How often these injuries happen
OSHA recorded 1,849 cases involving contact with hot objects or substances. Thermal burns account for 98 percent of these incidents.
These injuries lead to prolonged recovery times and significant medical needs. The severity of these burns often stems from direct contact with high-temperature sources that cause deep tissue damage.
Common injuries
Burn injuries often occur when you interact with steam, vapors, or hot liquids, which account for 42 percent of all reported sources. Common scenarios include splashing hot oil during food preparation, contact with pressurized steam from failing gaskets, or touching heated machinery surfaces during cleaning or maintenance.
| Injury Type | Incidents | |
|---|---|---|
| 1 | Thermal burns | 1,818 |
| 2 | Other or multiple types of burns | 8 |
| 3 | Burns, corrosions, electrical injuries— unspecified | 7 |
| 4 | Traumatic injuries or exposures— unspecified | 7 |
| 5 | Severe wounds or internal injuries and other injuries | 2 |
| 6 | Burns and toxic effects (including smoke inhalation) | 2 |
| 7 | Surface and flesh wounds and other injuries | 1 |
| 8 | Amputations, avulsions, enucleations | 1 |
Where injuries happen most
Manufacturing accounts for 55 percent of all burn cases, largely due to the prevalence of high-temperature processes and heavy machinery. Accommodation and food services also see high incident rates as you handle hot cooking oils and high-heat appliances.
Real cases like yours
Many reported incidents involve sudden equipment failures, such as gaskets blowing or fryers tipping, which expose you to scalding liquids or molten plastic. Other cases arise during routine maintenance when you encounter hidden heat sources that were not properly cooled or guarded. If your injury occurred under similar circumstances involving unexpected contact with heat, an attorney can help you review the specifics of your incident.
| Year | State | Industry | Incident summary | |
|---|---|---|---|---|
| 2025 | GA | Manufacturing | "On July 31, 2025, two employees were walking near a friction wash tank when a rubber gasket on top of the tank blew. Hot water mixed with 50% caustic chemical sprayed out and rained down on the employees. Both employees were brought to an emergency shower and were neutralized with vinegar. One employee was hospitalized with chemical and thermal burns to their upper back and eyes." | |
| 2025 | FL | Health Care | "An employee went outside to dispose of oil from a cooking pot into a large dumpster. When dumping the hot oil, it splashed back and burned her right hand. The employee was hospitalized." | |
| 2025 | SD | Accommodation & Food Services | "An employee was working to change the cooking oil in a 1-gallon countertop fryer. The fryer was held in place by three C-clamps. When two of the clamps were removed, the fryer fell and the hot oil contacted the employee from the waist down. The employee sustained burns to their lower body." | |
| 2025 | IL | Manufacturing | "On July 29, 2025, at approximately 1:15 PM, an employee was cleaning a vent on an extruder machine. He was breaking a hardened plastic clog by hitting it with a mallet and a screwdriver. When he broke through the first layer of plastic, hot liquefied plastic that was under the hardened surface splashed onto the employee causing burns to his face, neck, arms, and hands." | |
| 2025 | SD | Manufacturing | "An employee was priming a cook pump and sustained burns from contact with hot water (140-200 degrees F)." | |
| 2025 | OH | Manufacturing | "An employee was using a fork truck to move a tub containing molten iron that had been drained from the cupula. The tub tipped over and the molten metal came in contact with water. This caused the molten iron to splash back and burn the employee's upper torso." | |
| 2025 | LA | Accommodation & Food Services | "An employee transferred boiling water from a rethermalizer (kitchen equipment) into a bucket for cleaning the kitchen floor. Some of the hot water spilled onto the employee's left foot, causing severe burns." | |
| 2025 | TX | Mining | "An employee was working on a hot motor when radiator fluid sprayed onto his right hand, hip, back, and torso, resulting in second-degree burns that required hospitalization." | |
| 2025 | FL | Health Care | "At the end of an event, the injured employee was working with another employee to transfer a chafing dish from the bar area to the kitchen. The dish fell, causing hot water to spill onto the injured employee. The employee sustained burns to her stomach, right leg, and toes." | |
| 2025 | OH | Manufacturing | "An employee was prepping a dip pot for cleanout. He was moving a utility cart into position. While moving the dip pot onto the cart, hot weatherstripping product spilled out of the pot and onto the employee's hand. The employee sustained burns to his left hand and wrist requiring hospitalization." |
Source: OSHA Severe Injury Reports. Narratives are verbatim from filings; identifying details may have been redacted by OSHA.
Frequently asked questions
Yes, thermal burns sustained during the course of your employment are generally covered under Workers' Compensation. This system provides medical coverage and wage replacement. An attorney can help you ensure your claim is filed correctly to cover your full recovery needs.
Employers are required to provide appropriate personal protective equipment to prevent burn injuries. If your employer failed to provide necessary gear or ignored safety standards, this may impact your claim and the evidence needed for your case. An attorney can help you document these safety failures and understand your legal options.
Recovery time for thermal burns varies significantly based on the depth of the burn and the total body surface area affected. Severe cases often require multiple surgeries, skin grafts, and extensive physical therapy. An attorney can help you account for these long-term medical costs when evaluating your benefits.
Workers' Compensation is typically the exclusive remedy for workplace injuries, but there are exceptions if a third party, such as an equipment manufacturer, is liable for the defect. If a machine malfunctioned due to a design or manufacturing flaw, you might have a separate claim beyond Workers' Compensation. An attorney can help you evaluate the circumstances of your injury to determine if a third-party claim is possible.