Preventing and treating workplace burns: A practical guide for employers

Each February, the American Burn Association highlights prevention during National Burn Awareness Week, which is observed during a designated week in February and varies by year. For employers across the United States, this is more than a calendar reminder. It is an opportunity to strengthen alignment with OSHA requirements, reinforce training and reduce preventable injuries.

Burn injuries remain a serious workplace hazard, especially in industries such as construction, food service, manufacturing, utilities and healthcare. Employees may be exposed to electrical, thermal, and chemical hazards. A comprehensive burn prevention strategy should align with OSHA requirements for electrical safety, PPE, hazard communication, and emergency planning.

As EHS leaders, our responsibility is clear. We must anticipate hazards, train effectively and respond quickly when incidents occur.

Understanding workplace burn hazards

Burn injuries generally fall into three categories: electrical, thermal and chemical. Each requires specific controls under OSHA regulations and sound EHS management practices.

Electrical burns

Electrical burns can happen in a fraction of a second. Under OSHA electrical safety standards in 29 CFR 1910 Subpart S and 29 CFR 1926 Subpart K, employers must protect employees from electrical hazards, including exposure to energized parts.

OSHA distinguishes between “qualified” and “unqualified” employees based on training and demonstrated skills and knowledge related to electrical work, not job titles. Employees who are not qualified to perform electrical work may still be exposed to electrical hazards during normal operations, troubleshooting or work around energized equipment.

They should understand:

The hazards of exposed energized parts
The need to stay clear of overhead power lines and energized equipment
The importance of controlling hazardous energy when servicing and maintenance are performed, including lockout and tagout under 29 CFR 1910.147 when it applies
The requirement to follow established safe work practices and boundaries, as trained and instructed

When electricity passes through the body, resistance generates heat. This can cause deep tissue damage, even when the skin appears minimally injured. Serious burns may be internal and life-threatening. Never underestimate the severity of an electrical injury based on appearance alone.

Thermal burns

Thermal burns result from contact with hot surfaces, flames, steam or molten materials. OSHA requirements related to welding, cutting and brazing, hot work, equipment safeguarding and PPE may apply to these exposures, depending on the operation.

Common workplace sources include:

Welding, cutting and brazing operations
Steam lines, boilers and heated tanks
Molten materials in foundries and manufacturing
Industrial ovens and drying equipment
Commercial kitchens and food processing equipment

Surface temperatures in industrial ovens can reach several hundred degrees Fahrenheit, and many molten materials reach very high temperatures. Without proper guarding, insulation, warnings, safe work procedures and PPE, these exposures can lead to severe injuries.

Engineering controls, equipment maintenance and clear hazard identification are essential components of an effective burn prevention program.

Chemical burns

Chemical burns occur when corrosive substances contact the skin or eyes. OSHA’s Hazard Communication Standard, 29 CFR 1910.1200, requires employers to maintain Safety Data Sheets (SDSs), ensure proper labeling and train employees on hazardous chemicals in their work area.

Acids and caustics are common culprits:

Acids may cause surface burns or deeper injury depending on concentration and contact time
Caustic substances such as sodium hydroxide can cause severe tissue destruction
Industrial cleaners, water treatment chemicals and metal processing solutions can present significant risk

In some cases, chemicals can penetrate the skin and continue damaging tissue beneath the surface. Where employees may be exposed to corrosives, OSHA requires “suitable facilities for quick drenching or flushing” (29 CFR 1910.151(c)). ANSI Z358.1 is the commonly used consensus standard for emergency eyewash and shower equipment, including the benchmark that equipment should be reachable within about 10 seconds via an unobstructed path.

Degrees of burn injury

The severity of a burn is commonly classified by degree:

First-degree burns

Affect only the outer layer of skin
Cause redness, dryness and localized pain
Typically heal within a few days

Second-degree burns

Involve deeper skin layers
Cause redness, swelling and blistering
May take weeks to heal and can scar
Should be medically evaluated

Third-degree burns

Destroy all layers of skin and may damage tissue underneath
May appear charred or whitish in areas
May be painful or may have reduced pain if nerves are severely damaged
Require immediate emergency medical care and often advanced treatment such as grafting

Supervisors and first-aid responders should understand these distinctions to support appropriate response and accurate OSHA recordkeeping decisions under 29 CFR 1904.

Burn first aid treatment

When responding to burn injuries, remember three steps: cool, cover and consult.

General first-aid guidance includes:

Remove loose clothing around the burn. Do not pull away clothing stuck to the wound
Cool the area with clean, cool water. Do not use ice
Cover with a sterile bandage or clean cloth
Do not apply ointments, lotions or butter
Do not break blisters

For chemical burns:

Remove contaminated clothing carefully
Flush affected areas with clean water for at least 15 minutes, or longer if directed by the SDS
Ensure eyewash or emergency shower equipment is readily accessible for rapid flushing. Many employers design to ANSI Z358.1’s 10-second benchmark
Call emergency services for suspected third-degree burns, electrical injuries, or large-area second-degree or chemical burns. Always document the incident properly and evaluate whether it is OSHA recordable.

Burn prevention strategies for OSHA compliance

Effective burn prevention is built on hazard recognition, engineering controls, administrative controls and PPE.

Conduct hazard assessments

Under OSHA PPE standards, employers must assess the workplace to determine if hazards are present that require PPE and verify the assessment. Identify hot surfaces, energized equipment, steam lines and chemical hazards. Update assessments when processes change.

Provide and enforce appropriate PPE

Depending on the hazard, required PPE may include:

Flame-resistant clothing
Heat-resistant gloves
Face shields and goggles
Chemical-resistant aprons and gloves
Electrical protective equipment appropriate to the task and exposure

Employees must be trained on proper selection, use and limitations of PPE.

Strengthen hazard communication

Ensure all containers are labeled properly. Maintain current SDSs and train employees to understand:

Chemical hazards
Required PPE
First-aid procedures
Spill and emergency response expectations
Clear labeling and accessible SDSs reduce both chemical and thermal injury risks.

Maintain equipment and control flammables

Implement preventive maintenance programs for:

Boilers and steam systems
Welding equipment
Ovens and heating systems
Electrical panels and enclosures

Store flammable and combustible materials in accordance with applicable OSHA requirements and recognized fire safety practices. Control ignition sources and do not leave heat-producing equipment unattended when procedures require monitoring.

Develop and practice emergency action plans

OSHA requires a written emergency action plan for many workplaces and specific situations, and it is a best practice even when not strictly required.

Plans should include:

Fire response procedures
Evacuation routes
First-aid and medical response roles
Emergency contact information

Conduct drills as appropriate and ensure supervisors understand their leadership role during an incident.

Deliver meaningful safety training

Training must be job-specific and understandable.

Workers should know:

The burn hazards in their work area
Safe operating procedures
How to use PPE correctly
How to respond to burn injuries, including how to summon help quickly

Training is not a one-time event. Reinforcement during safety meetings and toolbox talks strengthens retention and reduces complacency.

Building a culture that prevents burns

Burn prevention reflects how effectively hazards are identified, controlled and reinforced through everyday operations. When leaders prioritize inspections, encourage reporting of near misses and invest in effective controls, burn injuries decline.

As EHS professionals, we must continually ask:

Are we identifying hazards before someone gets hurt?
Are our workers confident in how to respond?
Are our controls effective and maintained?

Workplace burns are preventable when hazards are systematically identified, controls are enforced and leaders hold the line on safe work practices every day.