Hydro Extrusion USA LLC

An employee was adjusting rolls of vinyl that were on a pole set horizontally on a rack. As the employee was pushing the vinyl with his right hand, the right side of the pole dropped about 3 feet, pulling the left side of the pole downward at an angle. The employee's left ring finger became trapped/pinched between the pole holding the vinyl and the rack that was holding the pole. The employee's fingertip was amputated.

An employee was conducting preventative maintenance on an extrusion press and using an impact wrench to remove rivets on the shear cylinder. When the last rivet was removed, the stored energy in the cylinder released and dropped it onto the employee's hand. Their right thumb was caught between the cylinder and the casing of the rivet gun, resulting in crushing injuries. The employee sustained an amputation of the thumb without bone loss. The machine was locked out/tagged out at the time.

An employee was broaching a keyway in a bore sprocket with a manually operated powered cylinder hydraulic press. On pressing the broach through the initial phase of cutting, he used an extension rod to finish broaching and clear the broach from the part. While setting up the extension rod, he placed his left index finger on top of the extension rod. The press extended and crushed his finger, resulting in an amputation.

While doing general labor, an employee developed signs of heat stress. After going home, later, he was hospitalized for dehydration and heat-related symptoms.

An employee was standing in front of a forklift carrying several 2,000-pound "logs" of aluminum. The logs were banded together; when the employee cut the banding so they could be unloaded, one of them rolled onto the employee's foot. The employee's steel safety toe collapsed, and the employee's toes and metatarsals were crushed. Part of the foot was medically amputated.

An employee was walking past a crossover conveyor when a ramp came down and hit them in the back. The employee sustained a broken back vertebra, as well as a concussion, and was hospitalized.

An employee was unloading frameless mirrors from a trailer. When unstrapped, the mirrors fell over onto the employee, who suffered a skull fracture, a brain bleed and blood clot, a broken left ankle, and lacerations.

A temporary employee was rigging secondary steel when the steel joist fell to the ground and struck his lower left leg, resulting in fractures to the tibia and fibula.

Two maintenance employees were dismantling a machine part (steel cylindrical rollers) on the ground. After unbolting a portion, part of the assembly fell approximately 6 inches onto one employee's left little finger. The employee was hospitalized and about 3/4" of their little finger above the top joint was surgically amputated.

An employee was stacking a pallet when the pallet fell, injuring her left leg. She was hospitalized and had surgery on her left leg.

An employee's left arm was caught in the fingers or jaws of the head stretcher machine, resulting in a laceration. The employee was hospitalized.

An employee was performing regular duties in the cast house and sustained heat exhaustion.

At 7:01 p.m. on June 16, 2025, two employees were pushing a saw horse with a bundle of aluminum on it when it flipped over onto the injured employee. The employee was hospitalized with a broken leg and required surgery.

On June 4, 2025, at approximately 1:00 AM, an employee was working when they experienced cramping and were hospitalized with a heat illness.

An employee was operating a crane when a bolster fell onto their right foot, amputating the big toe.

An employee was helping to lift the grating from a floor draining system when the grating slipped and landed on his hand, resulting in the amputation of his right middle finger at the first joint.

A casting machine jammed. An employee's hand was caught in the machine, where a belt line caught and amputated the tip of his finger.

During a workshop meeting in a hotel, an employee heard a drilling noise, so he walked outside to see what it was. An explosion occurred (possible gas line) and his face, ear, and hair were burned. He also fell and sustained a pelvic fracture.

An employee slipped on condensation on a walkway in a parking garage. She fell and suffered a closed fracture to the neck of the left femur.

An employee was using a tool to remove a rag from a roll on the tube mill. The roll pulled the tool and the employee's right hand into the roll, resulting in a partial amputation of the little finger and a fracture to the index finger.