How often these injuries happen
OSHA recorded 786 severe cases involving hot liquids and steam over the last decade. Thermal burns account for 95 percent of these incidents, often resulting in significant tissue damage that requires immediate hospitalization and long-term medical care.
These injuries frequently cause deep, painful wounds that impact your ability to return to your job. Because these incidents often involve high-temperature exposure, the resulting damage to skin and underlying structures can lead to permanent scarring or mobility issues.
How these injuries happen
Most injuries occur through direct contact with hot objects or substances, accounting for 95 percent of all reported incidents. Whether you are dealing with pressurized steam escaping from a pump or boiling water spilling during routine cleaning, these accidents typically happen when equipment is poorly maintained or when safety protocols for handling high-temperature materials are ignored.
| Cause | Incidents | |
|---|---|---|
| 1 | Contact with hot objects or substances | 744 |
| 2 | Struck by propelled object or substance | 25 |
| 3 | Struck by falling object | 2 |
| 4 | Exposure to harmful substance through exposed tissue | 2 |
| 5 | Ingestion of harmful substance | 2 |
| 6 | Inhalation of harmful substance | 2 |
| 7 | Overexertion while materials moving by hand | 1 |
| 8 | Indirect exposure to electricity | 1 |
Where injuries happen most
Manufacturing accounts for 53 percent of all severe cases, as you frequently interact with high-pressure pumps and steam systems. Accommodation and food services also see high injury rates, where the fast-paced environment and reliance on heavy kitchen equipment like rethermalizers create constant risks for spills and thermal exposure.
Real cases like yours
Recurring patterns in these reports show that many injuries occur during routine tasks like priming pumps, cleaning floors, or transferring hot food containers. These incidents often involve pressurized steam releases or accidental spills that could have been avoided with proper equipment guarding and clear safety procedures. 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 | SD | Manufacturing | "An employee was priming a cook pump and sustained burns from contact with hot water (140-200 degrees F)." | |
| 2025 | LA | Accommodation & Food Services | "An employee transferred boiling water from a rethermalizer (kitchen equipment) into a bucket for cleaning the kitchen floor. Some of the hot water spilled onto the employee's left foot, causing severe burns." | |
| 2025 | FL | Health Care | "At the end of an event, the injured employee was working with another employee to transfer a chafing dish from the bar area to the kitchen. The dish fell, causing hot water to spill onto the injured employee. The employee sustained burns to her stomach, right leg, and toes." | |
| 2025 | NE | Manufacturing | "An employee was working on a pump. When a cap was opened to prime the pump, pressurized steam was released and burned the left side of the employee's body. The employee was hospitalized." | |
| 2025 | NY | Manufacturing | "An employee was removing the prime port on the seal water recovery pump when water flashed over (became steam) and blew out of the port. The employee sustained first- and second-degree burns to their face, torso, chest, both arms, and upper right thigh." | |
| 2025 | OH | Manufacturing | "An employee was performing sanitation tasks and adjusting a valve by tapping it with a rubber mallet. The valve came apart and the employee was sprayed with 180-190-degree water. He was hospitalized with thermal burns to multiple parts of the body." | |
| 2025 | TX | Wholesale Trade | "An employee was working in the flake wash line and starting up the auger (9 feet tall) when a top cover on the auger came loose. Hot water and plastic flakes erupted from the top, causing second- and third-degree burns to 20% of his body." | |
| 2025 | TX | Mining | "An employee was mixing and transferring NaCl (salt water) from the mixing plant to storage tanks. The line may have became clogged causing fluid to continuously circulate and heat up to abnormal temperatures. While troubleshooting the issue, the employee removed the hose and was then sprayed with heated salt water. The employee sustained second- and third-degree burns to the front of their torso, both arms, and both upper legs." | |
| 2025 | NM | Mining | "An employee was standing behind a frac pump. A discharge hose failed and the employee was burned by hot water on the left upper abdomen. The employee was hospitalized." | |
| 2025 | GA | Accommodation & Food Services | "An employee had filled a bucket of hot water to mop the floor. As she was walking by the bucket, the bucket fell on her. She was hospitalized with second-degree burns to her legs and feet. " |
Source: OSHA Severe Injury Reports. Narratives are verbatim from filings; identifying details may have been redacted by OSHA.
Frequently asked questions
Yes, thermal burns sustained during the course of your employment are generally covered by Workers' Compensation. This system is designed to pay for your medical treatment and a portion of your lost wages. An attorney can help you ensure your claim is filed correctly to maximize your benefits.
If an equipment failure caused your injury, your employer may be held accountable for failing to provide a safe workplace. Employers are required to maintain machinery and provide adequate training to prevent exposure to hazardous temperatures. An attorney can help you investigate whether your employer violated safety standards and help you pursue the full compensation you deserve.
Recovery time for severe burns depends on the depth and extent of the injury, often requiring multiple surgeries, skin grafts, and extensive physical therapy. These injuries can lead to long-term complications that may prevent you from returning to your previous duties. An attorney can help you account for these long-term medical needs when evaluating your claim.
OSHA requires employers to protect you from recognized hazards, including thermal burns from hot surfaces and substances. This includes implementing proper guarding on pressurized equipment and providing appropriate personal protective equipment for tasks involving high temperatures. If your employer ignored these requirements, an attorney can help you document these safety failures as part of your case.