Thermal Burn Injuries at Work — Injury Statistics and Claims Information
Thermal Burn Injuries at Work
Severe burn incidents show a recent decline
OSHA reports document 1,849 severe incidents involving contact with hot objects or substances, with thermal burns accounting for 98.5 percent of these cases. These injuries often involve deep tissue damage that requires immediate hospitalization and long-term medical intervention.
The severity of these burns is reflected in the high frequency of injuries to multiple body parts, which account for 37.3 percent of all reported cases. Workers frequently suffer from extensive damage to hands, fingers, and extremities, leading to permanent scarring or loss of function.
What's Driving the Trend?
Over the last decade, severe burn incidents have decreased by 5.0 percent, though the 5-year trend shows a 27.6 percent increase. Steam, vapors, and non-chemical liquids remain the primary source of injury, representing 41.9 percent of all reported events.
Manufacturing industries lead with 54.8 percent of all cases, often due to the proximity of workers to high-temperature machinery and pressurized systems. Accommodation and food services follow, where high-volume cooking equipment and hot oil handling create consistent risks for staff.
Injury Types from Thermal Burn Injuries
Top causes based on OSHA incident reports
Thermal burns in the workplace often occur when safety barriers fail or when equipment is improperly maintained. Workers are frequently exposed to hot steam or liquids during cleaning, maintenance, or routine operation of machinery like extruders and fryers. Splashes from hot oil or the sudden release of pressurized steam from gaskets and valves are common mechanisms that lead to severe, life-altering burns.
| 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 |
Why This Matters for Your Case
Employers are legally required to mitigate these risks under 29 CFR 1910.132, which mandates the use of personal protective equipment to protect against thermal hazards. Furthermore, 29 CFR 1910.147, the lockout-tagout standard, is frequently cited when machinery is not properly de-energized, leading to accidental contact with heated components during maintenance.
Industries with Most Thermal Burn Injuries
Where these injuries occur most frequently
Manufacturing accounts for 54.8 percent of all severe burn incidents, largely due to the constant use of high-heat extruders and chemical processing tanks. Accommodation and food services represent 11.4 percent of cases, where the fast-paced environment and reliance on deep fryers and hot liquids create frequent opportunities for accidental contact.
High-Risk Industries and Your Rights
In high-risk sectors, employers must comply with 29 CFR 1910.212, which requires machine guarding to prevent contact with hot surfaces or moving parts. Additionally, 29 CFR 1910.1200, the hazard communication standard, requires employers to provide training on the specific thermal risks associated with the substances and equipment used in the facility.
Real Incident Reports
From actual OSHA investigation files
Reported incidents reveal a recurring pattern of failure during routine maintenance and cleaning tasks. Many injuries occur when workers attempt to clear clogs in machinery or handle hot oil without adequate protective gear or proper equipment stabilization. These narratives highlight how mechanical failures, such as blown gaskets or unsecured fryers, frequently result in immediate and severe thermal trauma.
"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."
"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."
"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."
"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."
"An employee was priming a cook pump and sustained burns from contact with hot water (140-200 degrees F)."
"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."
"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."
"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."
"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."
"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."
Common Questions About Thermal Burn Injuries Claims
The ClaimsBoost Research Team aggregates official government data to help workers understand workplace injury trends and their coverage options.
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