How to Prevent Caught in or Between Incidents

Caught-in or between hazards represent one of the most dangerous categories of workplace injuries and fatalities, especially in construction, manufacturing, and industrial sectors. Understanding these hazards and implementing robust safety measures is critical for protecting workers and complying with OSHA regulations.

This guide dives deep into what caught-in or between hazards are, their common types, causes, prevention strategies, and essential safety protocols to keep your workplace safe.

What Are Caught-In or Between Hazards?

Caught-in or between hazards occur when a worker is trapped, crushed, squeezed, or caught inside or between objects, equipment, or materials. These incidents typically involve:

• Being caught in machinery or moving parts

• Getting trapped between heavy equipment or structures

• Being crushed by collapsing trenches, walls, or materials

Such hazards are often severe or fatal due to the force and pressure involved.

Why Are Caught-In or Between Hazards So Dangerous?

Caught-in or between incidents often lead to:

• Severe crush injuries

• Broken bones

• Amputations

• Traumatic brain injuries

• Death

According to OSHA, caught-in or between hazards account for approximately 19% of construction-related fatalities. The high risk stems from the immense force that trapped workers endure, often leaving no room for escape.

Common Examples of Caught-In or Between Hazards

1. Trench Collapses
   Workers inside unprotected trenches risk being buried or crushed by soil cave-ins, often resulting in suffocation or crushing injuries.

2. Machinery Entanglement
   Loose clothing, hair, or limbs caught in moving parts of machinery such as conveyors, mixers, or presses.

3. Rolling or Falling Objects
   Being trapped between stacked materials, heavy equipment, or between vehicles and stationary objects.

4. Caught Between Vehicles and Fixed Objects
   Workers are crushed between forklifts, trucks, or cranes and walls, beams, or other immovable objects.

5. Collapse of Structures or Materials
   The collapse of scaffolding, walls, or stored materials can trap or crush workers caught in between.

Read Also: In the Hazardous Chemical Inventory Your Company Must?

Causes and Risk Factors

• Lack of proper machine guarding

• Inadequate trench protection systems

• Failure to follow lockout/tagout procedures

• Improper storage of materials leads to unstable loads

• Poor worksite housekeeping results in clutter and trip hazards

• Insufficient training and supervision

• Working in confined or restricted spaces without proper protocols

Legal and Regulatory Requirements

OSHA classifies caught-in or between hazards of the Fatal Four leading causes of worker deaths in construction. Key regulations include:

• 29 CFR 1926 Subpart P – Excavations and trenches must have protective systems.

• 29 CFR 1910.147 – Control of hazardous energy (lockout/tagout) to prevent machinery startups.

• 29 CFR 1910.212 – Machine guarding requirements to protect employees from moving parts.

Non-compliance can lead to heavy fines, legal liabilities, and loss of reputation.

Effective Prevention Strategies

1. Trench Safety Measures

• Always use trench boxes, shields, or sloping methods to prevent cave-ins.

• Conduct daily inspections by a competent person before work begins.

• Provide safe entry and exit points, such as ladders, within 25 feet of workers.

2. Machine Guarding and Lockout/Tagout

• Install fixed guards and interlocking devices on all moving parts.

• Train workers on the proper use of lockout/tagout procedures during maintenance or repairs.

• Never bypass or remove machine guards.

3. Safe Material Handling and Storage

• Stack materials securely to prevent shifting or collapse.

• Use mechanical means like forklifts and cranes properly with trained operators.

• Keep work areas clean and organized to reduce trip hazards.

4. Vehicle and Equipment Safety

• Establish spotter systems when operating heavy machinery near workers.

• Use barriers and signage to keep workers clear of equipment operating zones.

• Implement traffic control plans on busy sites.

5. Training and Awareness

• Conduct regular safety training specific to caught-in or caught-between hazards.

• Encourage workers to report unsafe conditions immediately.

• Promote a culture of hazard recognition and proactive prevention.

Emergency Response and Rescue Plans

Despite prevention efforts, incidents may still occur. Ensure your workplace has:

• A comprehensive emergency response plan tailored to caught-in or between scenarios.

• Rapid communication systems to alert rescue teams.

• Properly trained rescue personnel are equipped with the necessary tools.

• Post-incident review to identify root causes and prevent recurrence.

Read Also: In Which Workplaces Are Written Hazard Communications Not Required?

Case Study: How Proper Trench Safety Prevented Fatalities

At a mid-sized construction site, a trench collapse was narrowly avoided due to the installation of an OSHA-compliant trench box and daily inspections. Workers were trained to recognize signs of soil instability and immediately evacuated when minor cracks appeared. This proactive approach saved lives and avoided costly shutdowns.

Conclusion

Caught-in or between hazards is among the most severe workplace dangers. Preventing these injuries requires a multi-layered approach combining engineering controls, administrative policies, worker training, and emergency preparedness.

Employers must prioritize hazard recognition, ensure compliance with OSHA standards, and foster a safety-first culture to protect their workforce and business.

Frequently Asked Questions (FAQs)

Q1: What is the difference between caught-in and caught-between hazards?
Caught-in hazards involve entrapment inside machinery or equipment, while caught-between hazards involve being crushed or trapped between two objects.

Q2: How often should trench inspections be conducted?
Trenches must be inspected daily and after any event that could affect soil stability, such as heavy rain or vibrations.

Q3: Can caught-in hazards happen in industries other than construction?
Yes, manufacturing, agriculture, and warehousing also face caught-in or between risks due to machinery and material handling.

Q4: What are the key OSHA standards for caught-in or between hazards?
Main standards include 29 CFR 1926 Subpart P for excavations, 29 CFR 1910.147 for lockout/tagout, and 29 CFR 1910.212 for machine guarding.

Q5: How can workers protect themselves from caught-in hazards?
Workers should follow all safety protocols, wear appropriate PPE, stay alert to their surroundings, and never disable machine guards.