8 Common Machine Shop Injuries and How To Avoid Them

worker and heavy machinery

Machine shop injuries are a significant concern in various settings, including workplaces, construction sites, and even homes. Understanding the risks associated with machinery operation is crucial for both individuals and employers to ensure personal safety and prevent accidents. By being aware of the most common machine-related injuries, we can take proactive measures to minimize these risks and create a safer environment.

In this article, we will explore the top 8 most common industrial injuries, which encompass a range of potential hazards and can vary in severity. By discussing these injuries, we aim to provide valuable insights into their causes, consequences, and most importantly, effective preventive measures.

8 Common Machine Shop Injuries

1. Crushing Injuries

Crushing injuries occur when a person gets caught between two moving parts of a machine or when a heavy object falls on them. This can happen due to various factors, including improper use of machinery, lack of training, or equipment malfunction. Crushing injuries can lead to severe outcomes such as fractures, internal bleeding, or even death. The force exerted by machines can cause extensive damage to bones, tissues, and organs, requiring immediate medical attention.

To prevent crushing injuries, it is crucial to follow proper lockout/tagout procedures, wear appropriate protective gear, and receive thorough training on machinery operation and safety protocols. Employers should ensure that safety guards and devices are in place to prevent access to hazardous areas during machine operation.

2. Lacerations and Amputations

Lacerations and amputations commonly occur when workers come into contact with sharp edges or rotating parts of machines. Machines such as saws, presses, and power tools pose a higher risk of lacerations and amputations if not operated with caution. These injuries can result in severe bleeding, damage to nerves and tendons, and permanent loss of limbs or body parts. Lacerations and amputations often require immediate medical intervention and long-term rehabilitation.

To prevent lacerations and amputations, machines should have appropriate safety guards in place to prevent direct contact with hazardous parts. Proper training on machine operation and safety procedures, including lockout/tagout protocols, should be provided to workers. Regular equipment maintenance and inspections are also crucial to identify any potential hazards.

3. Burns and Electric Shocks

Burns can occur when individuals come into contact with hot surfaces, flames, or when machinery generates heat. Electric shocks, on the other hand, result from faulty electrical equipment or improper handling of electrical components. Burns can range from minor injuries to severe burns that require extensive medical treatment and may cause permanent scarring. Electric shocks can lead to cardiac arrest, nerve damage, or other serious injuries.

To prevent burns and electric shocks, proper maintenance and inspection of machines and electrical systems are vital. Employees should be trained in electrical safety protocols, and electrical equipment should be regularly checked for faults or malfunctions. Personal protective equipment (PPE) such as gloves, protective clothing, and insulation materials should be provided and utilized as necessary.

4. Strains and Sprains

Strains and sprains often occur due to repetitive motions, heavy lifting, pushing, or pulling while operating machinery. Improper posture or ergonomics can also contribute to these injuries. Strains and sprains can cause pain, inflammation, and damage to muscles, tendons, and ligaments. Over time, these injuries can lead to chronic musculoskeletal conditions and significantly affect an individual's ability to perform tasks comfortably.

To prevent strains and sprains, it is essential to incorporate ergonomic practices. This includes maintaining proper posture, using lifting aids or equipment when necessary, taking regular breaks, and implementing workplace design that supports body mechanics. Training employees on proper lifting techniques and promoting overall body awareness can greatly reduce the risk of strains and sprains.

5. Eye Injuries

Eye injuries can occur when working with machines that produce flying debris, sparks, or exposure to hazardous chemicals. Examples include grinding machines, welding equipment, or machines involving the use of high-pressure fluids. Eye injuries can range from minor irritations to severe trauma, including corneal abrasions, chemical burns, or even permanent vision loss. The eyes are highly vulnerable and require special protection.

Using appropriate eye protection, such as safety glasses, goggles, or face shields, is essential when working with machines that pose eye injury risks. Employers should enforce strict safety protocols, including the use of eye protection, regular inspections of machines, and providing emergency eyewash stations in case of exposure to hazardous substances.

6. Hearing Loss

Exposure to loud machinery, power tools, or industrial equipment can lead to noise-induced hearing loss. Prolonged or repeated exposure to high noise levels can cause irreversible damage to the inner ear. Noise-induced hearing loss not only affects the ability to hear but can also impact overall well-being, communication, and productivity. It can lead to social isolation, difficulty in understanding speech, and reduced quality of life.

To prevent hearing loss, it is crucial to implement hearing conservation programs that include noise assessments, engineering controls to reduce noise levels, and the provision of personal hearing protection devices such as earmuffs or earplugs. Employers should also educate workers about the importance of using hearing protection and enforce compliance with noise exposure limits set by regulatory bodies.

7. Respiratory Issues

Certain machines produce airborne contaminants or release toxic fumes that can pose respiratory hazards. These can include dust, chemicals, gases, or particulate matter generated during processes like cutting, welding, or material handling. Prolonged inhalation of hazardous substances can lead to respiratory conditions such as asthma, bronchitis, or occupational lung diseases. These conditions can have long-term health effects and impact an individual's quality of life.

Proper ventilation systems should be in place to minimize the concentration of airborne contaminants. Workers should also wear respiratory protection masks or respirators as recommended based on the type of hazards present. Implementing adequate exhaust systems, conducting regular air quality testing, and providing training on respiratory protection are crucial for preventing respiratory injuries.

8. Repetitive Strain Injuries

Repetitive strain injuries (RSIs) result from repetitive motions or prolonged, forceful movements while operating machines. Examples include typing on keyboards, using vibrating tools, or performing assembly line tasks. RSIs can occur due to various machines and activities, such as using vibrating power tools, operating machinery with repetitive motions, or performing tasks that require prolonged gripping or forceful exertion. Improper ergonomics and lack of breaks or rest periods can contribute to the development of RSIs.

Preventing RSIs involves implementing ergonomic practices such as maintaining proper posture, taking regular breaks, and using ergonomically designed tools and equipment. Employers should provide training on correct body mechanics, encourage stretching exercises, and promote awareness of early signs of RSIs. Rotating job tasks and providing opportunities for job rotation can also help reduce the risk of RSIs.

General Safety Measures to Prevent Machine Shop Injuries

Comprehensive Training and Education: Effective training programs should be in place to ensure that workers are adequately trained on machine operation, safety protocols, and the identification of potential hazards. Ongoing education and refresher courses are crucial to reinforce safe practices. National Commission for the Certification of Crane Operators (NCCCO), International Union of Operating Engineers (IUOE), and National Center for Construction Education and Research (NCCER) are organizations that offer licenses and training for heavy equipment operation.

Regular Maintenance and Inspections: Machines should undergo regular maintenance to identify and address any mechanical issues or malfunctions. Routine inspections help ensure that safety features, such as guards and emergency stop mechanisms, are in proper working condition.

Implementation of Safety Guards and Devices: Installing safety guards and devices, such as machine guarding, emergency stop buttons, or presence sensing systems, can significantly reduce the risk of accidents and injuries. These safeguards create barriers between workers and hazardous machine components.

Promotion of Ergonomic Practices: Employers should prioritize ergonomics by providing ergonomically designed workstations, tools, and equipment. This includes adjustable seating, proper lighting, and tools designed to minimize strain and fatigue.

Enforcement of Personal Protective Equipment (PPE): The use of appropriate personal protective equipment, such as safety glasses, gloves, helmets, or respiratory protection, should be enforced based on the specific hazards associated with each machine or task.

Encouraging Reporting and Communication: Creating a culture of safety involves encouraging workers to report any near misses, potential hazards, or incidents promptly. Establishing effective communication channels allows for timely resolution of safety concerns and the implementation of preventive measures.


1. Are machine shop injuries only common in industrial settings?
No, machine injuries can occur in various settings, including workplaces, construction sites, and even homes. It is important to be aware of the risks associated with machinery operation in all environments.

2. How often should machines undergo maintenance?
Machines should undergo regular inspections and maintenance as recommended by manufacturers to ensure their safe and efficient functioning. Regular maintenance helps identify and address any potential issues before they lead to accidents or injuries.

3. What should I do if I witness a machine-related accident?
If you witness a machine-related accident, immediately report it to the appropriate authorities and provide any necessary assistance while prioritizing your safety. Prompt reporting ensures that proper actions can be taken to address the situation and prevent further harm.

The material provided in this article is for general information purposes only. It is not intended to replace professional/legal advice or substitute government regulations, industry standards, or other requirements specific to any business/activity. While we made sure to provide accurate and reliable information, we make no representation that the details or sources are up-to-date, complete or remain available. Readers should consult with an industrial safety expert, qualified professional, or attorney for any specific concerns and questions.


Shop Tradesafe Products

Author: Herbert Post

Born in the Philadelphia area and raised in Houston by a family who was predominately employed in heavy manufacturing. Herb took a liking to factory processes and later safety compliance where he has spent the last 13 years facilitating best practices and teaching updated regulations. He is married with two children and a St Bernard named Jose. Herb is a self-described compliance geek. When he isn’t studying safety reports and regulatory interpretations he enjoys racquetball and watching his favorite football team, the Dallas Cowboys.