Caught In or Between Hazards: Safety and Prevention

Key Takeaways

• Caught between hazards are one of the leading causes of injuries on construction sites.
• Proper machine guarding and the use of Lockout/Tagout procedures are essential for preventing workers from being caught, squeezed, or crushed by machinery or equipment.
• Trenching and excavation hazards present a significant risk for workers, with cave-ins and collapsing materials being common causes of caught between injuries.
• Employers and workers must work together to follow occupational safety protocols, including regular training and the use of safety equipment to prevent accidents on construction sites.
• Awareness of the dangers associated with moving and stationary objects and maintaining clear communication can reduce the risk of accidents, helping to prevent injuries and fatalities in the workplace.

What Are Caught In or Between Hazards?

Caught in or between hazards occur when a worker is caught, crushed, or pinched between two or more objects. This type of hazard often results in serious injuries or even fatalities. These typically involve workers getting caught between heavy equipment, machinery parts, or collapsing structures.

These incidents are classified as part of OSHA's "Focus Four Hazards" due to their severe nature in construction and industrial environments.

Caught In vs. Caught Between Incidents

Though often grouped together, there is a subtle distinction between caught in and caught between incidents. Caught-in incidents occur when a worker is pulled into or stuck within moving machinery or equipment, such as being entangled in conveyor belts, gears, or rotating parts.

On the other hand, caught between accidents happens when a worker is crushed or squeezed between two heavy objects, such as walls, equipment, or vehicles. For example, getting pinned between a truck and a loading dock would be a caught-between hazard.

Dangers of Caught In Between Hazards

The risks associated with caught in between hazards are some of the most severe in industrial and construction settings. Here are the key dangers posed by these hazards:

• Crushing Injuries: Workers can suffer severe crushing injuries from being pinned between heavy machinery, vehicles, or structures, leading to broken bones, internal organ damage, or spinal cord injuries.
• Amputations: Contact with moving machinery or equipment with exposed parts can result in amputations of fingers, hands, arms, or legs, especially in industrial settings.
• Suffocation or Asphyxiation: Workers trapped in confined spaces or trenches are at risk of suffocation, as they may be unable to escape or breathe under the weight of collapsing materials.
• Fractures and Dislocations: Being caught in between objects often leads to broken bones or dislocated joints, requiring lengthy recovery times.
• Internal Injuries: The force from being caught between heavy objects can cause internal injuries, such as organ damage or internal bleeding, which may not be immediately visible.
• Death: Caught in between hazards are one of the top causes of workplace fatalities due to the overwhelming pressure and speed involved in incidents.
• Psychological Impact: Surviving a caught in between incident can cause lasting psychological trauma, including anxiety, PTSD, or fear of returning to similar work environments.

Caught In Between Hazards in Various Settings

Caught in between hazards can occur in a wide range of workplace settings, often linked to specific tasks or equipment. Understanding how these hazards present themselves in different environments is crucial to implementing effective safety measures.

Power Tools and Machinery

In environments where power tools and machinery are used, workers are at significant risk of being caught in moving parts. This includes exposure to rotating equipment, gears, belts, and presses. Improper machine safety practices or lack of protective equipment can lead to workers becoming entangled or pulled into the machinery, resulting in serious injuries like amputations or crushing.

Heavy Equipment

Workers operating or working near heavy equipment such as forklifts, cranes, or bulldozers are vulnerable to being caught between the equipment and other objects. Incidents can occur during vehicle operation, maintenance, or when workers are in the vehicle's blind spots. Heavy machinery can pin workers against walls or crush them under its weight if proper safety protocols aren't followed.

Trenching and Excavation

Caught in between hazards are particularly dangerous in trenching and excavation work, where the risk of cave-ins or trench collapses can bury workers. Soil or debris falling into the trench can trap and suffocate workers, making trench safety practices and shoring systems critical to avoid fatal accidents.

Materials Handling

In materials handling tasks, such as loading and unloading, workers are at risk of getting caught between heavy loads and structures or vehicles. Miscommunication, improper stacking, or inadequate training on safe material handling procedures can result in workers being crushed between materials or pinned by moving loads.

Logistics and Warehousing

Caught in between hazards are also common in logistics and warehousing environments, where workers handle pallets, packages, and operate forklifts. Accidents can occur when items fall from shelves, forklifts crush workers against racks, or employees become trapped between moving vehicles and stationary objects in the warehouse.

Safety and Prevention Strategies Against Caught In Between Hazards

Preventing caught in between hazards requires a combination of safety tools, equipment, and strict adherence to workplace safety protocols. Both employers and employees must work together to identify risks, enforce proper procedures, and use the right safety equipment to minimize accidents.

Safety Tools and Equipment Against Crush Injury

Several safety tools and equipment can help protect workers from crush injuries caused by caught in between hazards. These include:

• Machine Guards: Installing proper machine guards on machinery prevents workers from coming into direct contact with moving parts like gears, belts, and blades.
• Lockout/Tagout (LOTO) Devices: These LOTO devices ensure that machinery remains completely powered off during maintenance, preventing unexpected start-up while a worker is still inside or near the equipment.
• Personal Protective Equipment (PPE): Workers should wear appropriate PPE, such as gloves, steel-toed boots, and high-visibility clothing, to reduce the risk of injury when working around machinery and heavy equipment.
• Proximity Sensors: In some workplaces, heavy machinery and vehicles are equipped with proximity sensors that detect workers nearby and automatically stop or slow the machine to avoid accidents.
• Guardrails and Barriers: In construction sites or areas with moving vehicles, installing guardrails and barriers can help keep workers out of high-risk zones and protect them from being caught between equipment and structures.

Preventive and Control Measures for Caught In Between Accidents

Similarly, preventing caught in between hazards requires a proactive approach that includes regular risk assessments, proper training, and the implementation of control measures. Here are key preventive strategies that can help minimize exposure and risks of caught in or between hazards.

• Comprehensive Training: All workers should receive regular training on recognizing caught in between hazards, safe operating procedures for equipment, and the proper use of safety tools. This training should also cover emergency procedures in the event of an accident.
• Hazard Identification and Risk Assessments: Employers must conduct frequent assessments of the workplace to identify potential caught in between hazards, such as unguarded machinery, poorly maintained equipment, or areas with heavy traffic.
• Safe Work Zones: Establishing designated work zones that keep workers away from high-risk areas, especially around heavy machinery and vehicles, can greatly reduce the chances of caught in between incidents.
• Scheduled Maintenance: Regular maintenance and inspection of machinery and equipment help prevent unexpected failures or malfunctions that could result in workers being caught or trapped.
• Proper Communication: Workers and machine operators must maintain clear communication, particularly when operating heavy equipment. Using hand signals, radios, or other communication devices can prevent accidents caused by miscommunication.

Employers also have a legal responsibility to ensure safe working environments. In the event of such an incident, employers must act swiftly by implementing emergency protocols that provide immediate medical assistance and care to injured workers.

They are also required to conduct a thorough investigation to identify the cause of the incident, document the findings, and make any necessary improvements to safety procedures or equipment maintenance to prevent similar accidents from occurring in the future.

In addition to handling the immediate aftermath, employers are obligated to report serious caught in between incidents to OSHA or relevant safety authorities to remain compliant with safety regulations. Ensuring ongoing compliance also includes offering continuous safety training and regular safety meetings to keep workers up to date on the latest safety standards and practices. 

First Aid and Emergency Response in Caught In Between Accidents

In a caught in between accident, a fast and coordinated response is critical to minimizing the damage and providing life-saving care. Here is a comprehensive guide on first aid and appropriate emergency response in case of a caught in or between accident.

1. Assess the Situation: Ensure the area is safe to approach. Do not attempt to assist the worker if the machinery or equipment is still operational, or if other hazards are present. Always prioritize your safety and the safety of others nearby.
2. Shut Down Machinery or Equipment: If the accident involves machinery, immediately turn it off and use Lockout/Tagout (LOTO) procedures to ensure it cannot be restarted while assisting the injured worker. For non-machinery-related incidents, ensure that any sources of danger, such as heavy objects or collapsing structures, are stabilized.
3. Call Emergency Services: As soon as the situation is under control, contact emergency medical services (EMS). Provide them with detailed information, including the nature of the injury, the worker’s condition, and the location of the incident to ensure a quick and prepared response.
4. Safely Free the Worker: If safe to do so, carefully remove the worker from the caught in between hazard. Ensure that additional injury does not occur during this process, particularly if the worker is trapped by heavy objects or machinery. In certain cases, waiting for trained emergency personnel to assist in freeing the worker may be necessary.
5. Administer First Aid:

• For Crushing Injuries: Immobilize the injured area and apply pressure to control any external bleeding. Elevate the injured limb if possible to reduce swelling.
• For Amputations: Control bleeding by applying pressure to the wound and, if necessary, use a tourniquet as a last resort to prevent excessive blood loss.
• For Unresponsive Workers: If the worker is unresponsive or not breathing, perform CPR immediately until emergency services arrive.

6. Monitor the Worker’s Condition: Continue to monitor the injured worker for signs of shock, such as pale skin, coldness, or shallow breathing. Keep the worker warm and reassure them until professional medical help arrives.
7. Follow-Up Action: Once the worker is safely in the hands of medical professionals, ensure that the accident site is secured, and begin an internal review of the incident. This includes documenting the event, notifying relevant authorities, and ensuring all safety protocols are evaluated and updated.

Caught between hazards are a serious risk in the construction industry, particularly on a construction site where workers are frequently exposed to moving and stationary objects, heavy machinery, and trenching and excavation hazards. Whether being squeezed, caught, crushed, or pinched, these accidents can lead to severe caught between injuries or even fatalities. Implementing effective occupational safety measures, including proper training and the use of protective equipment, is crucial to preventing these incidents and ensuring worker safety.

FAQs

What are three causes of caught in and caught between fatalities?

Three common causes of caught in and caught between fatalities include improper machine guarding, failure to follow lockout/tagout procedures, and collapsing structures or materials. These incidents often occur when workers are exposed to moving machinery parts, heavy equipment, or trench collapses without adequate protection.

What objects can contribute to caught in or caught-between incidents?

Objects that contribute to caught in or caught between incidents include heavy machinery, such as forklifts and cranes, construction materials like steel beams or concrete slabs, and moving parts of equipment like conveyor belts, gears, and rotating shafts. These objects can trap, pinch, or crush workers, leading to serious injuries.

Who is responsible for keeping you safe from caught-in and -between hazards?

Both employers and workers share the responsibility for safety. Employers must ensure a safe working environment by providing proper training, safety equipment, and following OSHA regulations. Workers are responsible for adhering to safety protocols, using protective equipment, and reporting any hazards.

When would working with machinery be a common type of caught-in and caught-between hazard?

Working with machinery becomes a common caught-in and caught-between hazard when workers are exposed to unguarded moving parts, perform maintenance without lockout/tagout, or operate equipment in tight spaces. These situations increase the risk of being pulled into or trapped by machinery.