Pressure Vessel and Tire Explosions at Work — Injury Statistics and Claims Information
Pressure Vessel and Tire Explosions at Work
A decade of increasing severe injury reports
OSHA recorded 272 severe incidents involving the explosion of pressure vessel, piping, or tire over the last ten years. These events frequently result in fractures, which account for 27.8 percent of all reported cases, and thermal burns, which make up 24.8 percent of the total.
The physical impact of these explosions is often catastrophic, frequently affecting multiple body parts in 25.4 percent of cases. Workers often face life-altering consequences, including intracranial injuries and severe cuts and lacerations that require immediate surgical intervention.
What's Driving the Trend?
The 10-year trend shows a significant 40.9 percent increase in reported incidents, highlighting a persistent failure in equipment maintenance and safety protocols. Pressurized containers remain the primary source of danger, involved in 38.9 percent of all reported explosions.
Manufacturing and retail trade sectors lead in incident frequency, accounting for a combined 32.7 percent of all reports. These industries rely heavily on pneumatic tools and pressurized systems, where inadequate inspection of undercarriage components and piping often creates a high-risk environment.
Injury Types from Pressure Vessel and Tire Explosions
Top causes based on OSHA incident reports
Explosions typically occur when pressurized containers or pneumatic tires reach their failure point due to structural fatigue, improper inflation, or external damage. Workers often encounter these hazards when servicing vehicle undercarriages, inflating heavy-duty tires, or operating welding equipment near aerosol canisters. These incidents are rarely accidental, as they often stem from the failure to monitor pressure limits or maintain the integrity of hoses and tanks.
| Injury Type | Incidents | |
|---|---|---|
| 1 | Fractures | 75 |
| 2 | Thermal burns | 67 |
| 3 | Traumatic injuries or exposures— unspecified | 29 |
| 4 | Cuts, lacerations, punctures without injury to internal structures | 26 |
| 5 | Severe wounds or internal injuries and other injuries | 19 |
| 6 | Intracranial Injuries | 17 |
| 7 | Amputations, avulsions, enucleations | 11 |
| 8 | Injuries to internal organs and major blood vessels | 5 |
Why This Matters for Your Case
Employers are legally mandated to maintain safe operating conditions for all pressurized equipment under 29 CFR 1910.169, which covers the design and installation of air receivers. Furthermore, 29 CFR 1910.101 requires that compressed gas cylinders be inspected and maintained to prevent rupture. Failure to adhere to these specific safety standards often constitutes a direct violation of federal workplace safety regulations.
Industries with Most Pressure Vessel and Tire Explosions
Where these injuries occur most frequently
Manufacturing facilities account for 18.4 percent of all reported pressure-related incidents, largely due to the constant use of high-pressure air lines and welding gases. Retail trade follows closely at 14.3 percent, where employees frequently handle tire inflation and maintenance tasks without adequate protective barriers or training.
High-Risk Industries and Your Rights
In high-risk sectors like manufacturing and construction, employers must comply with 29 CFR 1910.169 regarding the safe operation of air receivers and pressure vessels. Additionally, 29 CFR 1910.132 requires employers to provide appropriate personal protective equipment to shield workers from the force of potential explosions. Failure to implement these safeguards leaves workers vulnerable to preventable, high-impact injuries.
Real Incident Reports
From actual OSHA investigation files
Incident reports reveal a recurring pattern of workers sustaining severe injuries while performing routine maintenance on tires or welding near pressurized canisters. These accounts consistently show that a lack of proper shielding or failure to inspect equipment for structural weaknesses leads to sudden, violent releases of energy that cause fractures and thermal burns.
"On July 19, 2025, an employee was filling a wheelbarrow tire with air when the tire exploded, resulting in severe injuries to their right hand including a partial amputation."
"An employee was moving a piece of metal he had just finished welding. The corner of the metal triggered the welding gun. The welding gun arced to an aerosol paint can and the can exploded. The employee sustained burns to his face, arms, and hands, and had blisters around his nose and mouth."
"A mechanic was replacing the airbag suspension on the front axle of a utility trailer. The airbag blew out, causing an injury to the mechanic's left foot that required hospitalization and surgery."
"An agricultural tire failed and struck an employee's face and left hand. The employee suffered a cut above the left eye and multiple fractures in the hand and was hospitalized for surgery."
"An employee was welding on a diesel transfer tank inside a garage. After several minutes of welding, the tank exploded. The employee was thrown from the truck on fire and suffered burns."
"An employee was lighting a pilot light that burns off residual oxygen in the purge chamber of a heat-treating furnace. Residual gas and built-up oxygen in the purge chamber caused an explosion, which blew the front of the furnace's door off its track and the hood/exhaust system off its rivets. The employee was knocked down and suffered burns and lacerations to the left side of his face."
"An employee was helping with directional bore operations. The drill hit a high-pressure gas line. The employee was thrown up into the air and fell to the ground. The employee suffered injuries to the front and back of the head, a broken wrist, and abrasions to the legs."
"A mechanic was replacing the passenger's side airbag on the rear end of a truck when the driver's side airbag on the rear end blew and the employee sustained injury to the left hand, wrist and forearm. The employee sustained fractures that required hospitalization and surgery."
"On April 22, 2025, at approximately 6:35 p.m., an employee was working on a turnaround project. The crew was venting off nitrogen from an 18-inch pipeline into a 2-inch silencer vessel. The 18-inch pipe was pressurized with nitrogen gas at approximately 1200 psig. The silencer suddenly ruptured and its internal components were blown away. The shell of the silencer struck downward, landed on the employee's left hand due to high pressure, and lacerated the employee's left index finger resulting in amputation. The employee's left wrist was also broken."
"An employee was inflating a new tire on a tug. The tire exploded, lacerating the employee's right hand and breaking their right hip."
Common Questions About Pressure Vessel and Tire Explosions Claims
The ClaimsBoost Research Team aggregates official government data to help workers understand workplace injury trends and their coverage options.
ClaimsBoost is not a law firm and does not provide legal advice. ClaimsBoost is not affiliated with, endorsed by, or connected to any government agency. Performance scores, rankings, and statistics displayed on this site are calculated by ClaimsBoost using publicly available government data from OSHA severe injury reports. Individual results may vary. Nothing on this site should be construed as legal advice or a guarantee of benefits. If you need legal help, we can connect you with licensed attorneys in your area.Some written content on this page was created with the assistance of AI to help interpret and explain the data. AI can make mistakes — all content has been reviewed for accuracy, but we encourage you to verify any information that is important to your situation.