Common Workplace Eye Injuries and Prevention

Each year, thousands of Australians suffer preventable eye injuries in the workplace. According to Safe Work Australia, eye injuries consistently rank among the most common workplace incidents, yet studies suggest that up to 90% of these injuries could be prevented with appropriate eye protection and safety practices. Understanding the types of injuries that occur, how they happen, and how to prevent them is essential knowledge for every worker and employer.

The Scale of Workplace Eye Injuries

Workplace eye injuries have significant impacts beyond the immediate pain and suffering:

• Thousands of workers' compensation claims are filed for eye injuries annually in Australia
• Many injuries result in permanent vision impairment or blindness
• Lost productivity and medical costs run into millions of dollars
• Construction, manufacturing, and mining sectors have the highest rates of eye injuries
• Many injuries occur to workers not wearing any eye protection

The most sobering statistic is that the majority of these injuries are preventable. Workers either weren't wearing protection, were wearing inadequate protection, or were injured by hazards that proper engineering controls could have eliminated.

Types of Workplace Eye Injuries

Foreign Body Injuries

The most common type of workplace eye injury involves foreign objects entering the eye. These can range from minor irritants to serious penetrating injuries:

• Surface foreign bodies: Dust, metal shavings, or wood particles that lodge on the eye surface. Often uncomfortable but usually not permanently damaging if treated promptly.
• Embedded foreign bodies: Particles that penetrate the cornea or sclera. These require medical removal and can cause scarring.
• Penetrating injuries: High-velocity particles that enter the eye itself. These are medical emergencies that can result in permanent vision loss.

Common sources: Grinding, cutting, sawing, drilling, hammering, and any activity that creates airborne particles.

Chemical Burns

Chemical injuries occur when corrosive or irritating substances contact the eye. The severity depends on the chemical type, concentration, and exposure duration:

• Alkali burns: Caused by bases like cement, ammonia, and drain cleaners. Alkalis penetrate deeply and cause progressive damage even after the chemical is removed.
• Acid burns: Caused by acids like battery acid, pool chemicals, and industrial acids. Generally cause immediate but more localised damage.
• Irritant exposure: Caused by solvents, detergents, and other chemicals that irritate but don't permanently damage with brief exposure.

Common sources: Chemical handling, laboratory work, cleaning operations, concrete and masonry work, battery maintenance.

Thermal Burns

Heat-related eye injuries occur through direct thermal exposure or radiation:

• Direct burns: From hot liquids, steam, or flames contacting the eye area
• Radiation burns: From welding arc, UV lamps, or laser exposure (discussed separately below)
• Hot particle burns: From welding spatter or grinding sparks that land on the eye

Common sources: Welding, furnace operations, cooking/catering, foundry work, hot liquid handling.

Radiation Injuries

Radiation eye injuries include damage from various electromagnetic wavelengths:

• UV radiation: Causes photokeratitis ("welder's flash" or "snow blindness"). Intensely painful but usually temporary.
• Blue light: Can contribute to retinal damage with prolonged exposure
• Infrared radiation: From furnaces and heating operations. Causes gradual lens damage leading to cataracts.
• Laser radiation: Can cause instant, permanent retinal damage even from brief exposure to powerful lasers.

Common sources: Welding operations, outdoor work (UV), laboratory lasers, industrial heating equipment.

Blunt Trauma

Impact injuries from objects striking the eye area can cause:

• Contusions: Bruising to the eye and surrounding tissues
• Subconjunctival haemorrhage: Bleeding under the eye surface (appears alarming but often heals without treatment)
• Hyphema: Bleeding inside the eye, a more serious condition requiring medical attention
• Orbital fractures: Broken bones around the eye socket
• Retinal detachment: Serious condition that can cause blindness if untreated

Common sources: Flying objects, falling tools, pressurised equipment failure, vehicle incidents.

Prevention Strategies

The hierarchy of controls applies to eye hazards just as it does to other workplace risks. Prevention strategies should be implemented in order of effectiveness:

1. Elimination

Remove the hazard entirely where possible:

• Use alternative processes that don't create flying particles
• Substitute less hazardous chemicals for corrosive ones
• Automate hazardous operations to remove workers from the danger zone

2. Substitution

Replace hazardous processes or materials with safer alternatives:

• Use water-based products instead of solvent-based ones
• Choose tools that generate less debris
• Select materials that don't require cutting or grinding

3. Engineering Controls

Implement physical barriers between workers and hazards:

• Machine guards that contain flying particles
• Local exhaust ventilation for dust and vapours
• Splash shields on chemical handling equipment
• Interlocked safety systems that prevent operation without guards in place

4. Administrative Controls

Work procedures and policies that reduce exposure:

• Safe work procedures for hazardous tasks
• Training on hazard recognition and safe practices
• Job rotation to limit individual exposure
• Warning signs and hazard communication

5. Personal Protective Equipment

Eye protection as the last line of defence:

• Safety glasses for impact hazards
• Chemical splash goggles for liquid hazards
• Face shields for severe hazards (in addition to glasses/goggles)
• Specialised protection for radiation hazards

Choosing the Right Protection

Selecting appropriate eye protection requires matching the protection to the hazard:

• Flying particles: Impact-rated safety glasses (minimum); goggles or face shields for severe hazards
• Chemical splashes: Chemical splash goggles (indirect ventilation)
• Dust and fine particles: Sealed goggles
• UV radiation: Safety glasses with UV400 protection
• Welding: Welding helmets with appropriate shade filters
• Lasers: Laser-specific eyewear rated for the wavelength and power level

For detailed guidance on selecting eye protection, see our Beginner's Guide to Safety Glasses and Safety Glasses vs Goggles comparison.

Creating a Safety Culture

Beyond providing equipment, creating a workplace culture that prioritises eye safety is essential:

• Lead by example: Supervisors and managers must consistently wear appropriate eye protection
• Make it easy: Provide readily accessible eye protection at all work locations
• Enforce consistently: Apply eye protection requirements uniformly, without exceptions
• Provide quality equipment: Uncomfortable eyewear that fogs or doesn't fit will be removed
• Communicate the "why": Workers who understand the risks are more likely to protect themselves
• Report near-misses: Use close calls as learning opportunities before injuries occur

Emergency Response

Knowing how to respond to eye injuries is as important as prevention. Quick, appropriate action can mean the difference between temporary discomfort and permanent vision loss.

For Foreign Bodies

• Do not rub the eye—this can embed particles deeper or scratch the cornea
• Allow tears to flush the particle naturally
• Use an eyewash station for stubborn particles
• Never attempt to remove embedded objects—seek medical attention

For Chemical Exposure

• Immediately flush with water for at least 15-20 minutes
• Hold eyelids open to ensure thorough flushing
• Remove contact lenses during flushing if possible
• Seek immediate medical attention after flushing
• Bring the chemical's Safety Data Sheet (SDS) to medical care

For Impact Injuries

• Apply a cold compress to reduce swelling (do not apply pressure to the eye itself)
• Do not rub or apply pressure to the eye
• Seek medical evaluation for any significant impact
• For severe injuries, cover the eye loosely and seek emergency care

Know Your Emergency Resources

• Know the location of all eyewash stations in your workplace
• Ensure eyewash stations are maintained and functional
• Know how to access emergency medical care
• Keep emergency eye care supplies in first aid kits

Conclusion

Eye injuries in the workplace are common, costly, and—most importantly—largely preventable. By understanding the types of hazards present, implementing appropriate controls, selecting proper eye protection, and creating a culture that prioritises safety, workplaces can dramatically reduce eye injuries. Remember: your eyes are irreplaceable. No task is so urgent that it justifies risking your sight. Wear appropriate protection, follow safe work procedures, and never take shortcuts with eye safety.

For more information about protecting your vision at work, explore our complete library of safety guides.