How often these injuries happen
OSHA recorded 153 severe incidents involving corrosive bases over the last decade. The vast majority of these cases resulted in chemical burns and corrosions, which often require you to undergo extensive medical treatment and long-term recovery.
These injuries are particularly severe because they often involve sensitive areas like your eyes and face. When caustic substances contact your exposed tissue, the resulting damage can be permanent, leading to significant impairment and life-altering complications.
How these injuries happen
Most injuries occur through direct exposure to harmful substances where the chemical contacts your exposed tissue. This often happens during the transfer of liquids, the cleaning of machinery, or when a pressurized hose or gasket fails unexpectedly. When these substances splash or spray, they cause immediate and deep tissue damage before you can reach an emergency shower or eye wash station.
| Cause | Incidents | |
|---|---|---|
| 1 | Exposure to harmful substance through exposed tissue | 114 |
| 2 | Contact with hot objects or substances | 16 |
| 3 | Inhalation of harmful substance | 10 |
| 4 | Ingestion of harmful substance | 6 |
| 5 | Exposure to harmful substances— unspecified | 2 |
| 6 | Exposure to harmful substance—multiple routes of exposure | 2 |
| 7 | Struck by propelled object or substance | 1 |
| 8 | Struck by falling object | 1 |
Where injuries happen most
Manufacturing accounts for 43% of these severe chemical injuries, largely due to the frequent use of caustic solutions in cleaning, processing, and mixing operations. Construction and transportation industries also report high numbers of incidents, typically occurring when you handle transfer hoses or maintain equipment that contains residual hazardous liquids.
Real cases like yours
Common patterns in these reports involve equipment failures, such as blown gaskets or leaking hoses, and human error during the mixing or cleaning of industrial machinery. You may have been performing routine maintenance when a pressurized system released caustic liquid onto your face, eyes, or limbs. 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 | GA | Manufacturing | "On July 31, 2025, two employees were walking near a friction wash tank when a rubber gasket on top of the tank blew. Hot water mixed with 50% caustic chemical sprayed out and rained down on the employees. Both employees were brought to an emergency shower and were neutralized with vinegar. One employee was hospitalized with chemical and thermal burns to their upper back and eyes." | |
| 2025 | NY | Agriculture | "An employee was cleaning a filler machine. The machine began to leak and was paused. Believing that the machine had been set to abort, the employee started to remove a clamp by the leak. Caustic wash sprayed out, striking the employee in the face and shoulder. He suffered a chemical burn to the side of the face and in the mouth." | |
| 2025 | OH | Manufacturing | "An employee mixed sodium hydroxide pellets into a 55-gallon drum of hot water. A chemical reaction occurred and mixture splashed out of the drum, causing burns to the employee's face and neck. Personal protective equipment was not in place at the time." | |
| 2025 | TX | Manufacturing | "Two employees were removing a discharge hose on a portable pump. A 50% caustic solution sprayed onto the employees, one of whom suffered burns to the eyes as well as an abrasion to the side of the body where the hose struck them. The employee was hospitalized." | |
| 2025 | GA | Transportation & Warehousing | "On April 28, 2025, an employee was unhooking a chemical transfer hose from the unloading valve on a tanker trailer when 45% caustic potash liquid fell onto the employee's left boot, resulting in chemical burns to the employee's foot. " | |
| 2025 | TX | Manufacturing | "A maintenance employee was troubleshooting a clean-in-place (CIP) line at the whey protein liquid processing area. The employee was repairing the CIP valve when a nearby valve pulsated and released hot water/caustic liquid that contacted the employee's abdomen and lower extremities. The employee was hospitalized for second-degree burns. " | |
| 2025 | ND | Manufacturing | "An employee was performing maintenance on a lime kiln sump pump when they sustained second- and third-degree chemical and thermal burns." | |
| 2025 | AR | Construction | "An employee was disconnecting a shotcrete line when they were exposed to an accelerant, sodium aluminate. The employee sustained chemical burns." | |
| 2025 | TX | Transportation & Warehousing | "An employee was offloading lime from a delivery truck. The line became clogged, and the employee hit it with a hammer. The chemical burst out of the hose and burned both the employee's eyes. The employee was hospitalized." | |
| 2025 | PA | Utilities | "An employee was unloading a tanker of sodium hydroxide when the line released the material onto the employee, causing them to be hospitalized with chemical burns." |
Source: OSHA Severe Injury Reports. Narratives are verbatim from filings; identifying details may have been redacted by OSHA.
Frequently asked questions
Chemical burns from corrosive bases can cause deep tissue destruction that extends far beyond the initial point of contact. You may face permanent scarring, vision loss if your eyes are affected, and chronic pain that requires ongoing medical intervention. An attorney can help you document these long-term medical needs to ensure your claim accounts for future care.
Employers are required to provide appropriate personal protective equipment and ensure that safety protocols are strictly followed for handling hazardous chemicals. If your employer failed to provide the necessary gear or failed to maintain a safe environment, they may be liable for your injuries. An attorney can help you investigate whether your employer met their safety obligations under federal law.
Workers' Compensation is designed to cover your medical expenses, rehabilitation costs, and a portion of your lost wages while you are unable to work. In cases of severe chemical burns, this may also include compensation for permanent impairment or disfigurement. An attorney can help you verify that your benefits are calculated correctly based on the severity of your injury.
OSHA mandates strict guidelines for the handling, storage, and labeling of hazardous chemicals under the Hazard Communication Standard. Employers must provide training, safety data sheets, and proper protective equipment to prevent accidental exposure. If you were injured, an attorney can help you determine if your employer violated these standards and how that impacts your legal options.