Steel Mill Lawsuit [2025 Update] | Occupational and Community Exposure Risks

Steel plants are large industrial facilities where raw materials are transformed into the structural metal that underpins modern society.

Steel production typically begins with either coal based steel in blast furnaces or recycling scrap metal in electric arc furnaces, with each method carrying distinct environmental and health implications.

Traditional blast furnaces rely on iron ore and coke, generating massive amounts of air pollution as byproducts of smelting, while electric arc furnaces melt recycled steel using electricity, representing one of the cleaner technologies in the sector.

Both types of facilities are operated by major steel companies and employ complex systems of heavy machinery to refine, shape, and finish steel products.

Coal based steel plants, also referred to as integrated steelworks, often stretch across vast areas with separate units for coking, sintering, smelting, and rolling.

In contrast, mini-mills that use electric arc furnaces are generally smaller, more flexible, and less polluting, though they still present occupational hazards for workers.

Steel plants also have a significant impact on indoor air quality for employees and surrounding communities, as dust, gases, and particulates often escape during production.

The Environmental Protection Agency (EPA) has identified industrial facilities like steel and coke plants as major contributors to regional and global emissions, from greenhouse gases to toxic pollutants.

While technological advances are pushing toward cleaner technologies, the industry remains one of the largest sources of localized environmental and health risks.

The major processes inside a steel plant involve multiple stages of heating, chemical reduction, and shaping:

• Coke production: converting coal into coke for use in blast furnaces.
• Sintering: agglomerating fine iron ore particles into larger masses suitable for smelting.
• Blast furnaces: reducing iron ore into molten iron using coke and limestone.
• Basic oxygen furnaces: refining molten iron into steel by injecting oxygen to reduce carbon content.
• Electric arc furnaces: melting scrap metal and sometimes direct reduced iron (DRI) using electricity.
• Casting and rolling: shaping molten steel into slabs, billets, or finished products like beams, sheets, and wires.
• Finishing operations: applying coatings, heat treatments, and other processes to prepare steel for industrial use.

Steel plants thus represent both economic engines and major sources of environmental stress.

While modern designs emphasize cleaner technologies, millions of workers and community members remain exposed to pollution risks created by traditional production methods.

How are People Exposed to Steel Industry Pollution?

Steel mills, whether they use coal-based steelmaking with blast furnaces and coke ovens, or electric arc furnaces powered by scrap, are significant sources of airborne and environmental pollutants.

Inside these industrial facilities, workers are exposed directly to gases, dusts, and fumes from smelting, coking, welding, and refining processes, despite standards set by the Occupational Safety and Health Administration (OSHA).

Meanwhile, communities living near such heavy industry can inhale pollutants emitted like sulfur dioxide (SO₂), nitrogen oxides (NOₓ), carbon monoxide, and silica dust, which degrade indoor air quality and contribute to serious respiratory conditions.

Asbestos exposure is another major exposure concern related to the steelmaking process.

Under the Clean Air Act, the Environmental Protection Agency (EPA) has long required that pollution from steel plants must be significantly reduced through technological upgrades and enforcement of air quality management standards.

These rules apply across production modes (from conventional coal-based steelmaking to newer, theoretically safer methods such as hydrogen-ready steelmaking) but health advocates argue that implementation often lags behind responsible development.

When equipment failures or large-scale releases occur, hazardous emissions (especially fine particulates and volatile air toxics) can drift miles downwind, exposing residents to elevated pollutant levels even inside their homes.

Over time, repeated exposures are linked to chronic health problems such as asthma, cardiovascular disease, and other respiratory diseases, as supported by public health research.

In short, whether it’s a worker inside the plant or a family living next door, exposure occurs through the air, contaminated soils, dust intrusion, and breakdown of historic protections in practice.

Steel production emits a wide array of harmful substances (depending on the methods used and materials processed) that pose serious risks to both workers and nearby communities.

Coal-based steelmaking (through coke ovens and blast furnaces) releases a particularly hazardous mix of carcinogenic and toxic substances.

Even electric arc furnaces (EAFs), often perceived as cleaner, generate significant metal-laden dust and dioxin emissions if fed contaminated scrap or materials.

These pollutants can remain airborne in fine particulates or settle into soil and waterways, entering breathing zones and damaging environments.

Some contaminants like sulfur dioxide and nitrogen oxides can travel regionally, contributing to acid rain and broader environmental imbalance.

Heavy metals such as lead, arsenic, and cadmium pose risks through inhalation or soil contact, especially where dispersion is poorly controlled.

Many of these substances are regulated due to their negative health effects, yet incomplete coverage and lagging control technologies allow exposures to persist.

Even with air quality management systems in place, gaps in enforcement or malfunctioning controls can cause spikes in pollutant levels.

The result is a compelling case for both occupational safety and broader environmental oversight to mitigate steel industry impacts.

Chemicals and pollutants emitted from steel production include:

• Benzene, PAHs, arsenic, cadmium, phenols: originate from coke oven emissions during coal carbonization; strongly linked to cancer and respiratory harm.
• Sulfur dioxide (SO₂) and nitrogen oxides (NOₓ): released throughout burning and smelting; contribute to acid rain, asthma, and respiratory diseases.
• Carbon monoxide (CO): generated during coke burning and EAF operations; presents immediate health risks and explosion hazards.
• Particulate matter (PM2.5 and PM): emitted from furnaces, coking operations, slag and dust; penetrates deep into lungs, causing cardiovascular and respiratory illnesses.
• Heavy metals (lead, mercury, chromium, manganese, nickel): found in coke oven emissions, EAF dust, and smelting byproducts; associated with neurological, developmental, immune, and carcinogenic effects.
• Dioxins and furans: produced during EAF operations and sintering; persistent environmental toxins that bioaccumulate and raise long-term health concerns.
• Naphthalene, ammonia, cyanide compounds, coke oven gas: discharged through wastewater and off-gassing; severely toxic to aquatic life and humans.

Occupational Exposure Risks

Workers at steel mills face significant occupational exposure risks due to the high-heat environments, heavy machinery, and diverse industrial processes involved in steel production.

Even though asbestos is no longer a part of the steelmaking process, its historical use for insulation, gaskets, refractory bricks, and protective gear continues to endanger workers through residual contamination and degraded equipment.

Additionally, welders, furnace operators, and maintenance crew are exposed to welding fumes and metal dusts (including chromium, manganese, and nickel) that are known to cause neurological harm and cancers.

Fine particulate matter, silica dust from grinding foundry molds and cores, and combustion byproducts (like PAHs from coke ovens) also pose inhalation risks and contribute to chronic respiratory and cardiovascular diseases.

Elevated exposures have been documented during tasks like repairing blast furnaces, handling slag, cleaning coke ovens, and working in poorly ventilated spaces where toxic gases accumulate.

Vigilance, proper protective equipment, and exposure controls are crucial, but even then, legacy hazards and process-related exposures present unresolved, serious threats to steel mill workers.

Occupational exposure risks include:

• Asbestos fibers from insulation, gaskets, refractory linings, and protective clothing used historically in high-heat areas
• Silica dust generated during the grinding of foundry molds, cores, and refractory materials; linked to silicosis and lung cancer
• Manganese, chromium, nickel fumes produced during welding, cutting, and smelting; associated with neurotoxicity and carcinogenicity
• Metal fume (zinc oxide, cadmium, lead) arising from welding or brazing galvanized or contaminated metals, causing metal fume fever and neurological damage
• PAHs and benzene emitted from coke ovens and high-temperature processing areas, known for carcinogenic risks

Community Exposure Risks

Living near steel mills exposes communities to a mix of chronic pollution and acute industrial incidents that can have lasting health impacts.

Even when operating within regulatory frameworks, these heavy industry sites release hazardous pollutants into the air, water, and soil that state agencies often struggle to fully control.

Research from Northwest Indiana, Pennsylvania (Bethlehem Steel), and other steel towns shows higher rates of asthma, cardiovascular disease, and cancer in populations downwind of mills.

These problems are magnified by socioeconomic disparities, with low-income and minority communities bearing a disproportionate share of the pollution burden.

Despite the protections of the Clean Air Act and other environmental laws, monitoring gaps and weak enforcement mean that exposures persist and, in many cases, must be significantly reduced.

Community exposure risks include:

• Air pollution: Elevated levels of sulfur dioxide, nitrogen oxides, PM2.5, and carbon monoxide from coal-based steelmaking linked to asthma, heart disease, and higher cancer rates (Indiana’s industrial corridor shows a 12% higher cancer rate).
• Emergency incidents: Explosions and fires, such as the Clairton Coke Works event in Pennsylvania, can spike community exposure to volatile organics, particulates, and sulfur gases in a matter of hours.
• Soil and water contamination: Settling particulates and runoff can introduce heavy metals and chemical residues into soil and groundwater, creating long-term exposure risks.
• Disproportionate impacts: Polluted air and degraded indoor air quality disproportionately affect low-income and minority neighborhoods located closest to steel and coke plants.
• Climate change factors: Changing weather patterns can alter dispersion of pollutants and worsen the effects of emissions, adding layers of risk to nearby residents.

These overlapping exposures create a public health crisis for many steel communities, raising urgent questions of accountability, corporate responsibility, and the adequacy of existing protections.

There is a growing body of evidence, from scientific studies, public health reports, and facility-level assessments, that steel production has measurable adverse effects on both worker and community health.

A recent report by Industrious Labs estimates that coal-based steel and coke operations across states like Indiana, Ohio, and Pennsylvania contribute to up to 892 premature deaths and $13.2 billion annually in healthcare costs and lost productivity

At Cleveland-Cliffs’ Middletown Works steel mill, emissions have been shown to significantly degrade regional air quality, prompting investments in “hydrogen-ready” and “green hydrogen” steelmaking technologies aimed at reducing reliance on coal.

Occupational health studies of steelworkers worldwide confirm elevated injury rates: more than half of workers in some pooled international cohorts reported work-related injuries, especially during shift work and without adequate PPE.

Reports emphasize the need for risk assessments and stronger controls to protect worker well-being, even as advancements in safety culture and hazard mitigation reduce injury rates industry-wide.

These comprehensive studies consistently show that exposure to steel industry pollutants and hazards is linked to serious chronic health outcomes, reinforcing the importance of responsible development and significant emission reductions.

Types of Cancer Linked to Steel Manufacturing Exposure

Occupational and environmental cancer risks associated with the steel industry are well-documented and supported by multiple scientific studies.

Foundry and steel mill workers (particularly those employed near coke ovens, blast furnaces, and in pouring areas) have shown significantly elevated lung cancer rates compared to general populations, even after adjusting for smoking histories.

A specific study assessing polycyclic aromatic hydrocarbons (PAHs) in electric arc furnace settings found that both inhalation and skin exposure could result in “excessive lung and skin cancer risks” for workers.

Welding fumes, especially from stainless or mild steel, contain carcinogenic metals such as nickel and chromium and have been shown in animal studies to promote lung tumors, reinforcing concerns about welding as a carcinogenic exposure route.

Long-term employment in foundry or welding roles has been specifically associated with increased lung cancer mortality among heavy smokers, highlighting occupational synergy with other risk factors.

Although comprehensive evaluation of other cancers is less robust, historical asbestos use in steel mills continues to contribute to mesothelioma and lung cancer risk among legacy workers.

Cancers associated with steel industry exposure may include:

• Lung Cancer – Significantly elevated rates among long-term steelworkers, especially in foundry and pouring roles, even after smoking adjustment.
• Skin Cancer – Linked to dermal exposure to PAHs in electric arc furnace environments.
• Mesothelioma and Asbestos-Related Lung Cancer – Resulting from past asbestos use in insulation, equipment, and protective gear.
• Respiratory Cancers (general) – Increased risk from combined exposure to carcinogens such as chromium, nickel, and steel particulate matter.
• Potential Additional Risks – Ongoing review suggests exposure to metals like arsenic, cadmium, and nickel may elevate risks for bladder, lung, and other cancers within steel and metalworking environments

Non-Cancer Health Impacts of Steel Plants

Health consequences associated with steel plant emissions extend far beyond cancer, affecting respiratory, cardiovascular, and overall well-being in both workers and nearby residents.

Epidemiological research has shown acute declines in lung function among people living near steel plants (even after short exposures) demonstrating how harmful pollutants can have immediate physiological effects.

One crossover study in Canada reported statistically significant changes in heart rate variability, suggesting that ambient particulate pollution near steel facilities disrupts cardiovascular regulation.

After the 2018 fire at the Clairton Coke Works, asthma patients in neighboring communities experienced worsened symptoms and increased reliance on inhalers.

A comprehensive U.S. analysis, as we’ve mentioned previously, estimated that coal-based steel and coke plants contribute to approximately 250,500 asthma cases and hundreds of premature deaths annually, imposing $13.2 billion in health costs.

WHO assessments of Italian steel facilities similarly found higher rates of disease and mortality in affected communities.

Documented non-cancer health effects include:

• Respiratory impacts: Reduced lung function, higher rates of chronic bronchitis, and worsening asthma symptoms linked to fine particulate matter and sulfur dioxide.
• Cardiovascular impacts: Disruptions to heart rate variability and higher risks of hypertension and cardiac events associated with exposure to particulate pollution and nitrogen oxides.
• Neurological effects: Cognitive decline and nervous system stress reported in populations near industrial facilities exposed to heavy metals and carbon monoxide.
• Developmental effects: Higher incidence of low birth weight and premature births near coke ovens and coal-based steelmaking plants.

These findings reinforce the urgent need for stricter emission limits, robust preventive measures, and a shift toward cleaner alternatives, especially when compared to the reduced health burden associated with renewable energy production.

The steel industry is one of the most heavily regulated sectors of heavy industry, due to its scale of emissions, energy use, and potential harm to surrounding communities.

Facilities are monitored by multiple agencies, including the Environmental Protection Agency (EPA), state environmental protection departments, and, when workplace exposure is at issue, the Occupational Safety and Health Administration (OSHA).

Regulation has evolved over decades, starting with the Clean Air Act of 1970 and subsequent amendments, which forced steel plants to adopt pollution control technologies and implement strategies for the significant reduction of emissions such as sulfur dioxide, nitrogen oxides, and particulate matter.

The Clean Water Act similarly established standards for wastewater discharges from steel and coke plants, particularly targeting toxic discharges of heavy metals and phenols into rivers and groundwater.

More recently, climate-related initiatives have also begun shaping steel industry oversight, with federal and state programs pushing for the adoption of hydrogen-ready steelmaking and electrification technologies to reduce reliance on coal.

Laws and regulations governing steel mills include:

• Clean Air Act (CAA): Requires industrial facilities to meet national air quality standards and apply best available control technologies.
• Clean Water Act (CWA): Regulates wastewater discharges from steel and coke operations, mandating permits under the National Pollutant Discharge Elimination System (NPDES).
• Resource Conservation and Recovery Act (RCRA): Governs the handling, storage, and disposal of hazardous wastes, including slag, solvents, and oils.
• Comprehensive Environmental Response, Compensation, and Liability Act (CERCLA/Superfund): Addresses historical contamination from abandoned steel and coke sites, funding cleanup of toxic soil and groundwater.
• Emergency Planning and Community Right-to-Know Act (EPCRA): Requires steel companies to report annual toxic chemical releases, providing transparency to local communities.
• OSHA standards: Establish limits for worker exposure to silica dust, asbestos, carbon monoxide, and other industrial toxins.

These laws are enforced by a patchwork of agencies, including the EPA, OSHA, and various state agencies tasked with localized monitoring of air quality and water safety.

The federal government also provides federal funding to support research, development, and deployment of cleaner technologies, particularly through the Department of Energy’s industrial decarbonization programs.

However, enforcement remains inconsistent, with steel companies often negotiating consent decrees or settlements after violations rather than making proactive investments.

Advocates argue that without stronger oversight and consistent funding, communities near steel plants will continue to face high pollution levels and elevated disease burdens.

Ultimately, achieving a sustainable and safer steel industry requires both stricter enforcement of existing laws and expansion of support for responsible development of low-emission processes.

People harmed by toxic exposures from steel mill operations may have grounds to take legal action against the companies responsible.

This includes both individuals who worked in steel plants and those living in surrounding communities who faced exposure to pollutants, contaminated water, or airborne particulates.

Gianaris Trial Lawyers is actively investigating cases in Illinois and Missouri where steel mill activity has been linked to cancer, respiratory illness, and environmental contamination.

Our focus in these states reflects the historic and ongoing concentration of steel production and heavy industry in the Midwest, as well as the impact on public health near our main law offices.

However, if you believe your health or property has been affected by steel-related exposure elsewhere, we would still like to hear your story.

Steel mill lawsuits can involve both chronic exposure (such as years of inhaling dust, gases, and fumes) and acute incidents, including explosions, fires, or sudden releases of toxic substances.

These cases aim to hold steel companies accountable for unsafe operations, failure to follow environmental laws, or neglect of worker and community safety.

By sharing your circumstances with us, we can assess whether your case aligns with existing legal avenues for seeking justice.

You may have a potential claim if you:

• Worked in a steel or coke plant and later developed a serious illness linked to occupational exposures (e.g., lung cancer, mesothelioma, leukemias, or chronic respiratory diseases).
• Lived near a steel mill and experienced long-term exposure to air emissions, water pollution, or soil contamination, followed by serious health effects.
• Were harmed by an acute incident such as a major blast furnace leak, fire, or hazardous release and developed lasting respiratory or neurological conditions.
• Lost a loved one to a diagnosis scientifically associated with steel industry pollutants.

Qualifying does not require a single catastrophic event.

Many claims arise from years of day-to-day exposure supported by employment records, medical evaluations, and environmental data.

Note: If you were a railroad worker servicing steel mills, your cancer claim may fall under the Federal Employers’ Liability Act (FELA). Our firm can review potential FELA claims in conjunction with third-party liability cases.

Steel mills remain central to American industry, but the toxic exposures they create have left lasting harm on both workers and surrounding communities.

From the inhalation of dangerous fumes inside the plants to the contamination of air, water, and soil beyond their gates, the consequences are severe and too often ignored.

Families coping with cancer, respiratory illness, and environmental damage deserve accountability and justice.

At Gianaris Trial Lawyers, we investigate these cases with precision and dedication.

Our work is focused primarily in Illinois and Missouri, where steel production and heavy industry continue to shape public health, but we are committed to hearing stories from anyone affected nationwide.

If you or a loved one has suffered illness or loss linked to steel mill exposure, contact us today for a free consultation.

You can also use the chat feature on this page to connect directly with our firm.

Your story matters, and our team is here to stand with you in seeking justice.