How often these injuries happen
OSHA recorded 227 severe cases involving hot or molten materials over the last decade. Thermal burns account for 93% of these incidents, often requiring extensive medical intervention and long-term rehabilitation.
The severity of these burns often stems from the high temperatures of the substances involved, which can cause deep tissue destruction in seconds.
How these injuries happen
Most injuries occur through direct contact with hot objects or substances, which accounts for 89% of all reported cases. This often happens when molten materials splash during transport, when protective equipment fails to block high-temperature liquids, or when you are struck by hot slag during furnace operations.
| Cause | Incidents | |
|---|---|---|
| 1 | Contact with hot objects or substances | 202 |
| 2 | Explosion of nonpressurized vapors, gases, or liquids | 9 |
| 3 | Struck by falling object | 7 |
| 4 | Ingestion of harmful substance | 2 |
| 5 | Struck by propelled object or substance | 2 |
| 6 | Explosion— n.e.c. | 2 |
| 7 | Exposure to environmental heat | 1 |
| 8 | Struck against stationary object | 1 |
Where injuries happen most
Manufacturing accounts for 83% of these severe injuries. The high volume of molten metal processing, plastic extrusion, and furnace work in these facilities creates constant exposure to high-temperature hazards that require rigorous safety protocols.
Real cases like yours
Common patterns in these reports involve equipment malfunctions, such as tubs tipping during transport, or unexpected splashes when molten material contacts water or hardened surfaces. You are often injured while performing routine maintenance or sampling tasks. 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 | IL | Manufacturing | "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." | |
| 2025 | PA | Manufacturing | "An employee was working near molten metal and experienced heat illness symptoms including cramps. The employee was hospitalized." | |
| 2025 | OH | Administrative Services | "On July 24, 2025, an employee was shoveling material when a piece of steel slag fell from a nearby furnace and struck them in the back. The employee was hospitalized with fractures to their thoracic vertebrae and a metatarsal." | |
| 2025 | OH | Manufacturing | "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." | |
| 2025 | TX | Construction | "An employee was obtaining a lab sample of AC oil for an asphalt mix design when oil contacted his heat protection glove gauntlets. The employee removed the gloves when the oil contacted both his palms and six fingers, resulting in second-degree burns." | |
| 2025 | IL | Manufacturing | "On July 7, 2025, at approximately 1:45 AM, an employee was moving vermiculite in a zinc pan with shovel. Molten zinc entered his left boot and caused burns to his shin and the top of his foot." | |
| 2025 | OH | Construction | "An employee was adding a solid block of crack filling compound into equipment for melting and it flamed up. The employee subsequently dropped the solid block into the heated material and the hot liquid splashed onto his head and face." | |
| 2025 | WI | Manufacturing | "An employee in the melt department was getting ready to put a recirculation pump into the pump housing area. He first put the pump in a cabinet to warm it up to avoid thermal shock. It shifted and the cold refractory contacted the hot metal. Molten metal contacted the employee, resulting in third-degree burns between their knee(s) and ankle(s). The employee was wearing some personal protective equipment (PPE) at the time but this was breached by the molten metal." | |
| 2025 | IN | Construction | "The injured employee was performing roofing work with a crew. A mop was being used to apply tar to the roof. Hot tar splashed onto the injured employee's left hand. The back of their hand was burned." | |
| 2025 | TX | Manufacturing | "On June 4, 2025, an employee was skimming molten aluminum when it dripped down from the skimming spoon onto the employee's left pant leg, burning the top of their left foot. The employee was hospitalized and required surgery." |
Source: OSHA Severe Injury Reports. Narratives are verbatim from filings; identifying details may have been redacted by OSHA.
Frequently asked questions
Seek immediate medical attention to document the severity of the burn and the circumstances of the injury. Once you are stable, report the incident to your employer in writing and ensure it is recorded in the official injury log. An attorney can help you document the scene and protect your rights to Workers' Compensation.
Employers are required to provide adequate personal protective equipment and maintain safe operating procedures for handling molten materials. If your injury resulted from a failure to provide proper heat-resistant gear or a lack of machine guarding, your employer may be held accountable. An attorney can help you evaluate whether safety violations contributed to your accident.
Workers' Compensation typically covers medical expenses, rehabilitation costs, and a portion of lost wages while you recover. Because burn injuries can involve long-term scarring or permanent impairment, you may also be eligible for disability benefits. An attorney can help you ensure your claim accurately reflects the full extent of your medical needs.
OSHA mandates strict safety standards for personal protective equipment and hazard communication when working with high-temperature materials. Employers must conduct thorough risk assessments and provide training to prevent accidental contact. If you suspect your employer ignored these regulations, an attorney can help you investigate the safety failures that led to your injury.