How often these injuries happen
OSHA recorded 114 severe cases involving flammable gases over the last decade. Thermal burns represent the most common injury type, accounting for 67% of all reported incidents and often requiring extensive hospitalization.
The severity of these incidents often stems from the sudden nature of flash fires, which can cause deep tissue burns and respiratory complications.
How these injuries happen
Injuries involving flammable gases typically occur when vapors leak from cylinders, valves, or hoses and meet an ignition source. Flash fires are the leading cause of harm, accounting for 57% of incidents, often triggered by welding torches or pilot lights near compromised equipment. Other incidents involve the inhalation of toxic vapors, which accounts for 26% of cases, or explosions caused by the rapid buildup of nonpressurized gases.
| Cause | Incidents | |
|---|---|---|
| 1 | Flash fire | 65 |
| 2 | Inhalation of harmful substance | 30 |
| 3 | Explosion of nonpressurized vapors, gases, or liquids | 10 |
| 4 | Contact with cold objects or substances | 3 |
| 5 | Fire— unspecified | 2 |
| 6 | Explosion— unspecified | 2 |
| 7 | Exposure to harmful substance through exposed tissue | 1 |
| 8 | Struck by propelled object or substance | 1 |
Where injuries happen most
Mining operations account for 20% of all reported flammable gas injuries. Manufacturing and construction sectors follow, accounting for 15% and 13% of incidents respectively, as you frequently handle pressurized cylinders and fuel lines that require rigorous inspection and maintenance to prevent catastrophic leaks.
Real cases like yours
Common patterns in these reports involve the failure to properly secure fuel lines or the use of open flames near equipment that has not been purged of residual fumes. You may be injured while attempting to move or recycle old cylinders that still contain pressurized gas. If your injury occurred during a similar task involving fuel storage or equipment maintenance, an attorney can help you review the specific circumstances of your case.
| Year | State | Industry | Incident summary | |
|---|---|---|---|---|
| 2025 | IL | Retail Trade | "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." | |
| 2025 | TX | Mining | "On July 17, 2925, an employee was working on a computer inside a vehicle when they began experiencing symptoms of carbon monoxide poisoning, resulting in hospitalization." | |
| 2025 | IL | Retail Trade | "An employee was filling a motor fuel cylinder from a bobtail. When he opened the handle on the fill nozzle it popped off the filler valve and pushed him back into a rack where he struck his head on a cylinder cage. He sustained a laceration to the back left side of his head. While working to wrestle the hose to the ground, he sustained burns from liquid propane on the right side of his chest and right arm, and sustained minor burns on the left side." | |
| 2025 | CO | Arts & Entertainment | "An employee was kneeling, lighting the pilot for a gas range, when gas that had leaked from a quick coupler at the back of the range ignited. The employee suffered serious burns to both arms and her neck." | |
| 2025 | GA | Other Services | "Employees were performing repairs on a propane tank at the front of a school. A torch was being used to melt a cable when residual fumes from the propane tank ignited. One employee sustained burns to their upper and lower body and was hospitalized. A second employee sustained minor burns." | |
| 2025 | FL | Retail Trade | "An employee was filling propane cylinders at a customer location when a flash fire occurred, resulting in burns to the face that required hospitalization." | |
| 2025 | ND | Mining | "An employee was servicing oilfield equipment. As he was swapping sides on a dual-choke manifold to check for wear, a flash fire occurred, resulting in burns to his face and the top of his right hand." | |
| 2025 | CT | Manufacturing | "During the fabrication of a metal railing, an employee was heating a metal bar with an acetylene torch to prepare the bar for bending. After heating the bar, the acetylene torch was extinguished and placed in the open end of a 4 rectangular tube. Acetylene from the torch leaked into the tube. Several minutes later, the employee used a hand grinder that produced sparks which ignited the acetylene. The employee sustained facial burns." | |
| 2025 | FL | Health Care | "Two employees were doing emergency medical service work. Their ambulance was leaking exhaust, and both employees developed carbon monoxide poisoning. Both were hospitalized." | |
| 2025 | PA | Transportation & Warehousing | "An employee was sitting in the cab of his truck at the end of the day. He had just finished driving for 8-10 hours. Exhaust from the truck had been leaking into the cab. The employee began having difficulty breathing and was sweating profusely. The employee was hospitalized for an asthma attack triggered by carbon monoxide." |
Source: OSHA Severe Injury Reports. Narratives are verbatim from filings; identifying details may have been redacted by OSHA.
Frequently asked questions
Flash fires most frequently cause severe thermal burns. These injuries often require specialized burn center care and long-term rehabilitation for skin grafting or nerve damage. An attorney can help you document the full extent of your medical needs for your claim.
Employers are required to maintain all pressurized equipment in safe working order and provide proper training for handling hazardous substances. If a leak occurred due to poor maintenance or lack of safety protocols, your employer may be liable for your injuries. An attorney can help you determine if your employer failed to meet these safety obligations.
Workers' Compensation covers injuries caused by the inhalation of harmful substances, including toxic vapors or carbon monoxide. These claims are valid when the exposure happens during the course of your employment. An attorney can help you gather the necessary medical evidence to support your claim for benefits.
Seek immediate medical attention and ensure the incident is reported to your supervisor as soon as possible. Documenting the scene and the equipment involved is vital for your Workers' Compensation claim. An attorney can help you navigate the reporting process and protect your rights to benefits.