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OSHA proposes $3.5M in fines after Channelview sulfuric acid spill injured workers

Federal investigators say three companies failed to protect workers during hazardous cleanup after a 1 million-gallon chemical release.

Chemical spill at a BWC Terminals facility in Channelview on Dec. 27, 2025. (KPRC)

CHANNELVIEW, Texas – The U.S. Department of Labor has proposed more than $3.5 million in penalties against three companies after federal investigators found they failed to protect workers during cleanup efforts following a massive sulfuric acid spill at an industrial facility in Channelview.

The department’s Occupational Safety and Health Administration launched three inspections after a Dec. 27, 2025, sulfuric acid spill at the BWC Terminals facility that injured multiple employees.

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According to OSHA, BWC Terminals mixed fresh and spent sulfuric acid despite safety warnings, causing a tank to become overpressurized. Investigators said the pressure ruptured a supply line, releasing about 1 million gallons of sulfuric acid and injuring multiple workers.

After the spill, BWC Terminals hired Coastal Environmental Solutions Inc. to oversee hazardous waste cleanup. Coastal Environmental Solutions then subcontracted One Way Environmental Services LLC to provide laborers for the cleanup and remediation work.

“Despite having full knowledge of the severe hazards involved in the spill and cleanup response, these three employers chose to bypass OSHA requirements and put their workers at serious risk,” Assistant Secretary for Occupational Safety and Health David Keeling said in a statement. “Their joint failure to protect workers was not an oversight, it was a choice that resulted in preventable employee injuries and environmental impacts. We will not hesitate to hold employers accountable when they ignore federal laws that are in place to protect workers safety and health.”

OSHA cited One Way Environmental Services LLC with 18 willful egregious violations and five serious violations, alleging the company sent workers to clean up the chemical spill without adequate training, respirator fit testing or other required safety measures. The agency proposed $3,045,452 in penalties.

Coastal Environmental Solutions Inc. faces $392,501 in proposed penalties for two willful and five serious violations. OSHA said the company failed to provide adequate worker training, establish a safety and health program, develop an emergency response plan for hazardous waste operations and ensure proper respirator use.

BWC Terminals received six serious citations, with OSHA alleging the company exposed workers to chemical burns, failed to provide hazardous materials training and had deficiencies related to respirator use. The agency proposed $82,750 in penalties.

Combined, OSHA is seeking $3,520,703 in proposed penalties against the three employers.

The companies have 15 business days after receiving the citations to comply with OSHA’s findings, request an informal conference with the agency’s area director or contest the citations before the independent Occupational Safety and Health Review Commission.