Chemical burns at Work — Injury Statistics and Claims Information
Chemical burns at Work
Stable injury rates mask persistent safety gaps
OSHA has documented 740 severe cases involving chemical burns over the last decade. These injuries frequently impact multiple body parts, with cheek regions and eyes representing significant areas of concern for long-term health.
Chemical burns are uniquely dangerous because they often cause deep tissue destruction that continues long after the initial contact. Workers may face permanent scarring, vision loss, or chronic respiratory issues that limit their ability to return to their previous roles.
What's Driving the Trend?
The 10-year trend for chemical burns remains stable, yet the 5-year data shows a 47.1% increase in reported severe cases. This suggests that while overall incident numbers fluctuate, the severity of exposure events remains a critical safety failure.
Manufacturing accounts for 50.1% of all reported incidents, largely due to the widespread use of corrosive acids and bases in production processes. Transportation and warehousing also show elevated risks, often linked to the handling of leaking containers during transit.
How Chemical burns Happen at Work
Top causes based on OSHA incident reports
Exposure to harmful substances through direct skin contact is the primary cause of these injuries, accounting for 85.6% of all reported cases. These incidents often occur when workers handle corrosive cleaning agents or industrial chemicals without adequate protective barriers.
| Cause | Incidents | |
|---|---|---|
| 1 | Exposure to harmful substance through exposed tissue | 632 |
| 2 | Fall on same level | 30 |
| 3 | Inhalation of harmful substance | 17 |
| 4 | Ingestion of harmful substance | 15 |
| 5 | Exposure to harmful substance—multiple routes of exposure | 12 |
| 6 | Other fall to lower level | 10 |
| 7 | Exposure to harmful substances— unspecified | 4 |
| 8 | Explosion of pressure vessel, piping, or tire | 3 |
Why This Matters for Your Case
Employers are required to follow 29 CFR 1910.132, which mandates the use of personal protective equipment to prevent chemical contact. Furthermore, 29 CFR 1910.1200 requires comprehensive hazard communication training, ensuring workers understand the specific risks of the chemicals they handle daily.
Industries with Most Chemical burns
Where these injuries occur most frequently
Manufacturing leads all sectors with 371 severe incidents, driven by the constant interaction between workers and corrosive acids or bases. Transportation and warehousing follow, where workers are frequently exposed to leaking chemical products during loading and delivery tasks.
High-Risk Industries and Your Rights
Employers in these high-risk sectors must adhere to 29 CFR 1910.151, which requires the provision of suitable facilities for quick drenching or flushing of the eyes and body. Failure to maintain these systems or provide proper chemical handling protocols constitutes a direct violation of federal safety standards.
Real Incident Reports
From actual OSHA investigation files
These reports reveal a recurring pattern of equipment failure and inadequate containment during routine operations. Whether it is a ruptured sight glass releasing vapors or a leaking package during delivery, the lack of proper containment and personal protective equipment remains a consistent factor in these severe injuries.
"An employee was using a floor machine and chemical floor stripper to strip the finish from the floor. The employee slipped backward on the wet floor and landed on their back. The employee was hospitalized with chemical burns caused by the floor stripper."
"Employees were investigating the vapor conditions at the purification vent scrubber after a restart. Employees were looking through the sight glass, when the glass ruptured, releasing chemical vapors. Two employees sustained chemical burns to their upper body."
"An employee was delivering a package when it leaked acid on their skin, burning it."
"An employee was de-bundling cubed feedstock consisting of plastic barrels. The employee was putting feedstock into the shredders manually. She lifted a drum to put it in the shredding machine and sulfuric acid spilled down the front of her left leg. The employee sustained chemical burns to her lower leg requiring hospitalization."
"An employee was washing the tunnel equipment area using a sprayer and a chemical containing 5-10% hydrofluoric acid. The chemical seeped into his clothing and caused chemical burns to his abdomen and upper thighs. The employee was hospitalized."
"A bartender tasted a small amount of an unknown liquid found behind a bar. He had a severe reaction to the liquid, which proved to be concentrated liquid detergent, and he suffered burns to the interior of the mouth. He was hospitalized and required surgery."
"Three maintenance employees were working on chemical lines feeding into a large above ground wastewater treatment tank. Sodium hydroxide and sulfuric acid reacted in a floor drain and the chemicals sprayed onto the three employees. One employee was taken to the hospital for burns to his eyes."
"On June 24, 2025, at 2:11 p.m., an employee was about to unbolt a spool connected to a vessel flange that needed to be removed for another crew to clean it. The employee saw leaking chemical product. The employee began running away from the product when he slipped and fell into the product, resulting in chemical burns to his arms and legs. The employee was hospitalized. Personal protective equipment (PPE) was not worn at the time."
"An employee was lifting a level controller that had been on a vertical tank. Residual phenol-containing liquid dripped onto his right thigh, causing a chemical burn. He was hospitalized."
"An employee was using a pump to transfer hazardous waste between barrels when the pump broke and sprayed the mixture into the employee's face, resulting in chemical burns to their face and eyes."
Common Questions About Chemical burns Claims
The ClaimsBoost Research Team aggregates official government data to help workers understand workplace injury trends and their coverage options.
ClaimsBoost is not a law firm and does not provide legal advice. ClaimsBoost is not affiliated with, endorsed by, or connected to any government agency. Performance scores, rankings, and statistics displayed on this site are calculated by ClaimsBoost using publicly available government data from OSHA severe injury reports. Individual results may vary. Nothing on this site should be construed as legal advice or a guarantee of benefits. If you need legal help, we can connect you with licensed attorneys in your area.Some written content on this page was created with the assistance of AI to help interpret and explain the data. AI can make mistakes — all content has been reviewed for accuracy, but we encourage you to verify any information that is important to your situation.