Vehicle or machinery fire · Second degree heat (thermal) burns
At a glance
Federal OSHA recorded a severe workplace injury
at Real Alloy Recycling, Inc., 7505 Durand Ave., STURTEVANT, WISCONSIN 53177
on — Second degree heat (thermal) burns, affecting the forehead.
Final narrative
An employee was charging a furnace by adding material using a powered industrial vehicle. An explosion occurred, causing a fireball to come out of the furnace. The employee jumped from the vehicle to avoid the fireball and landed on the ground. He suffered first and second degree burns to the forehead and injuries to his left knee.
HospitalizedForeheadForging machinery
More severe injuries at Real Alloy Recycling, Inc.
An employee was in a manlift, troubleshooting the pilot for the main burner on a furnace. The furnace door was opened and contacted the manlift basket. The employee fell about 8 feet and suffered contusions to his left thigh, knee, and shin area.
On January 8, 2021, an employee tripped and fell. His left hand and forearm entered a tube of molten aluminum as he braced himself. He was hospitalized, having suffered second- and third-degree burns on his forearm and wrist.
An employee removed the spark plugs and was rotating an engine to evacuate condensate from the cylinders. An unknown source ignited the condensate and natural gas. The employee sustained burns to the back of his hands and upper leg area.
An employee was operating a front-end loader when a hydraulic line broke, causing the front-end loader to catch on fire. The employee jumped from the cab to the ground and sustained fractures to the T-6 vertebra and a heel.
An employee was moving two totes of turpentine. Noticing that one of them was leaking, he stopped his forklift and began to look for the leak. The forklift caught fire, and the employee suffered severe burns. He was hospitalized.
An employee was performing maintenance on a machine when part of an adjacent machine caught fire. The employee extinguished the fire and suffered smoke inhalation.
More severe injuries in this industry (NAICS 331314)
On July 29, 2025, an employee working near a metal furnace. Toward the end of his shift, he was charging a furnace and began to experienced heat exhaustion. He had also been in areas of elevated temperatures due to heat sources such as direct sunlight and a combustion engine. The employee was hospitalized with dehydration.
An employee was using a pry bar to remove a piece of aluminum cone from a mold on the cone line. The cone broke loose and the employee's left middle finger was caught between the pry bar and the cone line frame. The employee's fingertip was partially amputated.
An employee was machining a trunnion using a grinding rig when their left hand was caught between the grinding stone and the trunnion, resulting in fractures to the middle, ring, and little fingers, as well as severe damage to the skin and amputations of the middle and ring fingers to the distal knuckle.
On August 7, 2024, a maintenance technician was descending a fixed cage ladder when the ladder broke and they fell approximately 12 feet to the concrete ground. The employee sustained head injuries and fractured ribs.
The injured employee was assisting five other employees with bracing a wall panel that was being stood up. Another employee slipped on frost on the floor surface. The employees went to evacuate the area in anticipation of the wall panel falling over. The injured employee went to jump through a window opening within the wall panel and their lower half was crushed by the falling wall panel. The employee sustained a fractured pelvis.
An employee was using a vertical band saw to cut a thick piece of rubber material. While being cut, the material shifted, causing the employee s right hand to contact the moving blade. The employee's thumb was amputated below the knuckle. The employee was hospitalized, undergoing surgery.
A production sanitation employee was pre-rinsing an incline conveyor and noticed cheese stuck between the belt idler. The employee went to remove the cheese and their glove got caught and pulled their left forearm into the conveyor. The employee's arm was fractured. The machine was not locked out/tagged out at the time.
An employee was on a ladder, taking measurements for a new gutter installation. The ladder slipped out from under him and both he and the ladder fell to the ground. He was hospitalized with seven broken ribs and a broken clavicle.
An employee was unloading a truck for a delivery job. While moving boxes in the truck, the employee tripped over a pallet and fell out of the truck to the ground, resulting in four broken ribs.