How often these injuries happen
OSHA recorded 1,377 severe incidents involving metal materials over the past decade. These events frequently result in amputations, which account for 38% of all reported injuries, and fractures, which make up 33% of cases.
The severity of these injuries is often tied to the weight and density of the metal involved. Finger injuries are the most common, representing 40% of all cases, often leading to permanent loss of function or digit amputation.
How these injuries happen
Most injuries occur when you are struck by falling metal objects or compressed between moving equipment and metal parts. These incidents often happen when metal is improperly secured, stored on unstable surfaces, or when machinery lacks adequate guarding to prevent contact with heavy metal stock.
| Cause | Incidents | |
|---|---|---|
| 1 | Struck by falling object | 713 |
| 2 | Compressed between running equipment and other object(s) | 313 |
| 3 | Struck by propelled, falling, or suspended object— unspecified | 60 |
| 4 | Struck by rolling, sliding, or shifting objects—non-running | 50 |
| 5 | Struck by propelled object or substance | 48 |
| 6 | Struck by suspended or swinging object | 36 |
| 7 | Injured by object handled by person | 27 |
| 8 | Struck against stationary object | 24 |
Where injuries happen most
Manufacturing accounts for 46% of all severe metal-related injuries, while construction follows at 35%. These industries rely heavily on the constant movement and processing of raw metal, creating risks where a single failure in handling procedures or equipment maintenance can lead to a crushing injury.
Real cases like yours
Common patterns in these incidents include metal parts shooting out of presses, heavy castings falling from furnace interiors, and fingers being crushed between metal stock and rollers. If any of these scenarios sound like what happened to you, an attorney can help you review the specifics of your incident to determine if employer negligence played a role.
| Year | State | Industry | Incident summary | |
|---|---|---|---|---|
| 2025 | NJ | Manufacturing | "An employee was operating a 2 1/2 inch extruder press when aluminum became jammed in the press. Pressure built up and the piece of aluminum shot into the employee's left index finger, resulting in hospitalization and surgery." | |
| 2025 | OH | Manufacturing | "At about 11:00 p.m. on March 12, 2025, an employee entered a reduction furnace tower to remove a thermowell tube that had broken and became lodged in the furnace. While he was shifting the thermowell, the metal hit the wall of the furnace, causing a "scab" of iron ore (3 feet x 1 foot x 8 inches) to fall from the furnace's interior surface. It struck the employee's head. The employee lost consciousness and was hospitalized." | |
| 2024 | MO | Manufacturing | "On October 9, 2024, an employee was repositioning the end of a metal casting that was not attached to the hoist. The employee's left ring finger was crushed between the part and the work table, resulting in the amputation of their left ring fingertip." | |
| 2024 | MO | Manufacturing | "An employee was manually moving steel across rollers when their right ring finger was caught between the steel and the rollers. The employee's fingertip was amputated." | |
| 2024 | OH | Manufacturing | "An employee was working as a hammer forge helper in a crew of seven employees. As the hammer forge cycled, a piece of metal shot out from it and broke the employee's lower right leg." | |
| 2024 | IL | Manufacturing | "An employee was operating an overhead crane to move a 31" x 27" x 10" piece of machined metal with a hole through the middle weighing approximately 1,350 pounds to prepare for the next welding operation. The material was 16-20" above the ground when the lift strap broke and the material fell onto the employee's lower legs. This caused him to fall backward and the material landed on his left foot. The employee sustained bruising and scraping injuries to the legs from the knees down to the ankle, as well as a foot injury. " | |
| 2024 | MA | Other Services | "A piece of steel fell onto an employee's foot and fractured it." | |
| 2024 | AR | Manufacturing | "An employee was cutting bands off steel billets when a 20-foot long billet rolled and landed on their right lower leg, resulting in a compound fracture. " | |
| 2023 | LA | Construction | "An employee was moving a piece of an I-beam for welding when it rolled off the cribbing. The employee went to catch it when it fell and crushed the employee's finger, resulting in a partial amputation." | |
| 2023 | NE | Manufacturing | "An employee was overseeing facility operations. They moved out of the way to accommodate facility workflow and stepped into a sorting bin area while rebar was being placed by a pneumatic kicker arm. The employee's legs and feet were struck by the rebar, resulting in injuries." |
Source: OSHA Severe Injury Reports. Narratives are verbatim from filings; identifying details may have been redacted by OSHA.
Frequently asked questions
Yes, Workers' Compensation is designed to cover your medical expenses and lost wages for severe injuries like amputations sustained on the job. Because these injuries often require extensive surgery and long-term rehabilitation, an attorney can help ensure your claim accurately reflects the full extent of your impairment and future needs.
Employers often attempt to shift blame to you, but Workers' Compensation is a no-fault system in most states. Even if an error occurred, you are likely still entitled to benefits, and an attorney can investigate whether your employer failed to provide proper machine guarding or safety training as required by OSHA.
OSHA mandates strict requirements for material handling and machine guarding to protect you from being struck by or caught between objects. If your employer failed to follow these safety standards, it may strengthen your case for additional compensation, and an attorney can help you identify these regulatory violations.
Insurance companies often offer low initial settlements that fail to account for the long-term impact of a permanent injury or the need for future medical care. An attorney can evaluate your medical records and the nature of your injury to determine if the offer is sufficient and negotiate on your behalf.