How often these injuries happen
OSHA recorded 205 severe cases involving vehicle or machinery fires over the last decade. Thermal burns are the most common injury type, often requiring extensive medical intervention and long-term rehabilitation.
The severity of these incidents often stems from the proximity of flammable materials to high-heat engine components or pressurized hydraulic systems.
Burned by equipment? Check what benefits you may be owed.
Free Benefits ReviewCommon injuries
Fires in the workplace often occur when fuel sources like gasoline or hydraulic fluid contact hot surfaces such as mufflers, exhaust pipes, or friction-heated machinery. Trucks and specialized industrial equipment are frequent sources of these incidents, especially during refueling or maintenance tasks. When safety protocols regarding flammable liquid storage or equipment maintenance are ignored, the risk of sudden ignition increases significantly.
| Injury Type | Incidents | |
|---|---|---|
| 1 | Thermal burns | 160 |
| 2 | Effects of poison, toxic, or allergenic exposure— unspecified | 15 |
| 3 | Fractures | 6 |
| 4 | Severe wounds or internal injuries and other injuries | 5 |
| 5 | Burns and toxic effects (including smoke inhalation) | 5 |
| 6 | Poisoning, poisoning-related asphyxia | 3 |
| 7 | Burns, corrosions, electrical injuries— unspecified | 2 |
| 8 | Chemical burns, corrosions | 2 |
Where injuries happen most
Manufacturing accounts for 26% of all recorded fire incidents, largely due to the constant operation of heavy machinery and the presence of combustible materials. Mining and construction follow, where the use of high-powered equipment and the necessity of field refueling create environments where fire hazards are a persistent reality.
Real cases like yours
Common patterns in these reports include hydraulic line failures, improper refueling of hot engines, and the accidental ignition of spilled fuel. These incidents often occur during routine maintenance or operation, highlighting a recurring failure to manage heat sources and flammable liquids safely. 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 | MS | Construction | "An employee was operating the scraper when a hydraulic line ruptured and created a flame. The employee jumped off the equipment and broke a leg." | |
| 2025 | IL | Mining | "Three employees were servicing and cleaning an oil well when a fire occurred. All three employees were burned. One employee was treated and released. Two employees were hospitalized and one hospitalized employee required surgery." | |
| 2025 | TX | Construction | "On July 18, 2025, a light-equipment operator was using a pressure washer to remove cementitious material buildup from the internal wall of a tremie pipe. The operator was refueling the pressure washer using a 5-gallon gas can. The equipment's engine and exhaust were still hot and the gasoline ignited. Flames spread to the pressure washer skid, a nearby fire extinguisher, and the operator s clothing. The operator sustained second-degree burns to approximately 35% of their body including their hands, lower abdominal area, upper thighs, and knees. The employee was hospitalized." | |
| 2025 | IL | Administrative Services | "An employee was refueling a commercial-grade riding lawn mower. As he was refilling the tank, the gasoline splashed onto the muffler, which sparked and caught fire. The employee suffered burns to both thighs and the left side of his abdomen." | |
| 2025 | TX | Manufacturing | "An employee was removing burning material from a machine. While being used to extinguish a fire, the diffuser/horn of a fire extinguisher disconnected from the hose and the hose struck the employee's neck, back, side, and shoulder. The employee sustained a closed fracture of thyroid cartilage and a vertebral artery occlusion." | |
| 2025 | TX | Mining | "Employee 1 was operating a crane to move a pumping unit. Employee 2 was holding a tag line. The crane lifted the pumping unit and began rotating clockwise to place it on top of a concrete base. The front driver s side outrigger and float began to sink into the ground, causing the crane to lean over. This caused the pumping unit to swing and strike into an adjacent wellhead, breaking some piping and causing a fire. The crane then fell over and it's boom broke piping on a second wellhead, contributing further to the fire. Employee 1 fell out of the cab and crawled out of the fire. He sustained burns to his face and hands and had fractured ribs. He was hospitalized. Employee 2 was burned on his cheek, arm, and leg." | |
| 2025 | FL | Other Services | "An employee was repairing a forklift at a customer site when there was a flash fire (blowback from the throttle body), that burned their right forearm." | |
| 2025 | GA | Manufacturing | "An employee was doing brazing work on a copper line, part of a commercial refrigeration unit that was charged with propane. A blockage in one of the tubes resulted in a flame blowback. The employee suffered second-degree burns to the left side of the face and neck area. They were hospitalized, requiring surgery." | |
| 2025 | TX | Construction | "An employee was starting a large ventilation blower. Fire/gasoline shot out of the blower and burned his left shoulder and underarm." | |
| 2025 | PA | Construction | "An employee was using a saw to make cuts into concrete masonry units. The saw caught fire, which caused the employee to drop the saw and the gas cap broke. The gas spilled partially onto the employee and the fire spread to their clothing. The employee suffered burns to the waist area and was hospitalized. " |
Source: OSHA Severe Injury Reports. Narratives are verbatim from filings; identifying details may have been redacted by OSHA.