How often these injuries happen
OSHA recorded 186 severe cases involving miscellaneous chemical products over the last decade. Thermal burns are the most frequent injury type, representing 55% of all reported incidents and often requiring extensive medical intervention.
These injuries frequently impact specific body parts, leading to complex recovery paths. You may face long-term complications when chemical exposure causes deep tissue damage.
How these injuries happen
Injuries involving chemical products most often stem from direct contact with hot substances, which accounts for 37% of all recorded incidents. Flash fires and the inhalation of harmful vapors also frequently cause severe harm, often occurring when containment systems fail or maintenance procedures are ignored. You are often injured when pressurized lines rupture, spraying hazardous fluids onto your skin or into your eyes and mouth.
| Cause | Incidents | |
|---|---|---|
| 1 | Contact with hot objects or substances | 68 |
| 2 | Flash fire | 33 |
| 3 | Inhalation of harmful substance | 24 |
| 4 | Exposure to harmful substance through exposed tissue | 23 |
| 5 | Struck by propelled object or substance | 19 |
| 6 | Ingestion of harmful substance | 8 |
| 7 | Exposure to harmful substances— unspecified | 4 |
| 8 | Exposure to harmful substance—multiple routes of exposure | 3 |
Where injuries happen most
Manufacturing accounts for 54% of all severe chemical injuries, largely due to the high-volume use of industrial fluids and heating processes. Health care facilities also see significant incident rates, where you are exposed to hazardous cleaning agents and patient-related substances that require strict handling protocols.
Real cases like yours
Common patterns in these reports involve equipment malfunctions, such as leaking hydraulic lines or faulty quick-connect fittings, that release pressurized fluids. Other incidents occur when you are exposed to hazardous odors or substances in the air, leading to immediate respiratory distress or allergic reactions. If your injury resulted from a similar failure in equipment maintenance or a lack of proper protective protocols, an attorney can help you review the specifics of your case.
| Year | State | Industry | Incident summary | |
|---|---|---|---|---|
| 2025 | FL | Transportation & Warehousing | "An employee was performing a maintenance test of a hydraulic component (case drain overheat switch) that involved disconnecting the hose/switch. Hydraulic fluid began leaking and the employee went to reconnect the hose/switch but fire-resistant hydraulic fluid sprayed the employee's face, eyes, and mouth. The employee ingested some of the hydraulic fluid." | |
| 2025 | TX | Mining | "An oil rig catwalk began leaking while in the raised position. An employee was investigating the leak from a manlift when the catwalk injected hydraulic oil into their right palm. The employee was hospitalized, requiring surgery." | |
| 2025 | OH | Health Care | "An employee was getting water in the breakroom when the odor from an air freshener that was sprayed in a patient's room wafted into the room. The employee breathed in the air freshener and was hospitalized with an asthmatic episode." | |
| 2025 | TX | Mining | "Mechanics were straightening a ladder on the derrick in the shop using an acetylene torch and a 10-ton hydraulic jack. As the mechanics were extending the jack to straighten out the ladder, the cylinder on the jack was turning and the quick-connect fitting ended up against the footrail of the derrick. This caused the nipple to break and a mist of oil was released from the jack. The oil mist ignited resulting in a flash fire. The injured employee sustained second- to third-degree burns burns to the right hand, the left cheek, and the left side of their neck as well as burns to both arms. The employee was hospitalized." | |
| 2025 | PA | Health Care | "An employee was seeing a patient. The employee had an allergic (anaphylactic) reaction to petroleum jelly on a patient." | |
| 2025 | TX | Mining | "An employee was inspecting the liners of a mud pump that was making noise. The machine was shut down. As the pump was idling down, the inspection plate blew and knocked the employee back. Hot gear oil from the pump blew onto him, causing second-degree burns to his left arm and the left side of his face and ear. The employee was hospitalized." | |
| 2025 | OK | Wholesale Trade | "An employee was troubleshooting the lubrication system for kiln cooler gear. He locked out the system and shut off the compressed air to the lubrication system. Then, he went to unclog the system by pushing the cleanout plunger on the backside of the nozzle while holding the spray bar. His left hand slipped in front of the nozzle as the injector released stored oil pressure, resulting in the injection of air and oil lubricant into his hand at 3,000 psi." | |
| 2025 | ID | Transportation & Warehousing | "An employee was applying grease to a trailer when the grease gun sprung a leak and grease was injected into his right index finger. The employee was hospitalized and required surgery." | |
| 2025 | TX | Manufacturing | "An employee was working on a hydraulic cylinder at his work table. While he was removing a bleeder plug to reduce the pressure, the 3/8-inch steel plug was pushed out by oil pressure. The plug impacted his wrist, causing an abrasion where hydraulic oil went into his arm. The employee was hospitalized." | |
| 2025 | TX | Wholesale Trade | "An employee was using a welding torch to cut up a boom from a fire truck. Oil was leaking from the boom's hydraulics and caught fire, which spread and burned the employee. The employee was hospitalized with third-degree burns." |
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 ensure proper treatment. Report the incident to your supervisor immediately to create an official record, which is essential for your Workers' Compensation claim. An attorney can help you ensure that your employer has properly documented the exposure and that you are receiving the necessary medical care.
Yes, OSHA standards under 29 CFR 1910.132 require your employer to assess the workplace for hazards and provide appropriate personal protective equipment. If your employer failed to provide adequate gear or failed to train you on chemical safety, they may be held accountable for your injuries. An attorney can help you investigate whether your employer met these safety obligations.
Workers' Compensation covers injuries caused by the inhalation of toxic substances or harmful vapors in the workplace. These claims can be complex because the damage may not be immediately visible, making medical documentation critical. An attorney can help you assist in gathering the evidence needed to prove that your respiratory condition is work-related.
When an injury results from a machine malfunction, such as a leaking hydraulic hose or a failed valve, you may have a claim beyond standard Workers' Compensation. This could involve a third-party liability claim against the equipment manufacturer or a maintenance contractor. An attorney can help you evaluate the equipment failure to determine if other parties are responsible for your damages.