Every year, thousands of rail workers and community members are impacted by injuries that are avoidable 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 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 tough conditions. The good news? Most of these top injury types can be mitigated with a forward-looking safety approach, clear protocols, and the right technology to help teams spot problems before they become serious incidents.

In this guide, we’ll break down the top 4 injuries that occur in rail transportation facilities—and, more importantly, how to mitigate them. We’ll show how modern video intelligence solutions, like those offered by Spot AI, can help safety teams address risks before they escalate into incidents.

The Cost of Safety Negligence in Rail Transportation

In addition to the human impact, rail transportation safety incidents carry substantial regulatory and financial consequences. Additional costs include direct OSHA penalties for severe violations, operational downtime, legal fees, increased insurance premiums, and reputational damage. These incidents typically follow events 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. Anticipatory safety systems, regular training, and the use of real-time monitoring technology can help reduce the likelihood of these incidents. A forward-looking approach is always more effective (and less costly) than dealing with the aftermath.

The top common injuries in rail transportation and how to mitigate them

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

1. 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 are a major source of severe injuries—including crushing, amputations, and fatalities. 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 and avert an incident. Video review also helps teams analyze incidents and adjust protocols accordingly.

2. 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) are a major source of reported incidents in the sector. 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.

How video intelligence helps:
Video AI can monitor work zone perimeters and automatically alert teams to unauthorized vehicle entry—helping mitigate collision risks.

3. 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—can lead to a high rate of serious outcomes, including amputations. These injuries frequently occur during equipment maintenance or repair, particularly when training or procedures are lacking.

How video intelligence helps:
Video analytics can be used to review compliance with standard safety procedures, such as lockout/tagout. Post-incident, footage allows teams to pinpoint exactly where protocols failed, driving more effective training and enforcement.

4. Unauthorized Access and Trespassing

Scenario:
A pedestrian shortcuts across tracks in an urban corridor, unaware of an approaching train, resulting in an incident 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 timely alerts, and capture video evidence for law enforcement or community education campaigns. Over time, data can reveal high-risk locations for targeted interventions.

Common obstacles and their impact

How technology strengthens injury mitigation

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

1. Struck-by and Caught-between Incidents

Safety obstacle:
Switching operations and maintenance tasks put workers close to moving equipment. Human error or complacency can have severe consequences.

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 incidents helps teams refine protocols and training.

2. Vehicle and Railcar Collisions

Safety hurdle:
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 unauthorized vehicle entry rapidly, helping to mitigate collisions and enforce safe driving protocols.

3. Machine Guarding and Lockout/Tagout Failures

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

Tech Solution: Video review helps confirm that LOTO procedures are followed. When incidents occur, footage offers clear evidence, accelerating investigations and helping teams learn from mistakes.

4. Unauthorized Access and Trespassing

Security barrier:
Large, open facilities are complex 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 without delay to breaches, 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: Capable 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: Directly connect video insights with your existing safety, incident reporting, and compliance systems.

• Support Human-Led Safety: Technology supports—but does not replace—a strong safety culture, training, and protocols. It acts as an extra set of eyes, providing consistent, 24/7 monitoring.

When evaluating solutions, focus on platforms that offer alerts that enable rapid action, broad coverage, and easy integration with your workflows. Choose technologies that support your frontline teams—not just IT or security.

Strengthen your rail safety program

A forward-looking approach to managing injury risks in rail transportation protects your people, reputation, and bottom line while ensuring compliance. Video AI can help you detect unsafe events as they happen, cut investigation time, and avoid costly regulatory penalties.

Curious how video AI can help your rail operations? Request a Spot AI demo to see the platform in action and explore how it supports safety and compliance in real-world environments.

Frequently Asked Questions

What are the most common injuries in rail transportation?

The most common injuries are 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 mitigate injury risks in rail yards and facilities?

Video AI platforms, like Spot AI, turn existing cameras into anticipatory safety tools. They can detect events (unauthorized entry), monitor compliance (PPE, guarding), and alert teams about unsafe behaviors. This helps safety teams address risks before they escalate.

What are the obstacles to 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.

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.

What to look for in a real-time video analytics system for safety?

The most effective systems are those that support, not replace, your safety culture. Look for a platform that integrates with your existing cameras to avoid costly replacements and offers a centralized dashboard for easy, cross-site monitoring. Prioritize solutions that provide real-time, actionable alerts and empower your entire team with unlimited user seats, making safety a shared responsibility.

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.