Asbestos Exposure in U.S. Refinery Workers

For decades, oil refinery workers in the United States faced serious occupational hazards due to widespread asbestos use. Refineries process crude oil at extremely high temperatures, leading operators to rely heavily on asbestos for insulation. The material was used in equipment handling boiling petroleum, protective clothing, gaskets, and sealants. As a result, workers were frequently exposed to airborne asbestos fibers and dust, especially during installation, repair, and maintenance activities.

Oil refinery environments combined extreme heat, flammable materials, and asbestos-based insulation, creating long-term health risks for thousands of workers.

Oil Refinery Workers and Asbestos Exposure

The U.S. Environmental Protection Agency identified oil refinery workers as a group at high risk for asbestos exposure. Until the early 1980s, asbestos was extensively used in refineries nationwide. Research published in Toxicology and Industrial Health found that nearly 90 percent of refinery workers experienced asbestos exposure, with approximately half lacking adequate protective measures.

Why Asbestos Was Used in Oil Refineries

Asbestos was favored for its exceptional resistance to heat, making it an effective insulating material for refinery equipment operating under extreme temperatures. It was incorporated into refinery buildings, machinery, and worker protective gear.

Because petroleum is highly flammable, refineries faced constant risks of fires and explosions. Asbestos insulation helped shield machinery, infrastructure, and facilities from heat damage and fire-related hazards.

How Workers Were Exposed to Asbestos

Exposure commonly occurred while operating equipment, maintaining machinery, performing inspections, and managing pump systems. Maintenance and repair work posed the greatest danger, as workers frequently cut, sanded, or handled asbestos-containing materials.

These activities released microscopic asbestos fibers into the air, which workers inhaled or ingested. Because asbestos particles can remain airborne for extended periods, exposure was often unavoidable and accumulated over time.

Materials Containing Asbestos in Refineries

Asbestos was widely used in insulation for boilers, tanks, pipes, furnaces, pumps, reactors, heat exchangers, and other machinery. It was also present in gaskets, sealants, adhesives, roofing, flooring, packing materials, and protective equipment such as gloves, shields, and clothing worn by refinery workers.

High-Risk Job Roles in Oil Refineries

Occupations with the Greatest Exposure

Workers facing the highest levels of asbestos exposure included engineers, electricians, boilermakers, boiler operators, pipefitters, welders, millwrights, mechanical workers, processing unit operators, equipment designers, testing personnel, and maintenance and repair staff.

Health Risks of Asbestos Exposure

Inhaling or ingesting asbestos fibers can cause severe and often fatal diseases that may not appear until decades after exposure. Oil refinery workers have been diagnosed with mesothelioma, asbestosis, lung cancer, and other asbestos-related cancers.

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U.S. Regions with Elevated Asbestos Risk

Certain areas of the United States historically posed higher risks due to aging refinery infrastructure, industrial activity, and extensive asbestos use.

The Gulf Coast

Texas and Louisiana are home to some of the nation's oldest refineries, where asbestos was heavily used. Hurricanes and flooding can disturb aging asbestos materials, increasing exposure during repair and cleanup work.

The Rust Belt

States such as Pennsylvania, Ohio, Indiana, Illinois, and Michigan contain refineries built in the early 20th century. Renovations, shutdowns, and demolitions have exposed workers to asbestos in these aging facilities.

West Coast Refineries

California and Washington have long been major refining centers where asbestos was commonly used. Earthquakes pose an added risk by damaging structures and releasing asbestos fibers into the air.

Mid-Atlantic and Northeast

New Jersey and Pennsylvania have a long history of asbestos use in refinery insulation and fireproofing. Closed and abandoned sites continue to pose hazards during demolition and redevelopment.

Mountain West

Refineries in Wyoming, Montana, and Colorado operate under harsh weather conditions that accelerate the deterioration of asbestos-containing materials, exposing workers during decommissioning and maintenance.

Are Modern Refinery Workers Still at Risk?

The U.S. petroleum refining industry employs more than 170,000 workers across approximately 130 active refineries, most located in Texas. Although asbestos is no longer commonly used in new facilities, older refineries may still contain asbestos insulation.

In some cases, asbestos was illegally buried on refinery sites. Even today, workers in aging facilities may face exposure when deteriorating materials are disturbed, particularly if proper protective equipment is not used.