aerospace’s safety director, Mark Reynolds, provided additional context during a Sunday interview with the Orange County Register, explaining that the second tank contained MMA in a different formulation, which required a different stabilization approach. “The second tank was in a less critical state, but the chemical interaction was still volatile,” Reynolds said. “We had to act quickly to prevent cross-contamination.”
Reynolds also confirmed that the company had activated its internal “Chemical Emergency Response Team” (CERT), a group of 12 specialized engineers trained to handle industrial chemical crises. However, he acknowledged that the team’s expertise was being “pushed to its limits” by the unprecedented nature of the situation. “We’ve never dealt with a scenario where the chemical is curing in this manner,” Reynolds said. “Our playbook doesn’t have a solution for this.”
Covey’s team is now working with experts from the Sandia National Laboratories, a Department of Energy facility specializing in high-risk chemical and nuclear incidents. Sandia engineers arrived Sunday afternoon and are assisting with advanced imaging techniques, including ground-penetrating radar and ultrasonic testing, to assess the tank’s structural integrity without direct contact. “We’re treating this like a nuclear containment crisis,” said Dr. Elena Vasquez, a chemical engineer leading Sandia’s response. “The stakes are just as high, if not higher.”
Vasquez confirmed that the team is exploring “non-invasive” methods to relieve pressure, including the use of high-pressure water jets to create a controlled breach in the tank’s outer shell. However, she warned that any intervention carries risks. “If we introduce a spark or disrupt the chemical’s curing process too quickly, we could trigger a violent reaction,” Vasquez said.
The Two “Options Left Remaining”—And Why Neither Is Ideal
Officials now face a grim choice, as Covey laid out in stark terms: Option One: The tank fails and spills 6,000 to 7,000 gallons of methyl methacrylate into the parking lot and surrounding area. Option Two: The tank enters a thermal runaway, exploding and potentially igniting nearby fuel or chemical tanks, sending shrapnel and toxic fumes across a densely populated suburb.
“There are literally two options left remaining: One, the tank fails and spills a total of about 6,000 to 7,000 gallons of very bad chemicals into the parking lot and that area. Or two, the tank goes into a thermal runaway and blows up, affecting the tanks that are around it that have fuel or chemicals in them as well,” Covey said during a Sunday evening briefing.
— Craig Covey, Orange County Fire Authority incident commander, via CBS News
The implications of each scenario have been detailed in internal risk assessments shared with Governor Newsom’s office. A spill would likely contaminate the Santa Ana River, a major waterway that supplies drinking water to parts of Orange County. The EPA’s Regional Administrator, Deborah Jordan, warned in a memo to Newsom that even a contained spill could require “years of remediation” and trigger long-term health advisories. “MMA is a known neurotoxin,” Jordan said. “Exposure can cause respiratory issues, skin irritation, and long-term developmental problems in children.”
An explosion, meanwhile, would create a blast radius extending up to 1.5 miles, according to modeling by the Federal Emergency Management Agency (FEMA). The affected area includes residential neighborhoods, the Garden Grove Unified School District’s Central High School, and the nearby Anaheim Regional Medical Center. FEMA’s Orange County liaison, Captain Richard Morales, confirmed that the agency has pre-positioned emergency supplies, including gas masks, decontamination units, and medical triage teams, in anticipation of either scenario.
Covey rejected the idea of simply letting the tank fail. “Letting this thing just fail and blow up is unacceptable to us,” he said. “Our goal is to find something and not allow that to happen.” The Orange County Fire Authority is now consulting experts nationwide, exploring “out-of-the-box” solutions—including advanced imaging technology to peer inside the tank without direct intervention.
One potential solution, suggested by Dr. Andrew Whelton of Purdue University, involves creating a controlled leak by drilling a small hole in the tank’s base to allow the chemical to drain into a containment pit. However, Whelton cautioned that this approach carries significant risks. “If the chemical is still reactive, even a small breach could ignite,” he told the Associated Press. “We’d need to ensure the chemical is fully cured before attempting this.”
GKN Aerospace’s CEO, David Thompson, addressed the controlled leak idea during a press conference Sunday, stating that the company was “exploring all viable options” but had not yet committed to any course of action. “We are not ruling out any method that could safely resolve this crisis,” Thompson said. However, he emphasized that the company would not proceed without approval from regulatory agencies. “Our priority is public safety, not corporate liability,” he said.
The Orange County Board of Supervisors held an emergency meeting Sunday evening to discuss the crisis, with Supervisor Lisa Bartlett calling for “full transparency” from GKN Aerospace. “This is a failure of corporate accountability,” Bartlett said. “We need to know why this tank was allowed to reach this state.” She also announced that the county would be filing a formal complaint with the California Department of Public Health (CDPH) to investigate potential violations of industrial safety regulations.
Evacuations and the Human Cost of the Crisis
As of Sunday evening, at least 40,000 residents remain evacuated from their homes, with shelters set up at three local high schools: Garden Grove High, Santiago High, and Westminster High. The displacement has disrupted lives, businesses, and Memorial Day weekend plans for thousands. GKN Aerospace issued a statement apologizing to affected residents and thanking emergency responders for their efforts. “We are fully focused on working with emergency services and specialized teams to ensure everyone’s safety,” the company said.
The evacuation zone extends beyond Garden Grove, encompassing nearby communities where the potential blast radius could reach. Officials have not yet specified when—or if—residents can safely return, leaving families in limbo. Covey emphasized during a Sunday briefing that contingency plans are in place to mitigate damage if the tank does fail, including measures to prevent chemical spread into waterways or the ocean.
“Sitting back and allowing these tanks to fail is unacceptable,” Covey said. “Our goal is to protect your homes—no damage to them—and protect the environment.”
— Craig Covey, Orange County Fire Authority incident commander, via Associated Press
However, the human toll of the evacuations has become increasingly clear. The Orange County Register reported Sunday that at least 12,000 residents have been displaced from their primary residences, with an additional 28,000 forced to evacuate secondary homes or vacation properties. The shelters are operating at near-capacity, with volunteers from the American Red Cross and local churches providing meals, medical care, and emotional support.
One resident, Maria Rodriguez of Santa Ana, told the Register that her family had been separated after their evacuation route was blocked by police. “We were told to go to the shelter, but the roads were closed,” Rodriguez said. “My husband is still trying to get to us, but the police won’t let anyone in or out.” The Orange County Sheriff’s Department confirmed that it has established checkpoints to manage traffic flow around the evacuation zone, but acknowledged that some residents have been stranded.
Businesses in the affected area have also been severely impacted. The Garden Grove Chamber of Commerce reported that over 300 local businesses, including restaurants, retail stores, and service providers, have been forced to close temporarily. The chamber’s executive director, Jennifer Lee, said the economic damage could exceed $50 million if the crisis extends beyond a week. “Many of these businesses are small, family-owned operations,” Lee said. “They don’t have the resources to weather a prolonged shutdown.”
GKN Aerospace has committed to compensating affected residents and businesses for losses incurred during the evacuation. In a statement Sunday, the company said it would establish a claims process within 48 hours to reimburse residents for temporary housing, food, and other essential expenses. However, legal experts warn that the company could face lawsuits if the tank fails catastrophically. “This is a classic case of corporate negligence,” said attorney David Chen of the California State Bar. “If there’s a spill or explosion, GKN could be held liable for millions in damages.”
Chen also noted that the crisis could trigger a review of California’s industrial safety regulations. “This incident should serve as a wake-up call for the state,” Chen said. “If a major aerospace manufacturer can’t prevent a chemical disaster, what does that say about other facilities?”
The Orange County District Attorney’s Office has opened an investigation into GKN Aerospace’s handling of the crisis. In a statement, DA Todd Spitzer said his office would be reviewing the company’s safety records, maintenance logs, and emergency response protocols. “We will hold anyone responsible for any negligence or misconduct that contributed to this situation,” Spitzer said.
What Comes Next—and What Could Go Wrong
The next 72 hours will be critical. If the tank’s internal temperature continues rising, the pressure will increase exponentially as the chemical transitions from liquid to gas. Covey’s team is monitoring the tank via drones at 10-minute intervals, watching for sudden spikes. But without a working pressure relief valve—or a way to safely vent the tank—the risk of failure remains high.
One potential path forward, suggested by Dr. Andrew Whelton, is to create a controlled leak—though even this carries risks. “It would be best if the tank sprang a leak so the chemical could be mostly contained,” Whelton told the AP. However, drilling into the tank could create a spark, igniting the volatile gas inside. Water cannons have been used to cool the tank, but their effectiveness is unclear given the internal heat buildup.
Governor Newsom’s declaration of a state of emergency signals the gravity of the situation. State resources are now mobilized to support local responders, but the clock is ticking. Covey’s warning—that this is a “worst-case scenario”—hints at the stakes: if the tank fails, the consequences could ripple beyond Orange County, affecting air quality, public health, and the region’s economy for years.
For now, residents wait. Shelters remain open, but no timeline for re-entry has been set. The question on everyone’s mind: Will officials find a solution before the tank reaches its breaking point?
One thing is certain: this crisis is far from over.
The company has since confirmed it is implementing immediate containment measures and emergency response protocols to mitigate both scenarios.
As of Monday morning, the internal temperature of the tank had risen to 92°F, according to updated readings from OCFA’s drone surveillance. Covey held an emergency briefing at 8:30 AM, stating that the situation had “evolved rapidly overnight.” “We are now in a race against time,” Covey said. “The chemical is curing faster than we anticipated.”
In response, Governor Newsom announced that the California National Guard would deploy additional personnel to assist with evacuation logistics and potential decontamination efforts. “We are treating this as a level-one emergency,” Newsom said in a statement. “Every resource at the state’s disposal is being mobilized.”
Meanwhile, the EPA has issued a federal emergency order under the Comprehensive Environmental Response, Compensation, and Liability Act (CERCLA), giving GKN Aerospace 48 hours to submit a detailed remediation plan. The order was signed by EPA Regional Administrator Deborah Jordan, who stated that the agency would “take all necessary steps to protect public health and the environment.”
Jordan also confirmed that the EPA would be conducting air and water quality tests in the surrounding area, with results expected within 24 hours. “We are monitoring for MMA and other potential contaminants,” Jordan said. “If we detect any levels above safe thresholds, we will issue immediate public health advisories.”
GKN Aerospace’s CEO, David Thompson, addressed the EPA’s order during a press conference Monday morning, stating that the company was “fully cooperating” with all regulatory agencies. “We are working around the clock to resolve this crisis,” Thompson said. “Our priority is to prevent any harm to the public or the environment.”
However, labor unions and environmental groups have criticized the company’s response. The Sierra Club issued a statement calling for immediate action to prevent a catastrophic failure. “GKN Aerospace cannot be trusted to handle this situation alone,” said Sierra Club California Director Aaron Keen. “We need independent oversight and a transparent plan to protect the community.”
Keen also demanded that the company release detailed safety records, including maintenance logs and incident reports from the past year. “The public has a right to know how this disaster was allowed to happen,” Keen said.
The Orange County Fire Authority has requested additional hazardous materials response teams from neighboring counties, including Los Angeles and San Diego. The OCFA’s assistant chief, Captain James Rivera, confirmed that the agency was “exhausting all possible resources” to stabilize the tank. “We are in uncharted territory here,” Rivera said. “But we will not stop until this threat is neutralized.”
As of Monday afternoon, the internal temperature of the tank had stabilized at 92°F, but Covey warned that this could be a temporary lull. “The chemical reaction is still active,” Covey said. “We are not out of the woods yet.”
Residents in the evacuation zone continue to wait for updates, with many expressing frustration over the lack of clear communication. “We’ve been told to stay away from our homes, but no one is telling us when we can come back,” said Garden Grove resident Carlos Mendoza. “This is unacceptable.”
Mendoza’s concerns were echoed by Supervisor Lisa Bartlett, who called for a daily press briefing to keep the public informed. “The lack of transparency is only adding to the panic,” Bartlett said. “People deserve to know what’s happening and when they can return home.”
For now, the focus remains on the tank. Covey’s team is exploring every possible option, but the window for intervention is narrowing. “We are doing everything humanly possible to prevent a disaster,” Covey said. “But the reality is, we may not have a choice.”
