How often these injuries happen
OSHA recorded 36 severe cases of harmful substance exposure over the last decade. Effects of poison, toxic, or allergenic exposure account for 42% of these incidents, often resulting in complex medical needs that extend far beyond immediate first aid.
You face significant risks from these exposures, which often lead to long-term respiratory, neurological, or dermatological complications that require extensive and costly medical intervention.
Exposed to chemicals? Check what benefits you may be owed.
Free Benefits ReviewCommon injuries
Chemical exposure incidents typically occur when containment systems fail during routine maintenance or transfer operations. You are frequently injured when toxic non-metallic compounds or corrosive acids escape through faulty hoses, leaking fittings, or pressurized lines. These events often happen during tasks like clearing clogged nozzles or disconnecting hydraulic components, where residual chemicals are released unexpectedly into your breathing zone or onto your skin.
| Injury Type | Incidents | |
|---|---|---|
| 1 | Effects of poison, toxic, or allergenic exposure— unspecified | 15 |
| 2 | Chemical burns, corrosions | 12 |
| 3 | Poisoning, poisoning-related asphyxia | 2 |
| 4 | Traumatic injuries or exposures— unspecified | 2 |
| 5 | Burns and toxic effects (including smoke inhalation) | 2 |
| 6 | Allergic and irritant dermatitis— acute | 1 |
| 7 | Other diseases due to viruses | 1 |
| 8 | Poison, toxic, or allergenic effects— other respiratory | 1 |
Where injuries happen most
Manufacturing accounts for 42% of all severe chemical exposure incidents, largely due to the high volume of hazardous materials processed in these facilities. Administrative services and wholesale trade also face elevated risks, as you may handle chemical totes or transport hazardous substances without the specialized containment infrastructure found in heavy industrial plants.
Real cases like yours
Common patterns in these incidents involve the sudden release of pressurized chemicals during equipment maintenance or hose changes. You are frequently caught off guard when fittings disengage or lines clear unexpectedly, leading to direct contact with corrosive agents or the inhalation of toxic vapors. If your injury occurred during a similar equipment failure or maintenance procedure, an attorney can help you evaluate your claim and ensure you receive the full benefits you are entitled to.
| Year | State | Industry | Incident summary | |
|---|---|---|---|---|
| 2025 | ND | Manufacturing | "An employee was removing contaminants from a low point drain on an ammonia line through a hose and into a container of water. A release of pressure from the end of the hose exposed the employee to anhydrous ammonia, resulting in chemical burns to his face, arm, and chest as well as ammonia inhalation. He was hospitalized." | |
| 2025 | FL | Transportation & Warehousing | "An employee was performing a maintenance test of a hydraulic component (case drain overheat switch) that involved disconnecting the hose/switch. Hydraulic fluid began leaking and the employee went to reconnect the hose/switch but fire-resistant hydraulic fluid sprayed the employee's face, eyes, and mouth. The employee ingested some of the hydraulic fluid." | |
| 2025 | LA | Administrative Services | "An employee was performing preventative maintenance on a tanker trailer. He moved a hose for an inspection date and residual liquid toluene diisocyanate (TDI) came out of the hose and onto the employee's face, eyes, and hands. He was hospitalized with breathing issues." | |
| 2024 | FL | Manufacturing | "An employee was changing out a hose on a chemical tote. The fitting for the tote disengaged and the employee was exposed to peracetic acid that caused chemical burns and respiratory distress. " | |
| 2024 | OH | Utilities | "An employee was working to unplug a 1.5-inch hydrated lime injection nozzle and disconnected a flexible hose at a camlock fitting to access the nozzle. When the line cleared, the hydrated lime released the blockage and blew into the employee's face. The employee ingested and inhaled hydrated lime (a respiratory irritant) and was hospitalized. " | |
| 2024 | NY | Manufacturing | "An employee was operating a press. A billet was uneven as it entered the loader; it hit the ram and then sheared off a hydraulic line, which sprayed hydraulic fluid into the employee's mouth and was ingested. The fluid was ignited, and the fireball caught the employee's hair on fire and he sustained first-degree burns to his forehead and hand. Ingestion of the fluid and inhalation of the fumes affected the employee's airway. He was hospitalized." | |
| 2024 | TX | Manufacturing | "An employee was attempting to perform an under-pressure cleaning of a brewing tank with a 25% hydrogen peroxide and peracetic acid blend solution. The chemicals sprayed into the employee's face, resulting in chemical burns to the employees' mouth, esophagus and face. The employee was hospitalized." | |
| 2024 | OH | Manufacturing | "An employee was inside a down draft ventilation booth scooping and measuring Cyclobenzaprine. The employee lost consciousness and was hospitalized for overexposure to Cyclobenzaprine, a muscle relaxant. The employee was not wearing respiratory or skin protection on their face at the time. " | |
| 2024 | FL | Retail Trade | "On April 21, 2024, at 3:00 PM, an employee picked up a gasoline pump nozzle that had separated from the hose and still had gas flowing. They were exposed to gasoline through skin exposure and inhalation. The employee was hospitalized for poisoning by fluorinated hydrocarbon." | |
| 2023 | AR | Manufacturing | "On November 17, 2023, a maintenance employee opened a line and residual bromine was released. The employee sustained burns to their palm and left leg and also suffered an inhalation injury." |
Source: OSHA Severe Injury Reports. Narratives are verbatim from filings; identifying details may have been redacted by OSHA.