Five Injured, Two Critically, in Early Morning Fire at Signicast Facility in Hartford
HARTFORD, WI — July 3, 2025
An early morning fire at the Signicast manufacturing facility in Hartford, Wisconsin, left five people injured — two of them seriously — in a chaotic incident that drew a massive emergency response and prompted temporary evacuation of the facility. Authorities are currently investigating the cause of the blaze, which erupted around 5:15 a.m. on Thursday and sent thick plumes of smoke billowing into the pre-dawn sky.
According to the Hartford Fire & Rescue Department, crews were dispatched to the Signicast investment casting plant located on East Waterford Road after multiple 911 calls reported a fire inside one of the main production buildings. Firefighters arrived within minutes to find flames and heavy smoke coming from an area of the plant used for metal casting and furnace operations.
Fire Breaks Out During Early Shift
At the time of the fire, the facility was already active with early shift employees working inside. Eyewitnesses described hearing a loud popping sound, followed by sudden bursts of flames near an industrial furnace. Within minutes, the fire spread to adjacent equipment and parts of the ventilation system.
“Everything happened so fast,” said one worker who asked not to be identified. “There was a boom, and then the alarms went off. Some people were running, others were helping coworkers. It was chaos.”
The fire triggered a full-scale emergency protocol. Employees were immediately evacuated, and on-site safety personnel worked to assist the injured before paramedics arrived. Firefighters were able to contain the flames within approximately 40 minutes, though crews remained on the scene for several hours to conduct ventilation, overhaul hot spots, and assess damage.
Injuries and Medical Response
According to Hartford Fire Chief Paul Stephans, five individuals were injured in the incident. Two of the victims sustained serious injuries and were transported by Flight for Life helicopter to Froedtert Hospital in Milwaukee. Their conditions are reported as critical but stable.
The remaining three suffered minor burns and smoke inhalation and were treated at the scene or taken by ambulance to local medical facilities for further evaluation.
“This could have been much worse,” Chief Stephans said at a morning press briefing. “Thanks to the fast response of our first responders and the effective use of the facility’s emergency systems, we were able to prevent further injuries and contain the fire before it reached other parts of the plant.”
Investigation Underway
Officials from the State Fire Marshal’s Office, along with local investigators, are working to determine the exact cause of the blaze. Preliminary assessments suggest the fire may have originated near a high-temperature furnace or casting line, but investigators are not ruling out other possibilities, including electrical malfunction or mechanical failure.
The Occupational Safety and Health Administration (OSHA) has also been notified and is expected to conduct its own investigation, given the workplace nature of the incident.
“The safety of workers is our highest priority,” said Chief Stephans. “We will be working closely with all agencies involved to determine the cause and ensure that safety protocols are either upheld or strengthened to prevent future occurrences.”
Facility Impact and Company Response
Signicast, a division of Form Technologies, is one of Hartford’s largest employers and a global leader in precision investment casting for various industries, including automotive, aerospace, and medical device manufacturing. The company operates a massive, high-tech manufacturing campus in Hartford, which runs 24 hours a day.
In a statement released Thursday afternoon, a spokesperson for Signicast confirmed the fire and injuries, and expressed gratitude to emergency responders:
“We are deeply concerned for the wellbeing of our employees and are closely monitoring the condition of those who were injured. Our thoughts are with them and their families. We are cooperating fully with authorities in their investigation and are conducting our own internal review to assess the cause of the incident. Safety remains our highest priority.”
The facility will remain closed for at least 24 to 48 hours in the affected section as damage is assessed and cleaned up. It is unclear at this time whether production delays will affect customer orders, though the company has said it is working to minimize operational disruptions.
Community Support and Response
The Hartford community, known for its close-knit industrial base, has responded with concern and support for those injured in the fire. Local officials, including Mayor Tim Michalak, visited the scene and later issued a statement praising first responders and offering resources to the families of the injured.
“I want to thank the Hartford Fire & Rescue teams for their swift and courageous response,” Mayor Michalak said. “Our hearts go out to the injured workers and their families. The City of Hartford stands ready to support them in any way we can.”
Moving Forward
As investigations continue and repairs are made, questions remain about the fire’s root cause and what safety measures may need to be reviewed or revised. In the meantime, employees returning to unaffected parts of the Signicast campus are being offered counseling services and safety briefings before resuming duties.
Anyone with information regarding the incident or workplace conditions at the time is encouraged to contact the Hartford Fire Department or OSHA directly.