I Vomited Blue Bile After Painting Rivian’s R1T, I Asked For a Respirator But the Supervisor Denied My Request

Is Rivian in trouble?

Recent reports paint a concerning picture of the safety at Rivian Automotive Inc. The EV automaker's factory in Normal, Illinois, has accumulated more U.S. safety violations deemed 'serious' than any other automaker since the start of last year, according to a report from Automotive News (by subscription). 

Are Rivian's cost-cutting measures to blame? Automotive News says, "Rivian said it changed parts throughout the R1 platform and made new deals with suppliers to cut costs." 

The injuries are far from normal. 

There are incidents alleged by workers at the plant in Normal, Ill., that haven't made it into government reports, according to Bloomberg News. One former employee interviewed by Bloomberg said she complained to doctors last year of vomiting bile with a "Rivian Blue" hue after painting R1T pickup trucks its new Storm Blue color without a respirator.

According to the report, Rivian, a California electric vehicle automaker, received initial citations for 16 serious violations in the past 21 months from the U.S. Occupational Safety and Health Administration.

In contrast, Toyota, Honda, Volvo, Nissan, General Motors, and Ford received no more than ten violations in the past 21 months. While Volkswagen Group, BMW AG, and Subaru Corp. saw none.

Addison's story.

Automotive News says Addison Zwanzig, 20, joined Rivian in July 2023, thrilled at the opportunity to get into high-tech manufacturing and earn enough money to move out of the family home and into her own space. At Rivian, she was assigned to the paint room for about $23 an hour plus benefits, spraying the vehicles eight hours a day, six days a week.

Addison says her protection consisted of a polyester suit, rubber gloves, and plastic goggles. Within weeks, she complained of dizziness to a line leader. Soon, she was also experiencing nausea, vomiting, and diarrhea that led to weight loss and frequently having to leave her workstation to go to the bathroom.

Addison suspected that paint fumes were to blame for her symptoms and asked a supervisor for a respirator after she saw coworkers wearing them. Her request was denied, she said.

"They said that that (wearing a respirator) was uncomfortable and hot and that I'd prefer an N95 mask," she said in an interview.

CDBS, a mask supplier, says, "N95-rated masks can filter 95% of non-oil-based airborne particles. These include allergens, wood-shop dust, and airborne diseases. But they are NOT designed to filter or stop toxic substances from oil-based paint fumes. Most paint fumes are oil-based, so an N95 mask won't protect you from inhaling them."

The AN report goes on to say that by September, she'd seen doctors about her symptoms, including what she said was blue-tinged vomit. She said Rivian provided a respirator for her the next month and then for other coworkers who weren't previously issued one.

Addison filed a complaint to OSHA about the lack of a respirator and other issues. Still, it was dismissed after the company said in a rebuttal that it "found the allegations to be factually and legally incorrect," according to documents seen by Bloomberg.

AN says, "She is continuing to seek treatment from specialists and has consulted attorneys about whether she might have a legal case to seek compensation from Rivian." 

What does Rivian say?

Rivian declined to comment on specific workers' experiences, citing privacy requirements. "We provide all necessary safety equipment, including respirators," the company said in an email. However, in its own reports to the Labor Department, Rivian has recorded significant injuries to its workers. 

It's not only the paint department. 

In February 2023, an employee working at the paint shop's entrance suffered a lower back laceration that required hospitalization and surgery. Two months later, an employee working on an electric delivery van suffered a finger amputation when struck by a control handle. The next month, a worker's skull was fractured when they hit their head and fell.

UAW President Shawn Fain, in a statement, said, "Rivian sells itself as a cutting-edge car company, but they're dragging workers back to the 19th century."

He pointed out that many violations of safety law may go undetected by OSHA due to the agency's limited resources. 

Renee Leonard, 41, who has worked for Rivian since June 2022 on its van line and has been active in the union organizing effort, said in an interview,

"No one ever listens to your concerns. You have no idea what a policy is from day to day or from manager to manager."

More safety issues at Rivian

AN says forklifts were involved in several safety issues. In September 2023, Rivian's reports to OSHA show one worker driving a forklift suffered foot fractures from contact with a structure, while another experienced "traumatic injuries" when a forklift hit a tugger. 

Employees are aware of the hazards.

Jeff Schaefer, a 57-year-old factory worker who has been active in the union effort, shared his experience, saying, "You just gotta really keep your head on a swivel for it. They don't want to stop for anything. They're being pushed that they gotta get their times down, you know, from here to there."

OSHA found that pushing empty carts by 'bulldozing' them with forklifts, although unsafe, 'was an accepted practice' in the factory.  In an email, a Rivian spokesperson said that it wasn't an accepted practice and that the company is committed to safety.

Rivian says that in 2024, it instituted further mandatory training for forklift operators, including a requirement that they pass a test and that it "routinely carries out robust forklift inspections" throughout the plant. 

In July, the company received a serious violation for not ensuring forklifts were inspected at least daily, as required by the training program. OSHA said a safety manager told the agency "that daily inspections should have been completed, but was unaware if the Drive Unit Department was performing the inspections."

Addison, who said paint fumes were making her sick, shared medical documents with Bloomberg that showed her complaints to doctors. She was eventually transferred from the spray booth to a role wiping down vehicles at the end of the assembly process. She says she was asked to climb on top of a vehicle while it was still on the production line, known as the skids, to clean more thoroughly.

"That was something that we were told not to do in training," said Addison, who says she wasn't involved in the union efforts when she worked at Rivian, though she was acquainted with some of the organizers. "I'd heard stories about people getting their foot crushed and legs broken."

Addison asked for the request to be put in writing, which she thought would ensure she would qualify for workers' compensation in case of an injury. Instead, she said, a manager backed down and told her she'd be "responsible for the consequences" of poor quality.

Her employment was terminated the next month. According to messages Addison shared with Bloomberg News, the company cited a lack of documentation to justify her absences for illness.

Check out my report here on why Rivian is the 3rd least reliable car brand. 

Do you work at the Rivian plant in Normal, Illinois? If so, click the red Add New Comment link below and tell us about your experiences.

I am Denis Flierl, a Senior Torque News Writer since 2012. I’ve invested over 13 years in the automotive industry in a consulting role, working with every major car brand. I am an experienced Rocky Mountain Automotive Press member. You'll find my expert Subaru analysis here. Follow me on my X SubaruReport, All Subaru, WRXSTI, @DenisFlierl, Facebook, and Instagram.

Photo credit: Rivian