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 direct costs alone top $2.16 billion annually, with indirect costs—like lost productivity and legal expenses—doubling that figure.
But here’s the good news: most of these incidents are preventable. The construction leaders making real progress combine proven safety protocols with modern tools—especially AI-powered video analytics—to catch hazards before they escalate. This guide breaks down the true costs, root causes, and delivers a clear framework for moving from a reactive to a proactive safety model using modern technology.
Why Caught-In/Between Accidents Hit Construction Hard
Caught-In/Between injuries aren’t just numbers on a spreadsheet. Every incident means 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, 2025).
In addition to direct medical costs, companies face:
Project delays from work stoppages or investigations
OSHA penalties, with average fines exceeding $18,000 per incident
Indirect costs from lost productivity and team disruption
The Top 5 Causes of Caught-In/Between Accidents in Construction and How to Stop Them
Understanding why these accidents happen is the foundation of prevention. 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 Falling Objects
The Hazard:
During a busy afternoon, a crew is unloading steel beams using a forklift. One beam, not properly secured, slips from the forks and strikes a worker below, pinning his leg. Incidents like this—where materials fall or shift unexpectedly—are among the top drivers of Caught-In/Between injuries.
Traditional Prevention:
Material stacking guidelines and regular inspections
Use of tag lines and spotters during lifts
Barricades and warning signage below suspended loads
How AI Amplifies Prevention:
AI video analytics can monitor high-risk loading areas in real time. When a vehicle or forklift enters a restricted zone, or if materials block walkways, the system instantly flags the event. This enables 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 finger injury. Fingers are the most commonly injured body part in Caught-In/Between incidents.
Traditional Prevention:
Regular inspection and maintenance of guards on all equipment
Lockout/Tagout (LOTO) procedures for repairs
Supervisor sign-offs before restarting machinery
How AI Amplifies Prevention:
AI video 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 enabling 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—including forklifts and excavators—is involved in a significant share of Caught-In/Between incidents.
Traditional Prevention:
Operator certification and refresher training
Use of spotters and clear hand signals
Designated walkways and “no-go” zones on site
How AI Amplifies Prevention:
AI-enhanced video systems monitor for forklifts or vehicles entering restricted zones, and can instantly flag near-miss events between equipment and personnel. These real-time insights 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 Prevention:
Use of trench boxes and shoring for excavations deeper than 5 feet
Daily inspections by a “competent person”
Enforcement of safe entry/exit and atmospheric testing
How AI Amplifies Prevention:
AI video analytics can detect when unauthorized personnel enter active excavation zones or when work is happening without proper protective systems. These alerts prompt immediate action—closing the gap between policy and practice, and supporting compliance with 29 CFR 1926.650 (Source: OSHA, 2025).
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 Prevention:
PPE checks at site entry points
Toolbox talks emphasizing correct gear for each task
Supervisor spot checks and peer reminders
How AI Amplifies Prevention:
Video analytics can automatically flag instances where workers are missing required PPE. This supports contractor accountability and helps operations teams ensure that every person on site is properly equipped—without relying solely on manual checks.
Integrating a Modern AI Camera System: From NVR to AI Insights in Construction
Upgrading your site’s safety tech doesn’t mean overhauling your entire camera network. Modern AI-enabled camera platforms are built to work with your existing infrastructure—no need for a costly rip-and-replace.
Feature | Traditional NVR System | AI Camera Platform (Cloud NVR) |
|---|---|---|
Camera Compatibility | Requires new/specific models | Works with existing POE/legacy cams |
Storage | On-premise hardware | Secure, cloud-native, scalable |
Maintenance | Frequent, on-site | Minimal, remote updates |
User Access | Limited seats | Unlimited users, unified dashboard |
Incident Review | Manual, slow | AI-powered search & detection |
Actionable Insights | Passive footage | Real-time safety event alerts |
A cloud-based system bridges your on-prem cameras to a secure, cloud-native dashboard. This means you get instant access to real-time 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 act before a near-miss turns into an incident.
Practical Steps for Construction Teams:
Prioritize solutions compatible with current POE cameras and site layouts.
Ensure the platform supports unlimited user access, so safety isn’t siloed.
Integrate real-time analytics with daily toolbox talks and audit routines.
Align upgrades with OSHA compliance goals—especially around equipment safety, LOTO, and excavation protocols.
Transform Your Site Safety—Book a Safety Consultation
Every Caught-In/Between incident is a wake-up call—and an opportunity to get better. By combining robust training, disciplined site management, and AI-driven video analytics, you can drastically cut risks, accelerate investigations, and build a culture of safety your crews trust.
If you’re ready to see how AI-powered video can help your team prevent accidents and strengthen compliance, book a safety consultation with Spot AI’s specialists. Get tailored, actionable guidance for your sites: Book a safety consultation.
Frequently asked questions
What are the main causes of Caught-In/Between accidents on construction sites?
The leading causes are unsecured materials or falling objects, inadequate machine guarding, unsafe operation of heavy equipment, trench/excavation hazards, and missing or improper use of PPE (Source: OSHA Data, 2025).
How can construction teams implement safety technology without disrupting operations?
Modern AI camera 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 Caught-In/Between prevention?
OSHA standards require machine guarding (1910.212), trench protection (1926.650), and strict LOTO procedures (1910.147). Regular audits and documented training are also best practice (Source: OSHA, 2025).
What should construction companies consider before adopting AI camera 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 AI video analytics support incident investigations?
AI-powered video 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 managers?
AI analytics automate hazard detection and reporting, freeing safety managers from manual video reviews. This lets them focus on proactive planning, training, and supporting their crews—rather than reacting to every incident.
About the author
Joshua Foster, IT Specialist, Spot AI
Joshua Foster is an IT Specialist at Spot AI with hands-on experience in deploying, maintaining, and troubleshooting security camera systems for enterprise environments. He is passionate about helping businesses optimize their video surveillance for maximum uptime, safety, and operational insight.
