Exposure through intact skin, eyes, or other exposed tissue · Chemical burns and corrosions, unspecified
At a glance
Federal OSHA recorded a severe workplace injury
at Outokumpu Stainless USA, LLC., 1 Steel Drive, CALVERT, ALABAMA 36513
on — Chemical burns and corrosions, unspecified, affecting the lower leg(s).
Final narrative
An employee was removing a dozer pump and motor. As the employee was removing the bolts, the employee's hip contacted the drain line, which broke and released hydrofluoric acid. The acid burned the employee's right calf where the chemical suit had ridden up.
An employee replaced a hydraulic hose on a hydraulic cylinder that is used to close the furnace doors. The employee was testing the machine and went to adjust or fix the hose when his right arm was caught between the cylinder and the frame of the furnace. The employee was hospitalized with a fractured distal ulnar shaft.
An employee was sitting in the cab of a forklift while fueling the lift. The fuel started to overflow so the employee exited the cab and slipped and fell 3 feet to the cement. She landed on and fractured her ankle.
An employee was helping straighten out steel coils. Bands were in place to hold the coils; a hold-down bar was about to be lowered so that pressure could be applied to a coil and the bands would be further tightened. The bar was lowered while the employee's right hand was on top of the coil. His index fingertip was caught between the coil and the bar, resulting in an amputation.
An employee was lacing using an oxygen lancer. Concrete was heated by the lance and metal slag shot into the air and contacted the injured employee. The employee sustained burns to the left foot and right hand.
An employee was assisting the crane operator with the four way rigging to a crop bucket for removal at the melt shop area of the plant and was caught between the lifting device and the hand rail resulting in three fractured ribs on the right side.
On November 27, 2023, an employee was emptying a 2-inch product line that transports sodium hydroxide liquid from a rail car to a 275-gallon tote tank. The nozzle came out of the tote and sprayed sodium hydroxide onto the employee's face. The employee was hospitalized with chemical burns to their face, mouth, and neck.
An employee was working with sulfuric acid as part of the production process. While transferring the chemical from a large container to a smaller container, it splashed on his body and hand, resulting in a chemical burn.
An employee knelt in wet concrete while performing work as a concrete finisher and sustained a chemical burn to the right shin. The employee was hospitalized and required surgery.
An employee was using a 5-gallon bucket to unload acid product from a tank. Residual product leaked into the containment area, causing the employee to sustain first- and second-degree burns to the chest, as well as third-degree burns to the arms.
An employee was transferring an alkaline cleaning chemical from a bulk container into 1-gallon containers. The employee lifted a gallon container by its label tag. The tag broke causing the container to fall approximately 14-18 inches. The container struck the ground and the contents splashed onto the employee causing chemical burns to their eyes.
More severe injuries in this industry (NAICS 331513)
An employee was unloading metal from two drums on a pallet. The employee removed the lid from the second drum and the drum fell over onto his ankle. The employee sustained a fractured ankle.
An employee was working with team members on the pouring line, casting a sand mold. Molten metal entered the employee's personal protection suit and severely burned his left leg, calf, and ankle.
An employee was jointing a board with a jointer. The board jumped when it came into contact with the jointer's cutter head, and the jolt caused the employee's left hand to slide between the board and the guard and come into contact with the cutter head. He suffered lacerations/partial amputations to the middle, ring, and index fingers.
An employee was turning off a gas valve when he bumped into a die brush and struck the spinning die. The die pin struck him on the back, resulting in contusions, abrasions, and a severe laceration to his back that required hospitalization and surgery.
At 11:45 a.m. on June 13, 2025, an employee of Staley Steel, LLC, was performing preventive maintenance on an overhead crane. While he was holding a grease gun hose and nozzle, he contacted electrical components inside an electrical box. He suffered a first-degree electrical burn on the palm of the left hand, as well as pain up his left arm to the shoulder, and was hospitalized.
An employee was traveling down the maintenance aisle of a warehouse on a single-pallet front rider jack. The jack malfunctioned, causing the brakes to apply; the employee fell forward onto the concrete warehouse floor. The employee suffered an injury to the left leg and was hospitalized, requiring surgery.
An employee was operating a metal roller machine to roll a small piece of metal. The employee's right index finger became caught between the metal and the machine, and the fingertip was amputated.
An employee was directing a truck driver to a dump site when the truck's peanut trailer slipped off the kingpin. As the trailer fell, a ladder attached to it lacerated the employee's ear. The employee was hospitalized.
An employee was unloading a forklift from a trailer to the ground. The employee was climbing down the ladder of the trailer when their foot slipped through one of the rungs, causing them to fall backward onto the forklift forks. The employee was hospitalized for fractured ribs.