Machine Injury & Accidents

Date	City	State	Employer	Body Part	Event
2021-11-15	Mingo Junction	Oh	JSW Steel USA Ohio, Inc.	Multiple body parts	Contact with hot objects or substances
On November 15, 2021, an employee was splashed with molten metal while measuring steel in a mold. The employee sustained multiple third degree burns on their neck, right hand, and right leg.
2021-11-10	Fort Lupton	Co	Golden Aluminum, Inc.	Leg(s)	Contact with hot objects or substances
An employee was draining a filter bowl of molten metal during a cast shutdown when the molten metal spilled from the bowl onto the employee's legs, resulting in burns to the backside of his legs.
2021-10-01	Kingsville	Mo	STAHL SPECIALTY COMPANY	BODY SYSTEMS	Inhalation of harmful substance-single episode
On September 1, 2021, an employee was using a forklift to empty hoppers. The employee inhaled dust and fumes from the molten metal and was hospitalized.
2021-09-10	Bessemer	Al	U.S. Pipe and Foundry Company	Hip(s) and leg(s)	Contact with hot objects or substances
An employee was pouring iron at a casting machine when a crane bumped the employee's ladle resulting in molten iron splashing onto the employee. The employee was hospitalized with burns to the right hip, ankle, and foot.
2021-08-24	Newton	Ms	Weir ESCO Newton	Foot(feet) and leg(s)	Contact with hot objects or substances
An employee had just finished pouring a mold using a pouring ladle. The ladle would not stop pouring; while it was being moved by crane, it spilled molten metal onto the employee. The employee's right leg and foot were burned.
2021-07-20	Elmira	Ny	Kennedy Valve, A Division of McWane, Inc.	Foot (feet)	Contact with hot objects or substances
An employee was moving a ladle of molten metal by monorail tractor when molten metal spilled onto his leg, causing third degree burns to his foot.
2021-06-29	Nashua	Nh	Bronze Craft Corporation	Hand(s) and wrist(s)	Contact with hot objects or substances
An employee was preparing to pour molten bronze from a pot when the pot erupted and the molten bronze contacted the employee, resulting in burns to his left wrist, hand, and palm. Personal protective equipment was worn at the time of the incident.
2021-06-23	Wheatland	Pa	Zekelman Industries, Inc.	Wrist(s)	Contact with hot objects or substances
An employee was aligning and feeding pipes into the galvanizing tank at a charging station when the pipes slid in at an angle, resulting in the molten zinc shooting up the pipe and onto the employee. The employee suffered burns to their right wrist.
2021-01-19	Blackwell	Ok	Oklahoma Investment Casting Company	Multiple head locations	Explosion, n.e.c.
An employee was monitoring a foundry with molten metals inside when a tree was introduced into the foundry, causing an eruption of molten metal. The employee tried to rapidly leave the area but tripped and fell to the ground. The erupted molten metal landed on the employee causing burns of different degrees to their face and head.
2021-01-09	Appleton	Wi	Luvata Appleton LLC	Multiple body parts	Explosion of nonpressurized vapors, gases, or liquids
An employee was scraping slag off an alloy melting furnace pot when residual liquid nitrogen mixed with molten metal still in the furnace. The instantaneous mixing caused an explosion, which knocked the employee to the ground. His protective helmet and face shield were knocked off and he suffered second- and third-degree burns to the neck and left arm.
2021-01-08	Sapulpa	Ok	Real Alloy Recycling INC	Wrist(s) and arm(s)	Fall onto or against object on same level, n.e.c.
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.
2020-10-06	Zanesville	Oh	Casting Solutions, LLC	Multiple body parts	Contact with hot objects or substances
An employee was using a slag spoon to skim off impurities on molten gray iron. The employee dipped the spoon into the zircon wash and gray iron popped onto the employee. The employee sustained first and second degree burns to the left side of the palm, the forearm, and the abdomen.
2020-09-01	Sheboygan	Wi	Watry Industries LLC	Multiple body parts	Contact with hot objects or substances
An employee was charging an aluminum furnace by adding a solid aluminum ingot into the molten aluminum bath. When the ingot was added, an explosion occurred and the employee sustained burns to multiple parts of the body.
2020-07-30	Latrobe	Pennsylvania	Carpenters Technolongy	Leg(s)	Contact with hot objects or substances
An employee was taking a sample of molten metal when a piece of slag contacted the tongue of his boot. The employee was hospitalized with burns to his leg.
2020-06-09	Albertville	Alabama	Alloy Resources, Inc.	Head and neck	Contact with hot objects or substances
An employee was inserting an oxygen lance into a furnace to melt metal that had solidified over the argon injection ports. Molten metal splashed out onto the employee's face and neck, melted the employee's face shield and safety glasses, and caused first- and second-degree burns over five percent of the employee's face and neck. The employee was hospitalized.
2020-04-06	Miami	Arizona	FREEPORT MCMORAN - MIAMI MINE	BODY SYSTEMS	Exposure to environmental heat
An employee had been collecting molten copper samples for testing and started feeling sick. The employee was hospitalized for heat exhaustion.
2020-02-22	Hogansville	Georgia	MANDO AMERICA CORPORATION	Multiple body parts	Contact with hot objects or substances
An employee was pouring molten iron back into a furnace using a ladle. The metal splashed onto his lower body, burning his waist and legs.
2020-01-31	Wakeman	Ohio	Concast Metal Products	Ankle(s) and leg(s)	Contact with hot objects or substances
On January 31, 2020, an employee was tearing down a die and emptying molten metal from a mold when the molten metal contacted the employee, burning his right leg and ankle. He was hospitalized.
2020-01-24	Mansfield	Ohio	AK STEEL CORPORATION	Nonclassifiable	Explosion
On January 23, 2020, an employee working for AK Steel was starting to pour an electric arc furnace when an explosion inside of the furnace caused molten metal to be ejected from the furnace, striking the employee. The employee was hospitalized with serious burns to her upper body.
2020-01-14	Bessemer	Alabama	U.S. Pipe and Foundry	Foot (feet)	Contact with hot objects or substances
An employee was helping to clean up an iron spill. A 3-foot skimming rod was laid on top of the machine ladle of a casting machine. The rod had been previously dipped in the blacking liquid. The wet rod fell into the ladle, causing a reaction that ejected molten iron from the ladle. The molten iron contacted and burned the employee's left foot.
2019-09-19	Watertown	Wisconsin	Spuncast, Inc.	Multiple body parts	Contact with hot objects or substances
An employee was pouring molten steel into a mold. Some of the steel passed through a trench cover's lifting holes and came into contact with water. This created superheated steam, which caused the molten steel to spray back through the holes onto the employee. The employee suffered second-degree burns on 18 percent of the body: arms, upper front torso, face, and mouth.
2019-09-11	Chicago Heights	Illinois	TRIALCO, INC.	BODY SYSTEMS	Exposure to environmental heat
An employee became ill and was hospitalized due to heat stress while working on a molten aluminum production of sows.
2019-09-07	Leetsdale	Pennsylvania	HUSSEY COPPER	Multiple body parts	Contact with hot objects or substances
Four employee were pouring a 320" copper stock. A hose failed which caused the ram of the casting unit to drop during the pouring process. The falling of this ram, which was controlled by the caster, allowed molten copper to come in contact with steam inside the pit that is filled with water. This caused a violent reaction/explosion. All four employees received burns to their arms, body, and face when they were sprayed with molten copper.
2019-08-30	Marston	Missouri	MAGNITUDE 7 METALS, LLC	Multiple body parts	Contact with hot objects or substances
An employee was tapping the crucible of a bath when the crucible became full. The employee removed the looking glass and molten bath flowed out, contacting the employee. The employee received second degree burns to the arm and abdomen, requiring hospitalization.
2019-08-22	Cleveland	Ohio	Basic Aluminum Casting Co.	Back, including spine, spinal cord	Contact with hot objects or substances
A maintenance employee was servicing a casting machine when the automatic ladle spilled molten aluminum on the employee's back. The employee was hospitalized with severe burns to the back.
2019-08-12	Talladega	Alabama	Talladega Pattern & Aluminum Works, Inc.	Foot (feet)	Contact with hot objects or substances
An employee was pouring molten brass into a pig mold. Brass splashed into his boot, causing second-degree burns to the side of his right foot and third-degree burns to the top of the foot.
2019-07-24	Watertown	Wisconsin	Spuncast, Inc.	Foot (feet) and ankle(s)	Contact with hot objects or substances
The injured employee was holding materials while another employee was pouring molten metal using a spoon. The spoon failed, allowing the molten metal to spill and contact the injured employee's right leg. The molten metal then ran down into the employee's boot causing burns to the ankle and foot.
2019-07-22	Manitowoc	Wisconsin	Eck Industries	Leg(s)	Contact with hot objects or substances
An employee was pouring molten aluminum from a hand ladle when the aluminum spilled and burned his leg.
2019-07-21	Seneca Falls	New York	Scepter, Inc.	Multiple body parts	Fall on same level due to tripping
At 4:30 p.m. on July 21, 2019, an employee tripped over frozen metal and fell into a sow mold containing molten metal. The employee suffered burns to the arm and torso.
2019-07-18	Bensenville	Illinois	Chicago White Metal Casting, Inc.	Foot (feet)	Contact with hot objects or substances
While an employee was moving a bowl ladle with an automatic control, molten metal splashed from the bowl ladle and landed on the employee's feet. The employee sustained burns to both feet.
2019-07-10	Sheboygan	Wisconsin	Watry Industries LLC	Arm(s)	Contact with hot objects or substances
An employee was moving a piece of aluminum into a furnace. The aluminum fell off the forklift that was transporting it, landed in molten aluminum, and created a splash that caused molten aluminum to burn the employee's arm.
2019-07-10	Broken Bow	Nebraska	Becton Dickinson	Multiple body parts	Contact with hot objects or substances
Two employees were removing a screw from a high-speed injection molding machine. As they were removing the screw tip, pressurized molten plastic was released through an opening around the screw tip which resulted in both employees being burned by the molten plastic. They sustained burns to the forehead, right neck, face, right arm, and right hand. One employee was hospitalized.
2019-07-10	Braddock	Pennsylvania	United States Steel Corporation	Hand(s) and wrist(s)	Contact with hot objects or substances
An employee was pealing sand away with a bar to direct the flow of molten iron. The iron ejected and contacted the employee causing burns from the base of his left index finger to his left wrist. The employee was hospitalized.
2019-06-24	Pascagoula	Mississippi	Ingalls Shipbuilding Inc.	Thigh(s)	Nonstructural fire, n.e.c.
An employee was cutting T-beams with a cutting torch when the employee's pants caught on fire possibly due to a piece of molten slag, resulting in second and third degree burns to the employee's inner thighs.
2019-06-13	Commerce City	Colorado	AZZ GALVANIZING SERVICES	Multiple body parts	Contact with hot objects or substances
An employee was moving a steel box to remove excess molten zinc after it came out of a kettle when the wire holding the box broke and the box fell into the kettle. Molten zinc splashed on the employee, causing second and third degree burns to his neck, chest, and arms.
2019-06-11	Rumford	Maine	ND Paper, Inc.	Multiple body parts	Contact with hot objects or substances
An employee was "rodding" a boiler (unclogging a plug of smelt) when the plug let loose. The smelt, which was under pressure, then sprayed the employee. The employee was severely burned by molten smelt on the face, neck, shoulder, and leg, requiring hospitalization.
2019-04-26	Dalton	Georgia	Tarkett	Forearm(s)	Contact with hot objects or substances
An employee was performing a screen change on an extruder and was burned on the right forearm by molten polyvinyl butyral (PVB) after sliding the door open.
2019-04-02	Birmingham	Alabama	Metalplate Galvanizing, L.P.	Nonclassifiable	Contact with hot objects or substances
An employee was sweeping ash off a kettle when trapped moisture caused molten zinc to pop after steel was submerged in the kettle. The molten zinc contacted the employee, causing second degree burns.
2019-03-28	Fonda	New York	Keymark Corporation	Sole(s)	Contact with hot objects or substances
An employee had to remove a plug from one furnace to allow molten aluminum to move along a trough to another furnace. When he removed the plug, the molten aluminum splashed out of the trough and went on his pant leg and into his open boot, traveling into the bottom of his shoe and burning the bottom of his foot. Proper PPE was not worn at the time of the incident.
2019-03-21	Ashland	Ohio	Zephyr Industries	Foot (feet)	Contact with hot objects or substances
On March 21, 2019, an employee was pouring molten aluminum into a casting when the aluminum contacted the employee's foot, causing severe burns.
2019-03-05	Cleveland	Ohio	I. Schumann & Co.	Multiple body parts	Contact with hot objects or substances
An employee was using a dipper (a 5-foot pole with a cup) to retrieve molten metal from a gas rotary furnace. The metal splashed him, setting his cotton overalls on fire and causing burns to the left side of his torso and left arm.
2019-02-25	Troy	Texas	Anderton Casting, LLC.	Multiple body parts	Contact with hot objects or substances
An employee was helping to free a stuck shot tip and was struck by the automated ladling system. The molten metal caused second and third degree burns to his right shoulder, back, neck and face.
2019-02-09	Minerva	Ohio	Imperial Aluminum	Multiple body parts	Contact with hot objects or substances
An employee was attempting to remove remelt aluminum for a sow mold as it was not full. Ice on the piece of scrap metal he was using caused the molten metal to pop and splash onto his left wrist and the right side of his face, causing first- and second-degree burns. He was hospitalized.
2019-01-24	Thomaston	Georgia	Solo Cup Operating Corporation	Forearm(s)	Contact with hot objects or substances
An employee was repairing the gearbox in front of an extruder when he came in contact with molten plastic and sustained second degree burns to the left temple and third degree burns to the left forearm.
2019-01-10	Streator	Illinois	Owens-Brockway Glass Container Inc.	Hand(s) and arm(s)	Contact with hot objects or substances
An employee was operating a glass forming machine when the funnel closed on his left arm. The molten glass burned his left hand and forearm, and the machine caused contusions to his forearm and hand.
2019-01-09	Hamburg	Pennsylvania	Hamburg Plow Works, Inc.	Foot (feet)	Contact with hot objects or substances
An employee poured molten iron into a mold. The molten iron ran out of the mold at the bottom corner of the jacket and onto the employee's right foot causing a burn to the top of the foot, which required hospitalization.
2018-09-25	Monmouth Junction	New Jersey	Nuvida Plastic Technology	Multiple body parts	Contact with hot objects or substances
Two employees were trying to start up a plastics extruder after a maintenance shutdown. As they tried to resolve an overpressurization problem, molten plastic began spraying from the screen changer vents. Both employees suffered burns to the head, torso, and upper extremities. They were hospitalized.
2018-09-14	Conway Springs	Kansas	D J Extruding	Nonclassifiable	Contact with hot objects or substances
Two employees were working around an extrusion machine when it overheated and sprayed molten aluminum on them. They were hospitalized with burns.
2018-08-30	Shawnee	Oklahoma	Shawnee Tubing Industries, LLC	Multiple body parts	Explosion of nonpressurized vapors, gases, or liquids
An employee was operating the casting machine. A malfunction allowed molten copper to be poured into water creating an explosion. The employee sustained burns to the face, neck, and shoulder and an eye injury.
2018-08-30	Paragould	Arkansas	Corbitt Manufacturing Company, Inc.	BODY SYSTEMS	Exposure to environmental heat
An employee was using a ladle to pour molten aluminum into a tilt when he started feeling ill and then vomited. He later experienced aching arms and hands, and was hospitalized for severe dehydration.
2018-08-26	Minerva	Ohio	Imperial Aluminum - Minerva, LLC	Hip(s)	Other jump to lower level 6 to 10 feet
While taping an aluminum reverb, an employee believed that molten metal was over-flowing the trough and melting oxygen lines on the floor. The employee then jumped over the handrail of an elevated work platform and fell approximately 5 to 6 feet to the floor below, injuring his left elbow and fracturing the left side of his hip.
2018-08-21	West Point	Georgia	Stellar Staffing, LLC	Foot (feet)	Contact with hot objects or substances
An employee was performing metal casting work with molten steel when molten metal spilled onto his right leg and into his boot, burning his foot. Leg protection was not worn at the time of the incident.
2018-07-28	Minerva	Ohio	IMPERIAL ALUMINUM - MINERVA LLC	Multiple leg locations	Contact with hot objects or substances
An employee was working in the pit pulling impurities in the trough while facing backwards. The molten metal splashed and burned the employee's left leg. The employee received first and second degree burns to the thigh and calf areas.
2018-07-19	Browntown	Wisconsin	Grede Wisconsin Subsidiaries LLC	Head and neck	Contact with hot objects or substances
A employee was attempting to chisel through a tuyere on a cupola melt deck that had started to solidify. When he created a hole through the chilled iron, molten iron exploded out of the tuyere and struck him on the right side of his face and neck. As he moved out of the way, he tripped over a water pipe on the deck; he fell, striking his head on the metal deck and losing consciousness.
2018-07-10	Herculaneum	Missouri	JV Development	BODY SYSTEMS	Exposure to environmental heat
An employee became overheated while casting molten lead ingots, requiring hospitalization for severe heat exhaustion.
2018-06-17	New Castle	Pennsylvania	Ellwood Quality Steels Company	Multiple body parts	Contact with hot objects or substances
An employee was finishing a vertical mold set-up when the lid fell. The employee entered the mold to try to retrieve the lid. The mold next to the one he was in was filled with molten steel. He could not get out of the mold and was burned by the radiant heat from the adjacent mold. He suffered burns to 6% of his body (hands, back, buttocks).
2018-06-08	Mckinney	Texas	Encore Wire Corporation	Foot (feet)	Contact with hot objects or substances
An employee was cleaning slag from a vessel containing molten copper. The slag and molten copper splashed onto the employee's left foot burning it.
2018-05-25	Blytheville	Arkansas	NUCOR-YAMATO STEEL, Inc.	Foot(feet) and leg(s)	Contact with hot objects or substances
A caster operator was removing a safety blank while wearing heavy welding gloves to insert a smaller nozzle in a casting tundish holding molten steel. The blank fell onto the top of the shroud, causing the molten steel to splatter onto his flame-resistant clothing and metatarsal safety boots. He suffered second- and third-degree burns to his lower legs and feet.
2018-04-24	Selma	Alabama	Globe Metallurgical, Inc.	Multiple body parts	Struck bump, hole, rough terrain on driving surface, nonroadway
An employee was transporting a ladle from the furnace to the casting area using an industrial truck. The front tire hit a pothole causing the molten silicon to spill to the ground which caused an explosion resulting in second degree burns to the employee's face, upper back, left arm and neck.
2018-04-17	Pittsburgh	Pennsylvania	McConway & Torley, LLC.	Ankle(s) and leg(s)	Contact with hot objects or substances
An employee was performing a stream test and opening the ladle stopper mechanism when molten metal splashed on his leg and burned through his protective leggings. He suffered a small burn on his calf and upper ankle.
2018-04-14	Pittsburgh	Pennsylvania	Neville Chemical Company	Nonclassifiable	Contact with hot objects or substances
Employee #1 was shutting down the system where molten resin goes through a filter prior to being cooled and processed on the belt. The employee tried to clean the material from the filter using nitrogen. The O-ring on the filter failed, allowing hot molten resin to spray out. The employee moved away from the area thinking that the pressure was relieved from the filter. When he returned with another employee, more molten resin sprayed out, burning both employees.
2018-04-13	Minerva	Ohio	Imperial Aluminum	Lower extremities	Contact with hot objects or substances
An employee was skimming a trough of molten aluminum when it spilled into his boot, causing third and fourth degree burns.
2018-03-24	Reedsburg	Wisconsin	American Axle & Manufacturing, Inc.	Ankle(s) and leg(s)	Contact with hot objects or substances
An employee was standing on the floor removing a sample of molten iron from a furnace. The sample cup became caught on the lip of the furnace and molten iron spilled onto the employee's aluminized pants, contacting his leg through a pocket opening. He received burns to the thigh, calf, and ankle.
2018-03-21	Jacksonville	Florida	Enkei America, Inc.	Hand(s)	Contact with hot objects or substances
An employee was taking a sample of aluminum when molten aluminum splashed on his right hand, causing burns.
2018-03-14	Boss	Missouri	Doe Run	Multiple body parts	Contact with hot objects or substances
An employee was filling molds with molten lead. When he turned a valve to open it, the line split and sprayed him with the molten lead, burning his abdomen and right arm.
2018-03-07	Massillon	Ohio	OMNI DIE CASTING INC.	Multiple body parts	Contact with hot objects or substances
An employee was working at a press when the employee took a ladle coated in molten aluminum and dipped it in water. The ladle then popped/exploded, sending flying molten metal in multiple directions. The metal burned the employee's head, neck, back, and hand.
2018-02-26	Kansas City	Missouri	CONCORP INC	Foot(feet) and leg(s)	Other fall to lower level
An employee was working on a conveyor belt when he slipped and fell into a molten lead pot, suffering burns to both feet/legs. He was hospitalized.
2018-02-21	Maybrook	New York	Eastern Alloys, Inc.	Multiple body parts	Contact with hot objects or substances
An employee was pouring sows (molten metal) into a mold when the metal blew out, resulting in burns to the neck, chin, and hands.
2018-02-17	Monroe City	Missouri	Continental Casting, LLC	Hand(s) and arm(s)	Contact with hot objects or substances
An employee was skimming impurities from melt when he lost his footing and fell forward into a pot of molten aluminum. He was burned on the left arm and hand.
2018-01-05	Elmira	New York	Hardinge Inc.	Multiple body parts	Contact with hot objects or substances
An employee was preparing parts for treating in a salt bath when molten salt was propelled from the salt pot, causing second and third degree burns to the employee's hands and abdomen.
2017-09-15	Hondo	Texas	Martin Resource Management Corporation	Multiple body parts	Contact with hot objects or substances
An employee disconnected what he thought was a steam hose but was actually a molten asphalt hose. The molten asphalt splashed his chest and arms, causing second degree burns.
2017-09-03	Gadsden	Alabama	Tennessee Aluminum Processors, Inc.	Multiple lower extremities locations	Contact with hot objects or substances
An employee was walking through a furnace pit when the furnace trough kicked back. The employee then stepped back into a mold full of molten metal, suffering second degree burns to the right ankle and calf and to the left foot.
2017-08-30	Browntown	Wisconsin	Grede Wisconsin Subsidiaries LLC	Foot(feet) and leg(s)	Contact with hot objects or substances
An employee was using a skimming bar to remove slag from the top of a ladle of molten iron when the molten iron (2,600 degrees) poured down and burned his left leg and foot.
2017-08-17	Simsboro	Louisiana	Ardagh Glass, Inc	BODY SYSTEMS	Exposure to environmental heat
An employee was maintaining a forming machine (forms molten glass into glassware) when he became overheated and experienced stomach cramps and nausea. He was hospitalized for heat exhaustion.
2017-08-11	Russells Point	Ohio	HONDA TRANSMISSION MANUFACTURING OF AMERICA INC.	Foot(feet) and leg(s)	Ignition of clothing from controlled heat source
On August 11, 2017, an employee was changing the filter on a high-pressure die cast furnace when the employee's leg slipped off the edge and contacted molten aluminum. The employee's pant leg ignited, and the employee suffered burns to the right foot and lower leg.
2017-07-17	Greenville	Pennsylvania	Hodge Foundry, Inc.	Leg(s)	Ignition of clothing from controlled heat source
An employee was pouring a ladle of molten iron into a sand mold. Radiant heat from the pour caused the employee's jeans to catch fire. The employee was hospitalized with third degree burns on his right leg.
2017-07-11	Milwaukee	Wisconsin	Advance Die Casting Company, LLC	Foot (feet)	Contact with hot objects or substances
An employee was walking away from a furnace when molten metal sprayed from the furnace's crucible hole and contacted his foot, causing second degree burns.
2017-07-10	Wilder	Idaho	CTI-SSI Food Services, LLC	Multiple body parts	Contact with hot objects or substances
An employee was filling a molten unit. The discharge valve was closed at the time, and the line over-pressurized. The line burst, spraying the employee with scalding water that caused second and third degree burns to the ears, neck, hands, and chest.
2017-06-03	Middletown	New York	Revere Smelting & Refining Corporation	Foot (feet)	Contact with hot objects or substances
An employee was returning to his station at a molten lead kettle when a coworker added a sodium hydroxide treatment too quickly to the molten lead, causing it to react and spill over onto the injured employee. He suffered second degree burns on his left foot and was hospitalized.
2017-05-24	Borger	Texas	Poole Chemical Company, Inc.	Head	Contact with hot objects or substances
An employee was loading molten sulfur into a trailer when the line clogged and the molten sulfur spilled out, burning the front right side of the employee's head.
2017-04-27	New Brighton	Pennsylvania	Damascus Steel Casting Company	Nonclassifiable	Explosion, n.e.c.
An employee was melting steel in a furnace when the molten steel contacted piping carrying circulating water and caused an explosion. The employee was burned by steam and molten metal and was hospitalized.
2017-04-18	Canton	Ohio	TimkenSteel Corporation	Head and trunk	Explosion, n.e.c.
During the tap/pour process, an arc flash explosion occurred and an employee that was standing approximately 30 feet from the operation received multiple burns to the face and chest from the molten metal and solids. The employee also sustained lacerations to the thigh and forehead.
2017-04-12	Ripon	Wisconsin	AFK Corporation	Foot (feet) and ankle(s)	Contact with hot objects or substances
An employee's left foot and ankle were burned while cleaning out the ladle when the ladle tipped forward and the molten iron when into the employee's boot.
2017-04-10	Birmingham	Alabama	American Cast Iron Pipe Company	Foot (feet)	Contact with hot objects or substances
An employee was filling a quadrant ladle with molten iron from a holding ladle. The trough was not in the upright position because the machine was in between cycles. The quadrant ladle then overfilled, causing some of the molten iron to spill out and onto the employee's feet, burning them.
2017-04-05	Leetsdale	Pennsylvania	Libertas Copper, LLC	Multiple body parts	Contact with hot objects or substances
An employee received second and third degree burns to the hand, neck, ear and foot when molten copper contacted water and "popped."
2017-04-05	La Crosse	Wisconsin	Torrance Casting, Inc.	Foot (feet)	Contact with hot objects or substances
The bottom of an employee's right foot was burned when molten iron spilled over the mold and into the employee's boot.
2017-01-24	Cleveland	Ohio	Adalet/Scott Fetzer Co.	Nonclassifiable	Contact with hot objects or substances
An employee was pouring molten metal. The molten metal splashed onto and burned another employee that was standing nearby.
2017-01-06	Phelps	Wisconsin	Berntsen Brass & Aluminum Foundry, Inc.	Multiple body parts	Explosion, n.e.c.
An employee was placing a zinc ingot into an induction melting electric furnace. When the zinc ingot contacted the molten metal, the furnace blew up, causing severe burns to the employee's upper body and minor burns to a coworker.
2016-10-10	Madison	Alabama	Polaris Industries, Inc.	Multiple face locations	Contact with hot objects or substances
An employee was changing over the nozzles on an injection molding machine. When he went to unbolt the manifold, molten plastic sprayed in his face. He sustained second degree burns to the front and right side of his face.
2016-08-17	Syracuse	New York	Meloon Foundries LLC	Upper and lower limb(s)	Contact with hot objects or substances
An employee was preparing a no-bake sand mold. When the molten metal was poured into the mold, the aluminum ran through the lifting hole and entered the employee's right shoe, burning his foot and requiring surgery. He also suffered burns on both hands while attempting to remove his shoe.
2016-08-14	Burnsville	Mississippi	Mississippi Silicon, LLC	Multiple body parts	Contact with hot objects or substances
An employee was using a hardwood pole to clean a furnace's tap channel when molten metal slag suddenly released from the furnace, burning the employee's hands, head, face, left ear, lips, and mouth.
2016-08-05	Cumberland	Rhode Island	CUMBERLAND FOUNDRY COMPANY, INC.	Hand(s)	Contact with hot objects or substances
An employee was tipping over (breaking open) a mold that contained liquid molten iron. The molten iron came in contact with the cuff of his leather glove and traveled down the inside of his glove to the palm and fingers, burning his hand.
2016-07-15	Fremont	Nebraska	Magnus, L.L.C.	Multiple lower extremities locations	Contact with hot objects or substances
On July 15, 2016, an employee was skimming slag off the top of a pot of molten bronze when some of the slag and molten bronze dropped onto his coveralls. The molten bronze and slag, with a temperature over 2000 degrees Fahrenheit burned through his coveralls, seriously burning his shin, ankle, and foot before his boot could be removed.
2016-06-23	Midlothian	Texas	Gerdau Midlothian Mill	Nonclassifiable	Contact with hot objects or substances
An employee was moving a kettle of molten metal when the molten metal spilled and burned the employee.
2016-06-15	Hogansville	Georgia	Mando Corporation of America	Foot (feet)	Contact with hot objects or substances
An employee was pouring molten iron back into the furnace when the molten iron splashed onto the employee's foot resulting in burns to the foot.
2016-03-19	Sturgeon Bay	Wisconsin	Fincantieri Marine Group LLC	Back, including spine, spinal cord	Ignition of clothing from controlled heat source
An employee was cutting an overhead steel member with a cutting torch when molten slag fell onto his clothing and ignited it. He suffered 1st and 2nd degree burns to his back and additional burns on his hand.
2016-02-13	New Castle	Delaware	Croda, Inc.	Multiple body parts	Contact with hot objects or substances
An employee was heating and circulating a chemical batch in a process tank. The employee opened the automatic valve in the control room to begin the transfer of hot molten chemical material. Two bottom drain valves were left open on the transfer line spilling the hot molten chemical material onto the floor. The employee was hospitalized for second and third degree burns to the lower extremities and both hands and arms.
2016-01-21	Macedonia	Ohio	American Light Metals LLC	Foot (feet)	Nonroadway collision with other vehicle
An employee operating a fork truck backed into a second fork truck, which had just transferred molten metal from a larger furnace to a ladle. The 1300-degree residual molten metal splashed out and contacted the employee's left foot, causing third degree burns. The employee was hospitalized.
2015-10-27	Orrville	Ohio	Quality Castings Company	Lower extremities	Contact with hot objects or substances
An employee received second degree burns to the lower body when he slipped and fell while carrying molten metal in a ladle.
2015-10-19	Liverpool	New York	Scapa, NA	Hand(s)	Contact with hot objects or substances
An employee was looking into a hopper containing molten plastic to determine why the hopper was not running smoothly. Molten plastic backed up onto the employee's hands, burning them and requiring surgery.