The ‘Booming’ Career of Fireworks: Behind the Scenes of Fourth of July

Fourth of July is the time of year where everybody wants to pop up a lawn chair or lay on a blanket and watch as the night sky is illuminated with fireworks.

Pyrotechnics are a huge part of our celebrations. In fact, according to the U.S. Census Bureau, in 2007 America spent $231.8 million on fireworks. So who sets up all these fireworks and how do they work?

“There’s a lot to the firework industry. Someone shows up to the show and go ‘oh,’ they don’t realize the man and woman hours that go into all this,” said Dr. George Zambelli Jr., the chairman of the board for Zambelli Fireworks, a leading company in the pyrotechnics industry.

It turns out it’s a very detailed process. Here’s a look inside the process from Zambelli.

Pre-production

A fireworks display starts with a plan. Someone sets up a rough idea for a show, whether it be a company, government agency or private person.

The show is then designed or choreographed by a professional who understands pyrotechnic effects. He or she creates a computer projection of the fireworks display, which includes testing out the show virtually.

Next is manufacturing the pyrotechnics. While in the Zambelli family, Uncle Lou still works 7 days a week making custom fireworks, most of the fireworks for their displays are imported from other countries. This is a big trend in American fireworks. According to the Census Bureau, $209 million worth of pyrotechnics were imported from China in 2009. New batches of fireworks are tested at the Zambelli factory before their use in any display.

Storage and Transportation

Storing and moving fireworks is complicated. In Pennsylvania, the storing of fireworks is regulated by the bureau of Alcohol, Tobacco, Firearms and Explosives. There are many rules outlining how the fireworks have to be kept down to the locks on the building and the amount that can be stored in any one area.

Drivers transporting fireworks to and from areas where displays are being set up have to have special HAZMAT certifications through the Department of Motor Vehicles to drive around hazardous materials. The drivers have a computer program that creates routes that avoid tunnels and other areas where hazardous material cannot go.

Time for the Show

Once the fireworks are where they need to be, a few days before, the show crews begin creating a network of mortars. Mortars are the structure where the actual explosive shell rests inside and is shot out of. If the display is being controlled by a computer, the mortars are hooked up to a circuit board that can control each individual firework.

When it’s time for the show, one man on a computer orchestrates the timing of when each firework goes off. That’s when the public gets to enjoy their lovely pyrotechnic display.

“Now you know why I like being a cataract specialist!” Zambelli said after explaining the whole process. “It’s a lot easier.”