How often these injuries happen
OSHA recorded 36 severe cases of harmful substance exposure over the last decade. The most frequent injury type is effects of poison, toxic, or allergenic exposure, which accounts for 42% of these reported incidents.
These events are uniquely dangerous because they often cause systemic damage. With 42% of cases involving chemical burns, the long-term health consequences for you can be severe and life-altering.
Common injuries
Chemical exposure often occurs when safety protocols for handling hazardous materials fail. Toxic non-metallic compounds are the leading source of these injuries, frequently entering your body through accidental splashes, hose leaks, or pressure releases. When your employer fails to provide adequate personal protective equipment or maintain secure containment systems, you are left vulnerable to corrosive acids and hazardous gases.
| 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 reported chemical exposure cases. This rate is driven by the regular use of industrial chemicals in production lines, where a single equipment failure or improper hose connection can lead to immediate and severe injury.
Real cases like yours
Many reported incidents follow a pattern of equipment failure during routine maintenance or transfer tasks. You are frequently injured when hoses disengage, fittings fail, or pressure releases cause hazardous liquids to spray onto your face, eyes, and skin. If any of these scenarios sound like what happened to you, an attorney can help you review the specifics of your incident to determine if employer negligence played a role.
| 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.
Frequently asked questions
The most common injuries include chemical burns, respiratory distress from inhaling toxic fumes, and systemic poisoning. These injuries can affect your skin, eyes, and internal organs, often requiring immediate hospitalization. An attorney can help you document the full extent of your injuries for your claim.
Yes, Workers' Compensation is designed to cover medical expenses and lost wages for injuries you sustained on the job, including chemical burns. You are entitled to benefits regardless of fault, provided the injury occurred during the course of your employment. An attorney can help you ensure your claim is filed correctly to maximize your benefits.
Employers are required to follow strict safety standards, such as the Hazard Communication Standard, to protect you from toxic substances. If your employer failed to provide proper training, safety equipment, or a safe work environment, they may be held accountable. An attorney can help you investigate whether your employer violated OSHA regulations that contributed to your exposure.
Seek immediate medical attention and ensure the incident is reported to your supervisor as soon as possible. Document the substance you were exposed to and take photos of the equipment or area where the failure occurred. Consulting with an attorney early can help you preserve critical evidence and protect your rights throughout the claims process.