Preventing Caught-In/Between Accidents on the Job Site

Caught-in or caught-between accidents are among the most dangerous and gruesome incidents on any job site. They are part of a group OSHA calls the "Fatal Four," the four leading causes of death in the construction industry. These accidents happen in an instant, but their consequences—severe injury or death—last a lifetime. Understanding these hazards is the first step toward creating a safer work environment. This article will walk you through what caught-in/between hazards are, where they hide, and most importantly, how to stop them before they happen.

​What Are Caught-In/Between Accidents?

​A caught-in or caught-between accident is exactly what it sounds like: a person is squeezed, caught, crushed, pinched, or compressed between two or more objects. Think of it like a human vise. The force is immense, and the human body is no match for the power of machinery or the weight of collapsing materials.

​These incidents can be categorized into a few main types:

• ​Caught-in: This usually involves a person being pulled into moving machinery or equipment. For example, a worker's loose clothing gets snagged by a rotating shaft, pulling them into the machine.

• ​Caught-between: This happens when a worker is crushed between two objects. Examples include being pinned between a forklift and a wall, caught between a piece of heavy equipment and another vehicle, or crushed under a collapsing structure.

​A common place for these accidents is in trenches. A trench collapse can bury a worker under thousands of pounds of soil in seconds, leaving no time for escape. According to OSHA, one cubic yard of soil can weigh as much as a car (around 3,000 pounds), making survival nearly impossible.

​Common Causes and Hazards to Watch For

​These accidents don't happen randomly. They are almost always the result of an identifiable hazard. Being able to spot these dangers is critical for prevention.

• Moving Machinery and Unguarded Parts: This is a huge one. Any machine with moving parts—gears, belts, rollers, or rotating shafts—is a potential caught-in hazard. If these parts are not properly guarded, a worker can easily get their clothing, hair, or limbs caught.

• Heavy Equipment: Equipment like excavators, cranes, and forklifts pose a significant risk. Workers can be crushed between the swinging superstructure of a crane and a stationary object, pinned by a backing vehicle, or caught under an overturned piece of equipment.

• ​Collapsing Materials: This includes trench cave-ins, the collapse of a scaffold, or being crushed by improperly stacked materials like pipes or lumber that can roll or fall.

• ​Tight Spaces: Working between a piece of equipment and a fixed object, like a wall or stack of materials, leaves no room for error. If the equipment moves unexpectedly, the worker can be instantly crushed.

​Prevention is Key: A Proactive Approach

​Preventing caught-in/between accidents requires a combination of engineering controls, safe work practices, and robust training. It's about creating a culture of safety where everyone looks out for each other.

​1. Machine Guarding is Non-Negotiable

​All moving machine parts must be guarded. Guards are physical barriers that prevent you from coming into contact with dangerous moving parts. Never operate a piece of equipment if the guards have been removed or are damaged. If you are the one servicing the machine, you must follow lockout/tagout (LOTO) procedures. This ensures the machine is de-energized and cannot be started up accidentally while you are working on it. Achieving a zero-energy state is the goal before any maintenance begins.

​2. Trench and Excavation Safety

​Never enter an unprotected trench that is 5 feet or deeper without an adequate protective system in place. These systems include:

• Sloping or Benching: Cutting back the trench wall at an angle inclined away from the excavation.

• Shoring: Installing supports, like hydraulic jacks and timber, to prevent soil movement.

• Shielding: Using trench boxes or other types of supports to protect workers from cave-ins.

​A competent person must inspect trenches daily and after any hazard-increasing event (like a rainstorm) to ensure conditions are safe. Keep soil piles and heavy equipment at least two feet away from the edge of the excavation.

​3. Situational Awareness Around Heavy Equipment

​Always be aware of your surroundings, especially when heavy equipment is in operation.

• Maintain Safe Distances: Keep a safe distance from moving equipment. Make eye contact with the operator before approaching to ensure they see you.

• Stay Out of Swing Radius: Never stand within the swing radius of cranes or excavators. These areas should be clearly marked and barricaded.

• ​Use a Spotter: For vehicles with limited visibility, a spotter can help guide the operator, especially when backing up.

​4. Proper Training and Communication

​Every worker on site should be trained to recognize caught-in/between hazards. This isn't just a one-time thing; it requires ongoing toolbox talks and safety meetings. Clear and constant communication is vital. Use hand signals and radios to stay in contact with equipment operators. Never assume an operator knows where you are.

​5. Personal Protective Equipment (PPE)

​While PPE is the last line of defense, it's still crucial. However, some PPE can create a hazard. Avoid wearing loose clothing, jewelry, or long hair that can get caught in machinery. High-visibility vests are essential to ensure you are seen by equipment operators.

​By identifying hazards, implementing protective systems, and fostering a culture of constant awareness, we can prevent these tragic incidents. Safety isn't just a set of rules; it's a commitment that every single person on the job site must make every single day.