How often these injuries happen
OSHA recorded 206 severe cases involving corrosive acids over the last decade. The vast majority of these incidents result in chemical burns, which often require extensive medical treatment and long-term recovery periods.
These injuries are severe because they frequently impact vital body systems. You may suffer permanent damage to skin, eyes, and respiratory tracts, leading to significant time away from your job.
How these injuries happen
Most injuries occur when you are directly exposed to harmful substances through skin contact or inhalation. This happens when containers leak, pipes fail, or protective equipment is inadequate during the transfer of hazardous chemicals. These accidents occur during routine maintenance or material handling tasks where the risk of splashing or spilling is high.
| Cause | Incidents | |
|---|---|---|
| 1 | Exposure to harmful substance through exposed tissue | 168 |
| 2 | Inhalation of harmful substance | 27 |
| 3 | Exposure to harmful substance—multiple routes of exposure | 5 |
| 4 | Exposure to harmful substances— unspecified | 3 |
| 5 | Flash fire | 1 |
| 6 | Ingestion of harmful substance | 1 |
| 7 | Explosion— unspecified | 1 |
Where injuries happen most
Manufacturing accounts for 58% of all reported acid-related injuries, as the high-volume use of industrial chemicals creates constant exposure risks. Transportation and warehousing account for 10% of incidents, often linked to the handling of leaking containers or improper storage of hazardous materials during transit.
Real cases like yours
Common patterns in these reports involve you being splashed during routine transfers, leaks from damaged containers, or exposure while cleaning equipment. These incidents stem from a lack of proper containment or inadequate personal protective equipment. If your injury occurred during a similar task, an attorney can help you evaluate the specific failures that led to your exposure.
| Year | State | Industry | Incident summary | |
|---|---|---|---|---|
| 2025 | MA | Transportation & Warehousing | "An employee was delivering a package when it leaked acid on their skin, burning it." | |
| 2025 | OH | Mining | "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." | |
| 2025 | NJ | Other Services | "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." | |
| 2025 | GA | Manufacturing | "An employee was preparing to remove enamel from copper leads by soaking them in a liter container of formic acid when one of the bottles fell. The employee was splashed with formic acid, resulting in first- and second-degree burns to his face." | |
| 2025 | OH | Wholesale Trade | "An employee was measuring a pipe when it fell off the bracket and residual sulfuric acid from the pipe splashed the employee. He was hospitalized with burns to his right chest and both forearms." | |
| 2025 | FL | Manufacturing | "An employee was cleaning a spray nozzle on the powder coating line when he was sprayed by hydrofluoric acid. The employee sustained chemical burns." | |
| 2025 | FL | Administrative Services | "An employee was unloading a truckload of sulfuric acid/soda ash water mixture at a water treatment plant. Residual mixture in a hose cap spilled onto his right forearm, burning it. He was hospitalized." | |
| 2025 | ID | Manufacturing | "Employees were transferring 93% sulfuric acid from a railcar using a transfer pump and hose. The transfer line became pressurized and forced a valve to open, causing sulfuric acid to spray an employee. The force of the spray went underneath his face shield and sprayed his face. The employee sustained second-degree burns." | |
| 2025 | TX | Manufacturing | "On February 21, 2025, an employee was assisting a contractor with the repair of a broken drip leg (90-degree PVC fitting) in the exhaust ventilation duct of the subfab. The employee was exposed to hydrofluoric acid that dropped from the exhaust onto the back of his right thumb. The employee experienced severe burning pain in his right thumb and hand, swelling throughout his hand, and chest pain. The employee was hospitalized." | |
| 2025 | NY | Education | "A student employee was working in a fume hood with trifluoroacetic acid solution. The bottle dropped/fell while they were working with it and the acid splashed up, hitting the student employee in the chin/face and causing chemical burns." |
Source: OSHA Severe Injury Reports. Narratives are verbatim from filings; identifying details may have been redacted by OSHA.
Frequently asked questions
You must seek immediate medical attention, as chemical burns can continue to damage tissue long after the initial contact. Ensure the area is decontaminated according to your workplace safety plan and document the incident with your supervisor. An attorney can help you ensure that your medical records accurately reflect the cause of your injury for your Workers' Compensation claim.
Employers are responsible for providing a safe environment, including proper chemical storage, adequate ventilation, and appropriate personal protective equipment. If your injury resulted from a failure in these systems, you may have a valid claim for benefits. An attorney can investigate whether your employer met their obligations under OSHA safety standards.
Workers' Compensation is designed to cover medical expenses and lost wages for work-related injuries, including long-term complications from chemical burns or toxic inhalation. This includes ongoing treatment, physical therapy, and potential disability benefits. An attorney can help you navigate the process to ensure your claim accounts for the full scope of your recovery.
OSHA requires employers to maintain a comprehensive hazard communication program, including proper labeling and the provision of safety data sheets for all chemicals. Employers must also provide training and protective gear to prevent exposure. If these standards were ignored, an attorney can help you hold your employer accountable for the resulting injuries.