105,313Records 71,083Employers 85,290Hospitalizations 27,770Amputations 2015-01-01 2025-10-31
Safety Incidents OSHA Severe Injury Reports · 2015–2025

Caldic USA Inc.

Flash fire · Thermal burns degree unspecified

Federal OSHA recorded a severe workplace injury at Caldic USA Inc., 2425 Alft Lane, ELGIN, ILLINOIS 60124 on — Thermal burns degree unspecified, affecting the Trunk and other upper extremities.

On June 5, 2024, an employee was mixing oils, powders, and other ingredients to make an antioxidant blend (a food ingredient) in a tank. A flash fire occurred and came out of the tank, burning the employee's chest and shoulder.

Hospitalized Trunk and other upper extremities Chemicals and hazardous materials unspecified

Myers Trucking, Inc.

An employee was using a torch to loosen a bolt on a water trailer. Natural gas was present in the water and it ignited, causing a fire. The employee sustained third-degree burns to their upper leg.

Brown & Root Industrial Services, LLC

An employee had been removing phosphorus pentasulfide while on a scaffold. He was using a non-sparking tool to dislodge the phosphoric material. The employee noticed a flash of flame. He descended the scaffold, but the flash ignited residual phosphorus pentasulfide that was on the outside of the employee's personal protective equipment (PPE). He sustained thermal burns to his right hand and right calf.

Phillips 66 Company dba Phillips 66 Refinery Wood River

An employee was taking a butane gas sample as part of the hydrocarbon refining process. A component disconnected and the butane ignited, resulting in first- and second-degree burns to the employee's forearms and to their face, including their cheeks, chin, and neck.

GREGGO AND FERRARA, INC.

An employee was troubleshooting a power washer in the field. Because there might have been water in its fuel, he brought it back to the shop and drained about a gallon of fuel from the tank into a plastic container. Some of the fuel spilled onto the floor and ignited. The employee was stomping out the fire when he lost his balance and tripped into a stool, which caused the plastic container to spill more fuel onto the fire. The employee's pants and shirt caught on fire, and he fell, abrading his knee while trying to get through the flames. As well as the knee abrasion, he suffered burns to the left leg and left lower quadrant of the torso. He was hospitalized.

MPW Industrial Services, Inc.

An employee was fueling a gasoline-powered pressure washer with a safety fuel can. During the transfer the fuel ignited, causing a fire. The employee sustained burns to his nose, and his right hand and forearm.

Sunny Sky Products, LLC

An employee fell approximately 10 feet from an elevated platform to the concrete floor. The employee sustained broken ribs and a collapsed lung.

Balchem Corporation

An employee was removing a walkie pallet jack from a pallet in the freezer. As he was dislodging the pallet jack forks that were stuck under the wood pallet, he lost his footing and was spun around landing on the concrete floor underneath the racking. The employee sustained a fractured left hip.

Givaudan Flavors Corporation

An employee was working on a valve replacement when their left middle finger became caught in the butterfly flapper of the valve, resulting in a fingertip amputation.

Lyons Magnus, LLC

An employee was walking when they were struck by a forklift. The employee's leg was caught between the forklift and a storage rack, resulting in a leg injury that required hospitalization.

Sensory Effects Powder Systems, Inc.

On August 18, 2023, at approximately 9:00 a.m., an employee was cleaning an overhead drain line while on a 6-foot A-frame ladder. The employee was descending the ladder when they slipped and the ladder frame shifted. The employee then fell to the ground below, resulting in two fractured vertebrae.

Takeda Pharmaceuticals U.S.A., Inc.

An employee fell while moving a water canister, resulting in fractures to four fingers on her right hand.

Great Dane Ltd. Partnership

An employee was changing a die in a press when the die slipped and crushed the employee's left index finger. The employee sustained an open facture of the tuft of the left distal phalanx and a partial amputation.

Olympia Food Industries Inc.

An employee was mixing sauce using a sauce barrel mixer when his left little finger was amputated.

AbbVie Inc.

An employee was driving a boom lift (in the lowered position) in an exterior dock area. The lift s left wheels rolled onto base plates that covered a 3-foot-deep sump pit. The base plates failed, and one side of the lift dropped. The employee's left leg was caught under the lift basket, and he suffered a fracture to the lower leg including the ankle.

TSA Processing - Montgomery

A temporary employee was carrying a nail gun through the warehouse when it hit his leg, activated, and fired a nail into the leg.