Explosion of nonpressurized vapors, gases, or liquids · Thermal burns third degree or higher
At a glance
Federal OSHA recorded a severe workplace injury
at WVA Manufacturing, LLC, US Route 60 East, ALLOY, WEST VIRGINIA 25002
on — Thermal burns third degree or higher, affecting the Multiple body parts n.e.c..
Final narrative
At about 7:30 p.m. on August 12, 2025, an employee was using a backhoe to excavate accumulated slag and debris from a furnace tap area and ladle pit. Residual water in the material had not fully evaporated; upon disturbance, it reacted violently, resulting in an explosion. The employee suffered first, second, and some third-degree steam burns, mainly to the arms and knees with additional burns to the hands and the back of the neck. The employee was hospitalized.
Hospitalized Multiple body parts n.e.c. Molten metal, slag
On 08/10/18, at approximately 2:00 AM, a maintenance employee was performing repairs to an oxygen line that was part of a plant's oxygen air system. The employee repaired the hose, tightened the clamp on the hose, and instructed another employee to turn the oxygen back on. When the oxygen was turned back on, the hose exploded in the maintenance employee's hands. The employee was hospitalized with burns to both hands.
Employee 1 was investigating a gas odor. While employee 1 was checking the equipment, a gas explosion occurred, resulting in a fire that burned the employee's face. Employee 2 entered the area and a second explosion occurred, causing burns to their face and arms. Employee 2 was hospitalized.
During fiberglass work, an employee mixed a methyl ethyl ketone peroxide (MEKP) catalyst with a cobalt chemical that they thought was a dye. A chemical reaction occurred, resulting in an explosion. The employee sustained second-degree burns on his back and a blister on his right arm.
An employee was cutting glass for a custom windshield and was using denatured alcohol during the cutting process. The denatured alcohol caught fire and the flame traveled to a gallon-sized container of the liquid. The can exploded and the employee sustained second- and third-degree burns from the waist up.
On April 18, 2025, an employee was cutting the lid off an empty 55-gallon drum using a plasma cutter. The drum originally contained a flammable liquid and residual liquid inside the drum ignited and exploded. The employee was hospitalized with burns to the face, chest, and arms.
An employee was painting the inside of a new parts-cleaning machine for electric motors and motor parts when the airborne paint exploded and burned the employee. The employee sustained burns to their neck, lower forearms, and hands.
More severe injuries in this industry (NAICS 331110)
An employee was doing a cable change on top of an electric overhead traveling (EOT) crane. They were positioned between the cable drum and the drive shaft. While rotating the cable drum, the employee reached for the new cable that was to be installed. The grease fitting on the drive shaft caught their fall harness and pulled them underneath the drive shaft. The employee was pinned between the drive shaft and two pieces of angle steel, resulting in a fracture to their left hip.
An employee was working to close a furnace door. The hydraulic mechanism that opens and closes the furnace door was non-operational and had been disconnected to allow the furnace door to be opened manually. As the employee was releasing the pins that held the door open, the door and the hydraulic cylinder fell, pinching their left hand between the hydraulic cylinder's base plate and the furnace. The employee suffered amputation of the little fingertip.
A rolling mill was shut down due to a cobble between two mill stands. The injured employee was cleaning the cobble from the delivery side of stand A, while another employee went to the control panel to move stand B and stand A moved instead. The injured employee's right thumb got caught between the delivery guide of stand A and the looper trough. The tip of his thumb required surgical amputation to the bone to allow for stitches.
An employee was helping another employee load stock material onto a press brake when the stock slipped. The injured employee's right index finger was caught between the press brake die and the stock, resulting in amputation at the first knuckle.
An employee was conducting routine maintenance on a mixer. New lid pins had been installed, and the employee was rotating by hand to ensure they had been installed correctly. The employee's left middle finger was caught between the lid and top of a pin. The momentum from the mixer continued, causing a crushing injury to the finger. The employee underwent a medical amputation from the top knuckle to the tip of the finger.
An employee was climbing down a 15-foot multipurpose ladder. The employee fell about 8 feet, landing on the concrete floor and the ladder itself. The employee suffered several injuries, all on the right side: broken ribs, a broken sternum, a broken temporal bone, broken shoulder, multiple fractures to the cheekbone, and a brain bleed.
An employee was rolling up the landing gear on his trailer when the handle began to unwind and struck his face, fracturing his jaw. The employee was hospitalized and required surgery.