Every year, thousands of workers in highway, street, and bridge construction are injured on the job. In 2023 alone, 898 people lost their lives in work zone incidents—a staggering 50% increase over the last decade (Source: Work Zone Barriers, 2025). For every fatality, there are countless more non-fatal injuries: in 2021, an estimated 42,000 people were hurt in highway work zones (Source: CDC, 2024). Behind these numbers are stories of lives changed, projects delayed, and teams shaken.

The most common and costly injuries—struck-by-vehicle incidents, falls, caught-in/between accidents, electrocutions, and heat-related illnesses—aren’t just tragic. They’re largely preventable. The good news? With the right safety protocols and practical use of technology, these dangers can be dramatically reduced.

That’s where a modern, tech-supported approach comes in. AI-powered video intelligence and real-time monitoring are now giving crews and safety managers new ways to spot risks, enforce protocols, and intervene before someone gets hurt. In this guide, we’ll break down the five most frequent, preventable injuries in highway, street, and bridge construction, explain what causes them, and show how human expertise, paired with smart technology, can keep every worker safer.

The Cost of Safety Negligence in Highway, Street, and Bridge Construction

Safety shortcuts in highway, street, and bridge construction come with a heavy price tag. The average OSHA penalty for serious incidents is $11,203, with the median at $5,839. The largest penalty in the past year reached $140,152—a sobering reminder of what’s at stake. Beyond the numbers are lives lost, families impacted, and organizations’ reputations on the line.

Prevention is always more effective—and less costly—than response. By enforcing proven safety programs and leveraging technology like AI cameras, construction organizations can avoid these tragic incidents, protect their workforce, and steer clear of devastating penalties.

The Top 5 Preventable Injuries in highway, street, and bridge construction

1. Struck-by-Vehicle Incidents

Scenario: A crew is setting up lane closures on a high-traffic highway at dawn. Despite cones, a speeding pickup truck veers into the work zone, striking a flagger.

Root Causes & Impact: Struck-by-vehicle incidents are the deadliest risk in this sector—accounting for 50% of work zone fatalities, double the rate seen in other construction jobs (Source: NIOSH, 2020). In 2025, 60% of highway contractors reported crashes into their work zones, with 13% resulting in worker fatalities (Source: AGC Study, 2025). The main culprits? Driver distraction, high speeds (workers face an 85% fatality risk if hit by a truck at 45 mph), poor visibility, and inadequate barriers (Source: IIHS, 2024).

How video intelligence helps: AI-powered cameras can monitor live traffic flow, detect vehicles breaching barriers, and trigger real-time alerts when vehicles enter work zones. Video review also enables teams to analyze near-misses and improve barrier placement for future projects.

2. Falls from Heights

Scenario: A bridge worker, without a harness, slips on a dewy beam and tumbles 15 feet to the pavement below.

Root Causes & Impact: Falls account for 35% of all construction deaths—often from scaffolds, bridge decks, or equipment platforms (Source: BLS, 2023). Common causes include missing guardrails, improper use of fall arrest systems, and bad weather. Injuries range from fractures and head trauma to fatalities.

How video intelligence helps: AI video systems can automatically detect when workers approach unprotected edges or are not wearing required fall protection. Managers receive instant notifications if someone bypasses safety protocols.

3. Caught-in/Between Incidents

Scenario: A laborer is guiding a steel beam into place when a nearby excavator swings unexpectedly, pinning his leg against a barrier.

Root Causes & Impact: Caught-in/between events include trench collapses, equipment rollovers, and machinery accidents. Inadequate machine guarding, overlooked lockout/tagout, and poor communication are frequent factors. These incidents often lead to amputations, crush injuries, and—too often—fatalities.

How video intelligence helps: AI monitors can track proximity between workers and moving equipment, flag unsafe machine operation, and capture potential violations—helping supervisors intervene faster.

4. Electrocutions

Scenario: A crane operator, working near a power line, accidentally contacts it with a boom. The resulting arc flash injures two workers below.

Root Causes & Impact: Electrocutions frequently involve cranes or other equipment contacting overhead lines, as well as faulty wiring. These incidents are severe, often fatal, and can cause burns, cardiac arrest, or secondary falls.

How video intelligence helps: Video analytics can be trained to identify when equipment comes dangerously close to power lines or when work is happening in unapproved areas. Video review supports root-cause analysis and strengthens future training.

5. Heat-Related Illnesses

Scenario: A paving crew works through a 100-degree afternoon. One worker collapses from heat stroke after missing a scheduled water break.

Root Causes & Impact: Construction accounts for 33% of all U.S. heat-exposure deaths (Source: BLS, 2024). Heat stress is compounded by long hours, heavy PPE, and insufficient hydration protocols. Effects range from dehydration and kidney issues to life-threatening heat stroke.

How video intelligence helps: AI cameras can monitor rest area usage, spot workers showing signs of distress (sitting, slowing, or stopping unexpectedly), and ensure compliance with scheduled breaks and hydration policies.

Challenges and Impact of Injuries

How Technology Strengthens Injury Prevention

Struck-by-Vehicle Incidents

Safety challenge: Traffic control alone isn’t enough: distracted drivers, speeding vehicles, and unpredictable patterns make work zones dangerous for everyone.

Tech Solution: Video analytics platforms like Spot AI provide a live, 360-degree view of work zones. They can send instant alerts if a vehicle enters a restricted area, allowing flaggers or supervisors to take immediate action. Video data also supports after-action reviews, helping teams identify patterns and adjust barrier placement or signage for better protection.

Falls from Heights

Safety challenge: Falls often happen when protocols slip—missing harnesses, skipped tie-offs, or poorly marked edges.

Tech Solution: AI cameras can be set to watch for workers at elevation who aren’t using fall protection. If someone steps onto a beam or scaffold without proper gear, supervisors get a real-time alert. This makes it easy to enforce safety rules and catch oversights before they lead to tragedy.

Caught-in/Between Incidents

Safety challenge: Crews and machines need to work closely, but poor line of sight, noise, and changing layouts increase the risk of pinch points and crush injuries.

Tech Solution: Modern video platforms track the movement of people and equipment. If a worker enters a “no-go” zone near operating machinery, the system notifies operators or safety leads immediately. Over time, analytics show where congestion and risks are highest, guiding workflow improvements.

Electrocutions

Safety challenge: Power lines and energized equipment are an ever-present risk, especially during heavy lifts and utility work.

Tech Solution: Video analytics can be programmed to recognize when cranes or aerial lifts approach overhead hazards. If a machine nears a power line, staff are alerted before contact happens. This empowers crews to stop work and reposition before an incident occurs.

Heat-Related Illnesses

Safety challenge: Even with policies in place, it’s easy for workers to skip breaks or push through in dangerous heat.

Tech Solution: AI video can confirm that rest stations are actually being used and flag when workers show signs of distress or spend too long in direct sun. Reviewing footage also helps safety managers audit compliance with heat protocols—supporting both prevention and continuous improvement.

Practical Implementation of Safety Technology

Integrating video intelligence into highway, street, and bridge construction sites isn’t about replacing people—it’s about empowering them. Modern AI camera systems, like Spot AI, work with most existing infrastructure. They’re easy to deploy and can be tailored to monitor specific hazards: traffic breaches, PPE compliance, machine operation, and more.

For best results:

• Map your risk areas: Identify where struck-by, fall, or equipment hazards are highest.

• Align with current safety programs: Use AI to support (not replace) toolbox talks, audits, and compliance checks.

• Train your team: Make sure everyone knows how to respond to real-time alerts.

• Review and learn: Use historical footage to identify trends and prevent repeat incidents.

When evaluating solutions, look for:

• Compatibility with your current cameras and IT systems

• Customizable alert settings for your site’s unique risks

• Simple search and retrieval for incident investigations

The goal is always the same: make safety the norm, not the exception.

Ready to Make Highway, Street, and Bridge Construction Safer? Partner for Results

Every incident you prevent is a life unchanged, a crew that goes home safe, a project that stays on track. The right technology is a powerful tool—but it’s your commitment to safety that makes the difference. If you’re ready to see how AI-powered video could support your safety goals, book a safety consultation with Spot AI’s experts. We’ll help you assess your risks, explore options, and build a comprehensive plan for safer, smarter operations. Book a consultation.

Frequently Asked Questions

What are the top safety challenges in highway, street, and bridge construction?

The biggest challenges include unpredictable traffic, falls from heights, close-quarters equipment operation, exposure to live utilities, and working in extreme heat. These combine to make highway construction one of the most dangerous jobs in construction (Source: Work Zone Barriers, 2025).

How can AI cameras improve work zone safety?

AI cameras can detect barrier breaches, monitor compliance with PPE and fall protection, track worker proximity to equipment, and send real-time alerts for unsafe behaviors or conditions. They help safety teams respond faster and prevent incidents.

What are the best practices for integrating safety technology on construction sites?

Start by mapping your highest-risk areas, then select technology that supports those needs. Train your staff on responding to alerts, and use video review for ongoing improvement. Integrate AI monitoring with existing safety meetings and audits for a holistic approach.

How do I ensure compliance with OSHA and industry standards using video technology?

Use AI video to document compliance with requirements like fall protection (OSHA 1926.501), work zone traffic controls (OSHA 1926.200–202), and PPE policies. Video records can support training, audits, and incident investigations.

What should I look for in a video intelligence platform for construction safety?

Prioritize ease of integration, customizable alerts, secure data storage, and user-friendly search features. The platform should work with your current camera systems and be simple enough for your team to use daily.

How does technology support human-led safety programs?

AI cameras and analytics don’t replace people—they give safety leaders better data, help enforce rules, and enable faster intervention. Technology empowers crews to stop problems before they escalate.

About the Author

Joshua Foster
‍IT Systems Engineer, Spot AI

‍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.