How often these injuries happen
OSHA recorded 36 severe cases of chemical exposure over the past decade, with effects of poison or toxic exposure accounting for 42% of all incidents. These injuries often result in immediate hospitalization due to the rapid onset of respiratory distress or systemic poisoning.
Because these incidents often involve corrosive substances, you may suffer damage to multiple body parts simultaneously, leading to complex and lengthy recovery processes.
Common injuries
Chemical exposure at work typically occurs when safety protocols for handling hazardous materials fail. Toxic non-metallic compounds are the leading source of these incidents, often released during maintenance on pressurized lines or when transferring liquids between containers. You are most at risk when fittings disengage, hoses leak, or pressure releases cause unexpected spraying of corrosive acids and bases.
| 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 chemical exposure incidents, largely due to the high volume of industrial processes involving hazardous reagents. In these environments, the complexity of piping systems and the frequency of chemical transfers create constant opportunities for containment failures. Administrative services and wholesale trade also see elevated risks, often linked to the handling and storage of bulk chemical products.
Real cases like yours
Many reported incidents follow a pattern of equipment failure during routine maintenance, such as disconnecting hoses or clearing clogged nozzles. These scenarios often lead to sudden releases of pressurized chemicals onto your face, eyes, or hands. If your injury occurred during a similar maintenance task or due to a sudden equipment malfunction, an attorney can help you review the specific circumstances of your exposure.
| 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
Chemical exposure can lead to chronic respiratory issues, permanent skin damage, or long-term organ toxicity depending on the substance involved. Even after initial treatment, you may face ongoing medical needs and potential complications that require long-term care. An attorney can help you document these future medical requirements to ensure your claim accounts for your long-term recovery.
Workers' Compensation is designed to cover medical expenses and lost wages for injuries sustained during the course of employment, including chemical burns and toxic inhalation. You are generally entitled to benefits regardless of who was at fault for the exposure. An attorney can help you verify that your claim accurately reflects the full extent of your medical needs.
In most cases, Workers' Compensation is the exclusive remedy for workplace injuries, meaning you cannot sue your employer directly for negligence. However, there may be third-party claims if a defective product or equipment manufacturer contributed to the exposure. An attorney can help you evaluate whether a third-party claim is possible in your specific situation.
OSHA requires employers to maintain strict hazard communication programs, provide appropriate personal protective equipment, and ensure that all chemical handling equipment is properly maintained. When these standards are ignored, the risk of severe injury increases significantly. An attorney can help you determine if your employer failed to meet these safety obligations.