Each year, Caught-In/Between accidents take a steep toll on the construction industry—impacting project timelines, workforce safety, and bottom lines. These are the incidents where workers get pinned, trapped, or crushed between equipment, materials, or collapsing structures. They’re one of OSHA’s “Focus Four” hazards for a reason: the costs are substantial, with indirect expenses like lost productivity and legal fees often doubling the direct financial impact.

But here’s the good news: most of these incidents can be mitigated. The construction leaders making real progress combine proven safety protocols with specialized tools—especially video AI—to catch hazards before they escalate. This guide breaks down the true costs, root causes, and delivers a clear framework for shifting from a reactive to a safety model focused on risk reduction using current technology.

Why caught-in/between accidents hit construction hard

Every Caught-In/Between incident translates to lost workdays, operational headaches, and potential OSHA penalties. New workers are especially at risk—first-year employees make up 44% of construction injuries, often because they don’t have enough safety training or experience to spot hazards (Source: Liberty Mutual).

In addition to direct medical costs, companies face:

• Project delays from work stoppages or investigations

• Substantial OSHA penalties

• Indirect costs from lost productivity and team disruption
  

The top 5 causes of caught-in/between accidents in construction and how to mitigate them

Understanding why these accidents happen is the foundation of risk mitigation. Here are the top five causes, what typically goes wrong, and how you can get ahead of them—combining site discipline with a technology edge.

1. Unsecured Materials and Objects

The Hazard:
During a busy afternoon, a crew is lifting steel beams with a crane. One beam, not properly secured in its rigging, moves and strikes a worker below, pinning his leg. Incidents like this—where materials move or shift unexpectedly—are among the top drivers of Caught-In/Between injuries.

Traditional Mitigation:

1. Material stacking guidelines and regular inspections

2. Use of tag lines and spotters during lifts

3. Barricades and warning signage below suspended loads

How AI Amplifies Safety:
Video AI can continuously monitor high-risk loading areas. When a vehicle or forklift enters a restricted zone, the system swiftly flags the event. This allows supervisors to respond before a hazard leads to injury. Reviewing flagged clips also helps identify recurring risks, so teams can adjust site layouts and storage practices proactively.

2. Inadequate Machine Guarding and Bypassed Safety Controls

The Hazard:
A worker is adjusting a conveyor belt. The safety guard was removed for maintenance and never replaced. His hand gets caught in the moving equipment, leading to a serious injury.

Traditional Mitigation:

1. Regular inspection and maintenance of guards on all equipment

2. Lockout/Tagout (LOTO) procedures for repairs

3. Supervisor sign-offs before restarting machinery

How AI Amplifies Safety:
Video AI can detect when personnel are present in restricted zones around running equipment or if a workstation is left unattended during machine operation. The system surfaces these events for review, supporting LOTO compliance and helping with targeted retraining—so safety protocols are enforced even during busy shifts.

3. Unsafe Operation of Heavy Equipment (Forklifts, Excavators, Loaders)

The Hazard:
A laborer is guiding an excavator into position when the operator loses sight of him. The worker is pinned between the machine and a concrete barrier. Heavy equipment, such as excavators, is involved in a major share of Caught-In/Between incidents.

Traditional Mitigation:

1. Operator certification and refresher training

2. Use of spotters and clear hand signals

3. Designated walkways and “no-go” zones on site

How AI Amplifies Safety:
Video AI systems automatically detect when heavy equipment or vehicles enter restricted zones. These detection events help safety teams intervene and adjust site access rules before a close call becomes a recordable incident.

4. Trench and Excavation Hazards

The Hazard:
A utility crew is working in an 8-foot trench that wasn’t properly shored. The walls collapse, trapping workers inside. Trench collapses remain a leading cause of Caught-In/Between fatalities.

Traditional Mitigation:

1. Use of trench boxes and shoring for excavations deeper than 5 feet

2. Daily inspections by a “competent person”

3. Enforcement of safe entry/exit and atmospheric testing

How AI Amplifies Safety:
Video AI can detect when unauthorized personnel enter active excavation zones. These alerts prompt timely action—closing the gap between policy and practice, and supporting compliance with 29 CFR 1926.650 (Source: OSHA).

5. Missing or Improper Use of Personal Protective Equipment (PPE)

The Hazard:
A new hire starts work on a demolition site without safety gloves or steel-toed boots. While moving debris, his foot becomes trapped under a shifting panel, causing an injury. Missing PPE is a persistent factor in Caught-In/Between incidents.

Traditional Mitigation:

1. PPE checks at site entry points

2. Toolbox talks emphasizing correct gear for each task

3. Supervisor spot checks and peer reminders

How AI Amplifies Safety:
Video analytics can automatically flag instances where workers are missing required PPE. This supports contractor accountability and helps operations teams verify that people on site are properly equipped—without relying solely on manual checks.

Integrating a video AI camera system: From NVR to automated safety analysis

Upgrading your site’s safety tech doesn’t mean overhauling your entire camera network. Video AI platforms are built to work with your existing infrastructure—no need for a costly rip-and-replace.

A cloud-based system bridges your on-prem cameras to a secure, cloud-native dashboard. This means you get seamless access to automated analytics, rapid incident review, and unlimited user access—all without the headaches of maintaining bulky servers.

The difference is the AI analysis layer. Instead of simply recording video, the system actively surfaces critical safety events—like vehicles in no-go zones, missing PPE, or workers lingering in restricted areas—so your team can address risks before they escalate into an incident.

Practical steps for construction teams:

1. Prioritize solutions compatible with current POE cameras and site layouts.

2. Ensure the platform supports unlimited user access, so safety isn’t siloed.

3. Integrate automated analytics with daily toolbox talks and audit routines.

4. Align upgrades with OSHA compliance goals—especially around equipment safety, LOTO, and excavation protocols.

Build a forward-looking safety program with video AI

Every Caught-In/Between incident is a wake-up call—and an opportunity to get better. By combining thorough training, disciplined site management, and video AI, you can significantly reduce risks, accelerate investigations, and build a culture of safety your crews trust.

Want to see how video AI can help your team reduce accidents and support compliance? Request a live demo to experience Spot AI in action.

Frequently asked questions

How can construction teams implement safety technology without disrupting operations?

Video AI platforms integrate directly with existing POE and legacy cameras. They add analytics without interrupting daily work, automating hazard detection and reporting—so your crew stays focused on the job.

What compliance standards apply to mitigating Caught-In/Between incidents?

Key OSHA standards require machine guarding (29 CFR 1910.212), trench protection (29 CFR 1926.650), and strict Lockout/Tagout (LOTO) procedures (29 CFR 1910.147). Regular audits and documented training are also essential for compliance.

What should construction companies consider before adopting video AI systems?

Start by mapping high-risk zones and current camera coverage. Get safety, operations, and IT aligned early. Pilot new systems in a problem area, review results, and then expand based on clear data and site feedback.

How does video AI support incident investigations?

Video AI platforms automatically flag events—like vehicles entering no-go zones or missing PPE—making it faster to review footage, understand root causes, and respond with targeted training.

How can safety technology help reduce stress for safety professionals?

Video AI automates hazard detection and reporting, freeing safety professionals from manual video reviews. This lets them focus on anticipatory planning, training, and supporting their crews—rather than reacting to every incident.

What makes a video AI platform effective for construction safety?

An effective system integrates with your existing cameras and provides automated, real-time alerts for specific hazards like no-go zone entry or missing PPE. It should also offer centralized access for rapid investigation, helping your team shift from passive recording to proactive safety management and coaching.

About the author

Joshua Foster is an IT Systems Engineer at Spot AI, where he focuses on designing and securing scalable enterprise networks, managing cloud-integrated infrastructure, and automating system workflows to enhance operational efficiency. He is passionate about cross-functional collaboration and takes pride in delivering robust technical solutions that empower both the Spot AI team and its customers.