The Case
A 36-year-old warehouse worker arrives with white, waxy patches on both hands and a sharp chemical odor clinging to his shirt. He says a drum ruptured while he was cleaning it, and his pain is surprisingly mild despite deep-appearing areas on the fingers. His eyes are tearing, and the exposure label is smeared beyond recognition. The contaminated clothing is still on his body as the team decides what comes off first.
Before You Read
- What must happen before examining the depth of the burn?
- Which chemical exposures require systemic calcium treatment?
- When does a skin exposure become an airway, ocular, or toxicologic emergency?
Why It Matters
Chemical injury continues until the agent is removed or neutralized, and apparent pain or superficial appearance does not reliably predict tissue destruction. Hydrofluoric acid can cause fatal dysrhythmias through systemic fluoride toxicity even when the skin findings look modest.
When to Think of It
Suspect chemical burn after industrial, laboratory, agricultural, construction, battery, drain-cleaner, cement, or household exposure. Ask what substance, concentration, duration, route, clothing contamination, enclosed-space exposure, and decontamination occurred. Examine airway, eyes, skin, distal pulses, sensation, range of motion, and circumferential involvement.
Sick or Not Sick
The most important call is whether this is a localized skin injury or a systemic/airway/ocular emergency. Inhalation symptoms, facial or oropharyngeal exposure, persistent abnormal pH, hydrofluoric acid exposure, hypocalcemia, dysrhythmia, circumferential injury, hand/genital/face involvement, or extensive burns require resuscitation and specialty consultation.
The First Fifteen Minutes
- Protect staff first: remove contaminated clothing and jewelry, bag them, brush off dry powders, and irrigate exposed skin with copious room-temperature water. Do not delay irrigation while identifying the chemical.
- For ocular exposure: immediately irrigate with normal saline or lactated Ringer’s; use topical anesthetic proparacaine 0.5%, 1–2 drops per eye once to facilitate irrigation. Avoid repeated outpatient anesthetic use because it delays epithelial healing.
- For severe pain: fentanyl 50–100 mcg IV, repeat every 5 minutes to effect; analgesia permits adequate decontamination and examination. Dose carefully in respiratory depression.
- If tetanus immunization is incomplete or unknown: Tdap 0.5 mL IM once; if the wound is major/contaminated and the patient is inadequately immunized, add tetanus immune globulin 250 IU IM once. Confirm vaccine history and local protocol.
- For hydrofluoric acid exposure with pain, visible tissue injury, or suspected fluoride absorption: apply 2.5% calcium gluconate gel to the skin with gloves and massage, replacing every 15–30 minutes; calcium binds fluoride locally.
- For persistent HF pain or deeper injury after irrigation: infiltrate affected tissue with 10% calcium gluconate, commonly 0.5 mL/cm², avoiding excessive tissue pressure; dosing and technique vary—consult toxicology/burn protocol.
- For systemic HF toxicity—hypocalcemia, hypomagnesemia, hyperkalemia, QT prolongation, or dysrhythmia: 10% calcium gluconate 10–20 mL IV over 10 minutes, repeat based on ECG and ionized calcium. Calcium chloride 1 g IV may be used through a central line in life-threatening instability. Confirm local protocol and monitor calcium closely.
- If shock from extensive burns or systemic toxicity: give lactated Ringer’s 500–1,000 mL IV bolus, reassess perfusion, and avoid blindly applying the Parkland formula to small chemical burns. Large burns require burn-center-directed resuscitation.
- If airway edema, stridor, voice change, facial burns, or enclosed-space exposure is present: early RSI and airway consultation; do not wait for progressive edema that may make intubation impossible.
Definitive Care & Disposition
Continue irrigation until skin pH is approximately 5–9 and stable after a period without irrigation; do not attempt neutralization reactions unless specifically directed by toxicology. Obtain ophthalmology consultation for persistent ocular pH abnormality, corneal epithelial defect, limbal ischemia, or visual symptoms. Burn surgery consultation is indicated for deep, circumferential, extensive, hand, face, genital, joint, or suspected full-thickness injuries. Admit systemic HF toxicity, significant ocular injury, inhalation injury, uncontrolled pain, extensive/deep burns, or patients needing serial calcium/ECG monitoring; minor superficial injuries may be discharged only after adequate decontamination, stable examination, tetanus planning, and reliable follow-up.
How This One Kills
The fatal miss is underestimating hydrofluoric acid because the skin injury looks small, allowing progressive hypocalcemia, hyperkalemia, QT prolongation, and ventricular dysrhythmia.
The Atypical Presentation
Chemical burns may be painless because the agent causes immediate nerve destruction or because the patient is intoxicated, hypothermic, or distracted. Dry powders can continue reacting after arrival, and alkali injuries may deepen despite initially modest erythema. Rely on the exposure history, serial examination, tissue pH, ocular findings, distal neurovascular status, and systemic laboratory/ECG abnormalities—not pain alone.
Back to Our Patient
Back to the 36-year-old warehouse worker with waxy hand lesions, chemical odor, tearing eyes, and contaminated clothing: recognize this as an ongoing chemical exposure with possible hydrofluoric acid or another corrosive agent until identified. Risk-stratify him as high risk because the hands and eyes are involved and the substance is unknown; protect staff, remove clothing, brush off any powder, and begin immediate copious irrigation. After irrigation, check ocular pH, ECG, electrolytes, ionized calcium, magnesium, and potassium; if HF is suspected, apply calcium gluconate gel and treat systemic abnormalities with IV calcium. He needs toxicology, ophthalmology, and burn/hand consultation, with admission if pain, tissue depth, ocular injury, ECG changes, or calcium abnormalities persist.
Patient Presentation to Attending
“This is a 36-year-old warehouse worker with an unidentified industrial chemical exposure, presenting with contaminated clothing, waxy bilateral hand lesions, eye irritation, and a sharp chemical odor. Pain is mild, but the agent and concentration are unknown, and he has no current stridor or hypotension. We are removing clothing, protecting staff, brushing off any dry material, and irrigating skin and eyes while checking ocular pH and obtaining an ECG, electrolytes, magnesium, and ionized calcium. I am particularly concerned for hydrofluoric acid because the skin findings may underestimate systemic fluoride toxicity. I will apply calcium gluconate gel if HF is suspected, give IV calcium for ECG or calcium abnormalities, provide analgesia, and involve toxicology, ophthalmology, and burn surgery.”
Study Directive
- Memorize the first five actions for chemical exposure: staff protection, remove clothing, brush powders, irrigate, assess airway/eyes/systemic toxicity.
- Review the local hydrofluoric acid protocol, including calcium gel preparation, infiltration, IV calcium, and ECG monitoring.
- Practice an ocular chemical injury examination: pH, visual acuity, fluorescein, limbal ischemia, and fornix sweep.
- Work through three disposition cases: minor superficial injury, circumferential hand burn, and systemic HF toxicity.
- Perform a verbal “contamination timeout” before simulation: substance, route, duration, PPE, decontamination, and antidote.