Every year, thousands of rail workers and community members are impacted by preventable injuries across the U.S. rail network. In 2024 alone, there were 2,253 highway-rail grade crossing collisions, resulting in 263 fatalities and 756 injuries nationwide (Source: Operation Lifesaver). Meanwhile, rail yard workers, track maintenance crews, and contractors face serious risks from falls, equipment strikes, and vehicle incidents—often with life-changing consequences.

Behind these numbers are real people and organizations striving to keep operations running safely, despite challenging conditions. The good news? Most of these top injury types are preventable with a proactive safety approach, clear protocols, and the right technology to help teams spot problems before they become tragedies.

In this guide, we’ll break down the top 5 injuries that occur in rail transportation facilities—and, more importantly, how to prevent them. We’ll show how modern video intelligence solutions, like those offered by Spot AI, can help safety teams stay one step ahead.

The Cost of Safety Negligence in Rail Transportation

Rail transportation safety incidents don’t just impact people—they carry major regulatory and financial consequences. OSHA penalties for serious injuries in rail environments range widely, with a median penalty of $5,839, an average of $8,177, and the maximum penalty on record reaching $39,000. These penalties typically follow incidents that lead to severe injury or death, property damage, or regulatory violations.

Most stem from lapses in basic safety protocols—like lack of machine guarding, poor communication, or failure to secure equipment. Proactive safety systems, regular training, and the use of real-time monitoring technology can keep your team out of these headlines. Prevention is always more effective (and less costly) than dealing with the aftermath.

The Top 5 Preventable Injuries in Rail Transportation: What Every Safety Leader Needs to Know

Let’s look at each injury, the root causes, and how video intelligence supports prevention.

1. Slips, Trips, and Falls

Scenario:
A maintenance worker walks along an icy platform, slips, and falls from a locomotive runway, resulting in serious injury.

Root Causes & Impact:
Falls are the leading cause of injury in rail transportation, accounting for 35% of reported incidents (Source: OSHA Rail Transportation Injury Data Analysis). Slippery surfaces, uneven platforms, inadequate fall protection, and poor lighting all contribute. These injuries often result in fractures or even fatalities, with a quarter of reported falls leading to amputations (Source: OSHA Rail Transportation Injury Data Analysis).

How video intelligence helps:
AI-powered cameras can monitor walkways and platforms for hazards like ice, water, or clutter. They can alert teams in real time when someone enters a high-risk area or when a slip occurs, allowing for rapid response and hazard remediation.

2. Struck-by and Caught-between Incidents

Scenario:
An employee is pinned between a moving railcar and a loading dock during switching operations due to a breakdown in communication.

Root Causes & Impact:
Struck-by and caught-between events make up 37.5% of the most severe injuries—including crushing, amputations, and fatalities (Source: OSHA Rail Transportation Injury Data Analysis). These typically occur during switching, loading, or maintenance when workers are in proximity to moving equipment. Common contributors include poor communication, lack of spotters, and complacency during routine tasks (Source: SOFA Working Group).

How video intelligence helps:
Video analytics can detect when workers are in unsafe zones or too close to moving equipment. Real-time alerts can prompt operators or supervisors to intervene before an incident occurs. Video review also helps teams analyze near-misses and adjust protocols accordingly.

3. Vehicle and Railcar Collisions

Scenario:
A contractor’s truck enters a work zone without proper clearance and collides with a railcar, causing injury and service disruption.

Root Causes & Impact:
Transportation incidents (collisions or run-overs) account for 15% of reported incidents in the sector (Source: OSHA Rail Transportation Injury Data Analysis). These can involve trucks, forklifts, or mobile equipment striking workers or each other. Root causes include poor visibility, inadequate barriers, failure to enforce entry protocols, and speeding (Source: AGC 2025 Work Zone Safety Study).

How video intelligence helps:
AI video can monitor work zone perimeters and automatically alert teams to unauthorized vehicle entry, speeding in restricted areas, or unsafe driving behaviors—helping prevent collisions before they happen.

4. Machine Guarding and Lockout/Tagout Failures

Scenario:
During maintenance, a worker’s glove becomes caught in an unguarded railcar component, resulting in an amputation.

Root Causes & Impact:
Caught-in or compressed-by incidents—often caused by missing machine guards or skipped lockout/tagout (LOTO) steps—account for 17.5% of injuries, with a high rate of serious outcomes (including 25% amputations) (Source: OSHA Rail Transportation Injury Data Analysis). These injuries frequently occur during equipment maintenance or repair, particularly when training or procedures are lacking.

How video intelligence helps:
Video analytics can verify that machine guards are in place and highlight deviations from standard safety procedures. Post-incident, footage allows teams to pinpoint exactly where protocols failed, driving better training and enforcement.

5. Unauthorized Access and Trespassing

Scenario:
A pedestrian shortcuts across tracks in an urban corridor, unaware of an approaching train, resulting in a near-miss or fatality.

Root Causes & Impact:
Trespassing is the leading cause of pedestrian rail casualties, representing 88% of such incidents (Source: Operation Lifesaver). Common factors include inadequate fencing, poor signage, and recreational or shortcutting behaviors—especially in urban areas (Source: Operation Lifesaver Urban Corridor Study).

How video intelligence helps:
AI-enabled cameras can detect unauthorized access to restricted zones, trigger instant alerts, and capture video evidence for law enforcement or community education campaigns. Over time, data can reveal high-risk locations for targeted interventions.

Challenges and Impact of the Injuries

How Technology Strengthens Injury Prevention

Let’s look at how technology, paired with robust safety culture, addresses each top injury:

1. Slips, Trips, and Falls

Safety challenge:
It’s impossible for supervisors to monitor every walkway and platform all the time. Hazards like ice, spills, or debris can be missed.

Tech Solution:
AI-powered video systems can automatically flag when surfaces become slippery, detect if someone has fallen, and alert teams instantly. This empowers rapid response and helps identify patterns for preventive maintenance.

2. Struck-by and Caught-between Incidents

Safety challenge:
Switching operations and maintenance tasks put workers close to moving equipment. Human error or complacency can have catastrophic results.

Tech Solution:
AI cameras monitor work zones and can notify teams if workers enter unsafe areas or if equipment is moving without proper clearance. Reviewing footage of near-misses helps teams refine protocols and training.

3. Vehicle and Railcar Collisions

Safety challenge:
Work zones and yards are busy, with multiple vehicles and people moving at once. It’s easy for someone to miss an unauthorized vehicle or unsafe driving.

Tech Solution:
Video analytics can detect speeding vehicles, unauthorized entry, or unsafe operator behavior in real time—helping to prevent collisions and enforce safe driving protocols.

4. Machine Guarding and Lockout/Tagout Failures

Safety challenge:
Maintaining perfect compliance on guarding and LOTO is tough, especially during busy shifts or under pressure.

Tech Solution:
Video review ensures machine guards are in place and LOTO procedures are followed. When incidents occur, footage offers clear evidence, accelerating investigations and helping teams learn from mistakes.

5. Unauthorized Access and Trespassing

Safety challenge:
Large, open facilities can be hard to secure. Trespassers may enter undetected, especially in busy urban corridors or at night.

Tech Solution:
AI-enabled cameras monitor perimeters and restricted zones 24/7. They can alert teams to breaches instantly, provide evidence for authorities, and help map out where additional fencing or signage is needed.

Practical Implementation of Safety Technology

Rail transportation environments are unique—often large, dynamic, and reliant on both legacy and modern systems. Here’s how to implement safety technology effectively:

• Integrate with Existing Cameras: Modern platforms like Spot AI work with your current camera infrastructure—no need to rip and replace.

• Cloud-Native Dashboards: Centralize incident monitoring and response, making it easy for safety teams to investigate and act fast.

• Unlimited User Seats: Empower more team members to participate in safety reviews and investigations—democratizing safety data.

• Open APIs: Seamlessly connect video insights with your existing safety, incident reporting, and compliance systems.

• Support Human-Led Safety: Technology is not a replacement for strong safety culture, training, and protocols. It’s an extra set of eyes—always on, never distracted.

When evaluating solutions, focus on platforms that provide actionable alerts, comprehensive coverage, and easy integration with your workflows. Choose technologies that empower your frontline teams—not just IT or security.

Ready to Lead on Rail Transportation Safety?

Preventing injuries in rail transportation isn’t just about compliance—it’s about protecting your people, your reputation, and your bottom line. Modern video intelligence can help you spot hazards before they hurt someone, cut investigation time, and avoid costly regulatory penalties.

Want to see how this works in your environment? Get tailored guidance for your rail operations—book a consultation with our team. Together, we’ll make your rail workplace safer, smarter, and more resilient.

Frequently Asked Questions

What are the most common preventable injuries in rail transportation?

The most common preventable injuries are slips, trips, and falls; struck-by and caught-between incidents; vehicle and railcar collisions; machine guarding and lockout/tagout failures; and unauthorized access or trespassing. These injuries are well-documented in OSHA and industry data and can be addressed with strong protocols and technology support.

How can video intelligence help prevent injuries in rail yards and facilities?

Video intelligence platforms, like Spot AI, turn existing cameras into real-time safety tools. They can detect hazards (slippery surfaces, unauthorized entry), monitor compliance (PPE, guarding), and alert teams about unsafe behaviors or near-misses. This helps safety teams act before an incident occurs.

What are the challenges of implementing safety technology in rail environments?

Rail environments are large, complex, and often have a mix of new and old equipment. The best solutions integrate with existing cameras and workflows, offer centralized dashboards, and allow unlimited users to participate in safety reviews. Partner with vendors who understand the unique needs of rail operations.

What best practices should rail organizations follow when deploying safety technology?

• Involve frontline teams in planning and deployment.

• Integrate with current camera infrastructure.

• Use video footage to support, not replace, human-led safety programs.

• Regularly review video insights to identify trends and update training.

• Foster a culture where reporting hazards and using technology is encouraged.

Can video analytics help with trespasser and perimeter security?

Yes. AI-powered cameras can monitor for unauthorized access 24/7, alert security teams in real time, and provide evidence for law enforcement or community outreach—all critical for reducing trespassing incidents.

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.