Thermal Burns at Work — Injury Statistics and Claims Information
Thermal Burns at Work
Severe burn incidents are trending upward
OSHA has recorded 3,393 severe thermal burn incidents, with multiple body parts frequently affected in a single event. These injuries often involve the hands, face, and extremities, which are critical for daily function and professional tasks.
The consequences of a thermal burn extend far beyond the initial pain. Survivors often face extensive skin grafting, permanent nerve damage, and significant limitations in range of motion that can permanently alter their ability to perform manual labor.
What's Driving the Trend?
Over the last decade, severe burn cases have increased by 0.9 percent, with a notable 25.9 percent surge over the last five years. This upward trajectory suggests that current safety protocols are failing to keep pace with the hazards present in high-heat work environments.
Manufacturing accounts for 44.3 percent of all severe burn cases, followed by construction and food services. These industries rely heavily on high-temperature machinery and volatile substances, creating a constant risk of contact with steam, hot liquids, and molten materials.
How Thermal Burns Happen at Work
Top causes based on OSHA incident reports
Contact with hot objects or substances is the leading cause of these injuries, accounting for 53.9 percent of all reported cases. Workers are frequently injured when steam, vapors, or hot liquids escape from pressurized systems or when they come into direct contact with heated surfaces during routine operation.
| Cause | Incidents | |
|---|---|---|
| 1 | Contact with hot objects or substances | 1,818 |
| 2 | Flash fire | 545 |
| 3 | Ignition of clothing | 165 |
| 4 | Vehicle or machinery fire | 160 |
| 5 | Fire— unspecified | 99 |
| 6 | Fall on same level | 90 |
| 7 | Explosion— n.e.c. | 71 |
| 8 | Explosion of pressure vessel, piping, or tire | 67 |
Why This Matters for Your Case
Employers are required to maintain safe working conditions under 29 CFR 1910.132, which mandates the use of personal protective equipment to shield workers from thermal hazards. Furthermore, 29 CFR 1910.147, the lockout and tagout standard, is essential for preventing accidental activation of machinery that generates extreme heat during maintenance.
Industries with Most Thermal Burns
Where these injuries occur most frequently
Manufacturing leads all sectors with 44.3 percent of severe burn incidents, primarily due to the widespread use of high-heat extruders and molten materials. Construction and food services also present high risks, as workers in these fields frequently handle pressurized equipment and boiling liquids in fast-paced, high-pressure environments.
High-Risk Industries and Your Rights
In these high-risk industries, employers must adhere to 29 CFR 1910.212, which requires adequate machine guarding to prevent accidental contact with hot components. Additionally, 29 CFR 1910.106 regulates the handling of flammable liquids, which are a primary source of flash fires and ignition-related burn injuries.
Real Incident Reports
From actual OSHA investigation files
Common patterns in these reports reveal that many injuries occur during routine maintenance or the transfer of hot substances. Inadequate containment of hot liquids, failure to properly secure equipment during cleaning, and the lack of thermal-resistant barriers are recurring factors that lead to severe, life-altering burns.
"An employee was fueling a gasoline-powered pressure washer with a safety fuel can. During the transfer the fuel ignited, causing a fire. The employee sustained burns to his nose, and his right hand and forearm."
"An employee went outside to dispose of oil from a cooking pot into a large dumpster. When dumping the hot oil, it splashed back and burned her right hand. The employee was hospitalized."
"An employee was working to change the cooking oil in a 1-gallon countertop fryer. The fryer was held in place by three C-clamps. When two of the clamps were removed, the fryer fell and the hot oil contacted the employee from the waist down. The employee sustained burns to their lower body."
"On July 29, 2025, at approximately 1:15 PM, an employee was cleaning a vent on an extruder machine. He was breaking a hardened plastic clog by hitting it with a mallet and a screwdriver. When he broke through the first layer of plastic, hot liquefied plastic that was under the hardened surface splashed onto the employee causing burns to his face, neck, arms, and hands."
"An employee was priming a cook pump and sustained burns from contact with hot water (140-200 degrees F)."
"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."
"An employee was using a torch to burn off liquid petroleum gas from old 100-pound cylinders so they could be recycled. When he went to move a tank, some gas spilled onto the ground, then ignited in a flash that engulfed him. He was burned on the face, hands, and back and was hospitalized."
"An employee was using a fork truck to move a tub containing molten iron that had been drained from the cupula. The tub tipped over and the molten metal came in contact with water. This caused the molten iron to splash back and burn the employee's upper torso."
"An employee transferred boiling water from a rethermalizer (kitchen equipment) into a bucket for cleaning the kitchen floor. Some of the hot water spilled onto the employee's left foot, causing severe burns."
"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."
Common Questions About Thermal 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.