How often these injuries happen
OSHA recorded 272 severe cases involving pressure vessel and tire explosions over the last decade. Fractures are the most common outcome, appearing in 28 percent of these incidents and often requiring extensive surgical intervention.
These events frequently cause severe thermal burns and traumatic injuries that leave you with long-term physical limitations.
Common injuries
Explosions typically occur when pressurized containers fail due to mechanical stress, improper maintenance, or accidental contact with external energy sources. Common scenarios involve the failure of undercarriage components or the rupture of pipes and tubing during routine operations. When equipment is not properly inspected or guarded, a simple task like inflating a tire or welding near a tank can trigger a violent release of energy.
| 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 |
Where injuries happen most
Manufacturing accounts for 18 percent of these incidents, as the high volume of pressurized machinery creates constant exposure risks. You may interact with complex pneumatic systems that require strict adherence to safety protocols to prevent catastrophic failures.
Real cases like yours
Common patterns in these reports include sudden equipment failure during routine maintenance and accidental ignition of pressurized vessels during welding or repair work. You may be caught off guard by the speed and intensity of the blast, leading to severe hand, face, and limb injuries. If any of these scenarios sound like what happened to you, an attorney can help you review the specifics of your incident.
| Year | State | Industry | Incident summary | |
|---|---|---|---|---|
| 2025 | CT | Other Services | "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." | |
| 2025 | GA | Manufacturing | "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." | |
| 2025 | FL | Other Services | "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." | |
| 2025 | MT | Retail Trade | "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." | |
| 2025 | NY | Construction | "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." | |
| 2025 | NE | Manufacturing | "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." | |
| 2025 | CO | Construction | "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." | |
| 2025 | MS | Administrative Services | "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." | |
| 2025 | TX | Construction | "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." | |
| 2025 | GU | Professional Services | "An employee was inflating a new tire on a tug. The tire exploded, lacerating the employee's right hand and breaking their right hip." |
Source: OSHA Severe Injury Reports. Narratives are verbatim from filings; identifying details may have been redacted by OSHA.
Frequently asked questions
You may suffer from fractures and thermal burns due to the intense force and heat released during an explosion. These injuries often affect the hands, arms, and facial region, requiring immediate and often long-term medical care. An attorney can help you document these injuries to ensure your claim reflects the full scope of your medical needs.
Workers' Compensation is designed to cover your medical expenses and lost wages for injuries sustained during the course of employment, regardless of who was at fault. Because these explosions often involve complex equipment failures, you may be entitled to benefits that cover your entire recovery period. An attorney can help you verify that your benefits are being calculated correctly.
Employers are required to maintain equipment in a safe condition and follow OSHA regulations regarding the inspection of pressurized systems. If a failure occurred because of neglected maintenance or improper safety protocols, you may have additional legal options beyond standard Workers' Compensation. An attorney can help you investigate whether your employer violated safety standards that contributed to your injury.
Your first priority is seeking medical attention and ensuring your injury is documented by a healthcare professional. You should also report the incident to your supervisor immediately and keep records of all communications regarding the accident. An attorney can help you gather the necessary evidence to support your claim and protect your rights throughout the process.