Caught-In/Between Hazards: Analysis & Controls
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Caught-in or caught-between hazards occur when a worker is squeezed, compressed, crushed, pinched, or trapped between two or more objects, or between parts of an object. These incidents are one of OSHA's "Fatal Four" — the four leading causes of death in the construction industry — and they account for a significant share of workplace fatalities across multiple sectors every year. The mechanism of injury ranges from unguarded rotating machinery pulling a worker in, to a trench wall collapsing and burying a worker, to a worker pinned between a vehicle and a fixed structure.
The Bureau of Labor Statistics reports that contact with objects and equipment — the broader category encompassing caught-in/between events — resulted in 738 fatal work injuries in 2022. Within that total, roughly 50 workers per year die specifically from caught-in or compressed-by incidents. Nonfatal caught-in/between injuries numbered approximately 28,800 in 2022, many involving fractures, amputations, and crush injuries that carry permanent consequences. The construction industry accounts for the largest share of these fatalities, but manufacturing, agriculture, mining, and waste management also see disproportionate rates.
Preventing caught-in/between incidents requires a layered approach: proper machine guarding, trench protective systems, vehicle spotters, lockout/tagout procedures, and worker training on recognizing pinch points and crush zones. A thorough Job Safety Analysis is essential for identifying these hazards before work begins, particularly for tasks involving heavy equipment, rotating machinery, or excavation work where soil conditions can change rapidly.
Disclaimer
This content is provided for general informational and educational purposes only. It is not a substitute for a site-specific Job Safety Analysis conducted by a qualified safety professional familiar with your workplace conditions, equipment, and personnel. OSHA citations, BLS statistics, and hazard controls referenced here may not reflect the most current standards or apply to your specific situation. Always consult current OSHA regulations, manufacturer guidelines, and a competent person before beginning work. Health & Safety Systems LLC assumes no liability for actions taken based on this content.
Incident Statistics
~50
Fatalities (2022)
28,800
Nonfatal Injuries (2022)
Fatal Four
OSHA Focus Four hazard category
Contact with objects and equipment caused 738 fatal work injuries in 2022, with caught-in/between events comprising a significant subset that frequently results in amputations and crush injuries.
Source: Bureau of Labor Statistics, Census of Fatal Occupational Injuries (CFOI) and Survey of Occupational Injuries and Illnesses (SOII), 2022
Document Caught-In/Between Hazards: Analysis & Controls Controls in Your JSA
Use JSABuilder to identify hazards, assign controls, and share safety plans with your team.
Start Free TrialHierarchy of Controls
The hierarchy of controls ranks protective measures from most to least effective. Apply controls from the top of the hierarchy first.
Elimination
Remove the caught-in/between hazard entirely by redesigning the process so workers are never positioned near pinch points, rotating parts, or collapse zones.
- Use trenchless technology (horizontal directional drilling) to eliminate the need for open excavations
- Replace manual feeding of stock into machinery with fully automated feed systems that require no operator proximity
Substitution
Replace high-risk equipment or processes with alternatives that present lower caught-in/between risk.
- Substitute hydraulic bench-top presses for manual arbor presses that require hands near the point of operation
- Use prefabricated trench boxes rated for the soil type instead of relying on sloping alone in unstable ground
Engineering Controls
Install physical safeguards that prevent workers from contacting dangerous moving parts or entering collapse zones.
- Install fixed machine guards, interlocked barrier guards, and point-of-operation guards on all rotating or reciprocating equipment per 29 CFR 1910.212
- Use trench protective systems — shoring, shielding, or sloping/benching to the required angle based on soil classification
- Install proximity sensors and automatic shut-off devices on power presses and conveyor systems
Administrative Controls
Implement procedures, training, and work practices that reduce the likelihood and severity of caught-in/between incidents.
- Enforce lockout/tagout (LOTO) procedures before any maintenance or servicing of equipment with moving parts
- Require a competent person to inspect excavations daily and after every rainstorm per 29 CFR 1926.651(k)
- Establish vehicle spotting procedures and exclusion zones when heavy equipment operates near workers or structures
PPE
Provide personal protective equipment as the last line of defense when engineering and administrative controls cannot fully eliminate the hazard.
- Close-fitting clothing with no loose sleeves, drawstrings, or jewelry near rotating machinery
- Steel-toed or metatarsal-guard boots for crush protection in material handling and excavation work
Applicable OSHA Standards
Federal OSHA standards that address this hazard type, with enforcement data where available.
29 CFR 1910.212 — General Requirements for All Machines
1,644 citations (FY 2024)
Requires machine guarding to protect operators and nearby workers from hazards created by point of operation, ingoing nip points, rotating parts, and flying chips. One of the most frequently cited general industry standards.
29 CFR 1926.650 — Excavations — Scope, Application, and Definitions
216 citations (FY 2024)
Establishes scope for excavation safety in construction, including definitions for competent person, protective systems, and soil classification that form the foundation of Subpart P.
29 CFR 1926.651 — Excavations — Specific Excavation Requirements
604 citations (FY 2024)
Requires underground utility location, safe means of egress within 25 feet of travel, daily inspections by a competent person, and protection from water accumulation and loose rock.
29 CFR 1926.652 — Excavations — Requirements for Protective Systems
782 citations (FY 2024)
Mandates protective systems (sloping, benching, shoring, or shielding) for all excavations 5 feet or deeper, with system design based on soil classification (Type A, B, or C).
29 CFR 1910.147 — Control of Hazardous Energy (Lockout/Tagout)
2,554 citations (FY 2024)
Requires procedures for isolating machines from energy sources during servicing and maintenance to prevent unexpected startup or release of stored energy that could cause caught-in injuries.
Industries Most Affected
Construction
Excavation cave-ins, unguarded equipment on job sites, and workers caught between vehicles and structures make construction the leading industry for caught-in/between fatalities.
Manufacturing
Rotating shafts, gears, rollers, power presses, and conveyor systems create persistent caught-in hazards, particularly during cleaning, adjustment, and maintenance tasks.
Agriculture
Power take-off (PTO) shafts, grain augers, and harvesting equipment cause caught-in fatalities at a rate far above the national average for all industries.
Mining
Continuous miners, conveyor belts, ground collapse, and mobile equipment operating in confined underground spaces create high-frequency caught-in/between exposures.
Waste Management
Compactors, balers, refuse collection vehicles with automated loading mechanisms, and material sorting equipment present significant caught-in/between risks to sanitation and recycling workers.
Required Personal Protective Equipment
Frequently Asked Questions
What is a caught-in/between hazard?
A caught-in/between hazard exists when a worker can be squeezed, caught, crushed, pinched, or compressed between two or more objects, or between parts of a single object. Common scenarios include being pulled into unguarded rotating machinery, buried by a collapsing trench wall, or pinned between a reversing vehicle and a fixed object like a wall or column.
Why is caught-in/between one of OSHA's Fatal Four?
OSHA identifies falls, struck-by, electrocution, and caught-in/between as the four leading causes of construction worker fatalities, collectively called the Fatal Four or Focus Four. Caught-in/between incidents consistently account for a share of construction fatalities each year, and the injuries tend to be severe — often involving amputations, crush syndrome, or internal organ damage — making prevention a high priority in OSHA enforcement and training programs.
At what depth does OSHA require excavation protective systems?
Under 29 CFR 1926.652, protective systems such as sloping, benching, shoring, or shielding are required for all excavations 5 feet (1.5 meters) or deeper, unless the excavation is made entirely in stable rock. A competent person may determine that protective systems are not needed for trenches less than 5 feet deep if examination of the ground indicates no potential for cave-in.
What is the most common cause of caught-in/between fatalities?
Trench and excavation cave-ins are the most publicized cause, but unguarded machinery — particularly in manufacturing and agriculture — accounts for a large share of caught-in/between deaths and a majority of the nonfatal injuries. Power take-off shafts, conveyor rollers, and power presses are among the most frequently involved equipment types in nonfatal caught-in incidents.
How does lockout/tagout prevent caught-in/between injuries?
Lockout/tagout (LOTO) procedures under 29 CFR 1910.147 require workers to isolate equipment from all energy sources and apply locks and tags before performing maintenance, cleaning, or servicing. This prevents unexpected machine startup or the release of stored energy (hydraulic, pneumatic, spring, or gravitational) that could cause rotating parts to move, presses to cycle, or conveyors to activate while a worker is in the danger zone.
What should a JSA include for tasks with caught-in/between hazards?
The JSA should identify every step where a worker could contact moving parts, be positioned between mobile equipment and a fixed structure, or enter an excavation. For each step, list the specific caught-in/between mechanism (rotating shaft, closing press, collapsing soil), the control measures in place (guarding, LOTO, trench box), and the responsible person for verifying those controls before work begins. Include emergency procedures for entrapment and rescue.