How often these injuries happen
OSHA recorded 79 severe cases involving the explosion of nonpressurized vapors, gases, or liquids over the last decade. These incidents frequently result in thermal burns, which account for 73% of all reported injuries in this category.
You may face long-term recovery from deep tissue burns and complex wounds that require extensive medical intervention and time away from your job.
Common injuries
Explosions often occur when flammable residues in nonpressurized containers are exposed to heat sources like cutting torches or plasma cutters. Petroleum and coal products are the leading source of these incidents, frequently igniting during routine maintenance or cleaning tasks when safety protocols for handling volatile substances are overlooked.
| Injury Type | Incidents | |
|---|---|---|
| 1 | Thermal burns | 58 |
| 2 | Amputations, avulsions, enucleations | 4 |
| 3 | Fractures | 2 |
| 4 | Burns, corrosions, electrical injuries— unspecified | 2 |
| 5 | Severe wounds or internal injuries and other injuries | 2 |
| 6 | Traumatic injuries or exposures— unspecified | 2 |
| 7 | Surface and flesh wounds and other injuries | 2 |
| 8 | Chemical burns, corrosions | 2 |
Where injuries happen most
Manufacturing accounts for 24% of these severe explosion incidents. The high concentration of industrial processes, combined with the frequent use of flammable liquids and molten materials, creates environments where a single ignition source can lead to catastrophic injury.
Real cases like yours
Common patterns in these reports involve the ignition of residual vapors during the cutting or cleaning of containers that previously held flammable materials. You are often injured when you assume a container is empty or safe to work on, only for trapped gases to ignite. If your injury occurred during a similar task involving flammable substances, an attorney can help you evaluate your claim.
| Year | State | Industry | Incident summary | |
|---|---|---|---|---|
| 2025 | OH | Other Services | "An employee was cutting glass for a custom windshield and was using denatured alcohol during the cutting process. The denatured alcohol caught fire and the flame traveled to a gallon-sized container of the liquid. The can exploded and the employee sustained second- and third-degree burns from the waist up. " | |
| 2025 | GA | Other Services | "On April 18, 2025, an employee was cutting the lid off an empty 55-gallon drum using a plasma cutter. The drum originally contained a flammable liquid and residual liquid inside the drum ignited and exploded. The employee was hospitalized with burns to the face, chest, and arms." | |
| 2025 | NY | Wholesale Trade | "An employee was painting the inside of a new parts-cleaning machine for electric motors and motor parts when the airborne paint exploded and burned the employee. The employee sustained burns to their neck, lower forearms, and hands." | |
| 2025 | IL | Utilities | "On March 7, 2025, at 11:24 a.m., an employee was in a customer's basement working to light a water heater using an electric starter on the appliance. The employee pushed the ignitor when an explosion occurred, resulting in first- and second-degree burns on the face and neck as well as second- and third-degree burns on both hands." | |
| 2025 | IL | Manufacturing | "An employee was operating a mold machine when a pouring ladle that was coated with a water-based paste was submerged in molten aluminum. The moisture caused an explosion, resulting in severe burns over his body." | |
| 2024 | HI | Other Services | "An employee had used cleaning solvent to clean the engine room. The employee turned on a vacuum, which caused an explosion to occur, followed by a fire. The employee was hospitalized with second-degree burns." | |
| 2024 | GA | Construction | "Two employees were tack welding over a hole in a diesel tank. Diesel in the tank exploded. One employee suffered burns to the face; the other suffered severe burns over 40 percent of the back, shoulder, and arms." | |
| 2024 | NJ | Construction | "An underground crew was opening up a manhole for a visual inspection. Natural gas was leaking in the manhole. As they began to slide the cover off, a flash occurred when the leaking natural gas mixed with oxygen, creating a combustible environment. One employee was hospitalized." | |
| 2024 | GA | Manufacturing | "On September 11, 2024, an employee was attempting to remove a valve from an empty 55-gallon drum that had contained ethanol. The valve was stuck to the lower adapter ring. The employee tack welded the rings together to remove the entire valve when the drum exploded and the employee sustained burns and contusions." | |
| 2024 | TX | Construction | "Three employees were removing a cover from an oil well storage tank. Some of the bolts were corroded, so the employees used an electric grinder to remove the bolts. Sparks from the grinding wheel ignited liquid/fumes inside the tank, causing the tank to explode. One employee received severe burns to over 70% of their body." |
Source: OSHA Severe Injury Reports. Narratives are verbatim from filings; identifying details may have been redacted by OSHA.
Frequently asked questions
Thermal burns are the most frequent injury. These injuries can range from surface wounds to severe third-degree burns requiring surgery and skin grafts. An attorney can help you document the full extent of your medical needs for your claim.
Employers are responsible for ensuring that containers are properly purged, cleaned, and tested before any hot work is performed. If your employer failed to follow established safety procedures for handling flammable materials, you may have grounds for a claim. An attorney can investigate whether safety protocols were ignored.
Workers' Compensation is designed to cover your medical expenses and lost wages for injuries sustained on the job, including those from explosions. This coverage applies regardless of who was at fault for the incident. An attorney can ensure your claim accurately reflects the severity of your burns and long-term recovery costs.
Your first priority is seeking immediate medical attention and ensuring your injury is reported to your supervisor. Once you are stable, it is important to preserve any evidence, such as the equipment involved or witness statements. An attorney can help you navigate the reporting process and protect your rights to benefits.