Pipeline transportation is the backbone of our energy infrastructure—but it’s also one of the riskiest workplaces in America. The nonfatal injury rate in this sector is 4.2 per 100 full-time workers, a staggering 30% higher than the all-industry average (Source: BLS Employment Situation News Release, June 2025). The stakes are high: severe incidents like excavation damage, equipment strikes, and heat illness don’t just send workers to the hospital—they can cost millions, trigger regulatory penalties, and even result in fatalities.

What’s behind these numbers? The same handful of injuries keep cropping up, often for the same reasons: missed signals, rushed procedures, and gaps in real-time oversight. But in 2025, we’re no longer limited to just manual checks and after-the-fact reviews. Modern video intelligence platforms now give safety teams eyes everywhere—helping spot risks, enforce protocols, and intervene before anyone gets hurt.

In this guide, we’ll break down the top 5 injuries that can occur in pipeline transportation and, most importantly, how to prevent them. We’ll show how combining strong safety programs with the right technology—like video analytics—can turn your cameras into a frontline defense for your crews, your compliance record, and your bottom line.

The Cost of Safety Negligence in Pipeline Transportation

It’s not just about avoiding injury—it’s about avoiding major financial and reputational fallout. OSHA and PHMSA penalties for pipeline transportation safety violations are steep, with maximum fines reaching $85,000 and an average penalty of $9,229 per incident. The median penalty sits at $5,839. A proactive safety system—one that combines strong protocols with real-time monitoring—can stop most of these incidents before they escalate.

The Top 5 Preventable Injuries in Pipeline Transportation: What Every Operator Needs to Know

1. Struck-By and Caught-In/Between Equipment

Scenario:
A crew is performing maintenance on a pipeline valve. One worker steps away to grab a tool, not realizing a crane is repositioning overhead. Suddenly, a shifting load strikes his hand, causing a severe crush injury.

Root Causes & Impact:
Incidents where workers are struck by or caught in equipment account for 28% of total pipeline injuries (Source: OSHA Pipeline Incident Database, 2024). They often involve moving pipes, cranes, or heavy machinery—especially during maintenance or material handling. Amputations and severe fractures are tragically common: over a quarter of reported injuries in pipeline operations are amputations, mostly fingers or hands (Source: OSHA Workplace Injury Analysis: Pipeline Transportation Industry).

How video intelligence helps:
Video analytics can monitor equipment zones and alert supervisors when workers enter hazardous areas, or if procedures—like lockout/tagout—aren’t followed. Reviewing near-miss footage helps identify patterns and retrain crews. Spot AI, for example, enables rapid incident review and real-time alerts when unsafe proximity is detected between workers and machinery, making prevention practical and enforceable.

2. Falls—Both Same-Level and from Heights

Scenario:
A technician climbs a ladder to inspect a pipe joint. The ground is muddy from overnight rain. A slip sends him tumbling, resulting in multiple fractures.

Root Causes & Impact:
Falls (from the same level or height) are the third most common incident type, responsible for 11 serious injuries in recent OSHA records. Causes include wet or uneven surfaces, improper ladder setup, and cluttered work zones (Source: OSHA Workplace Injury Analysis: Pipeline Transportation Industry). Falls often result in fractures, head injuries, and lengthy hospitalizations—especially when working above ground or on platforms.

How video intelligence helps:
AI-powered cameras can monitor walkways, platforms, and ladder use. They spot clutter, spills, or unsafe behaviors (like workers not using fall protection). Automated alerts allow teams to intervene quickly—before an accident happens. Video review after a fall helps identify root causes, so fixes are targeted and effective.

3. Burns—Thermal and Electrical

Scenario:
During an emergency shutdown, a worker reaches over an energized panel to reset a breaker. An arc flash erupts, causing severe burns to the face and hands.

Root Causes & Impact:
Burns—whether from fire, hot substances, or electrical arc flash—are among the top five injury types in pipeline transportation, accounting for at least 13 incidents (Source: OSHA Workplace Injury Analysis: Pipeline Transportation Industry). These incidents often occur during electrical work, tank cleaning, or when hazardous materials ignite. Many result in hospitalization or, in the worst cases, fatalities.

How video intelligence helps:
Video systems can monitor high-risk work like electrical maintenance or hot work permits, ensuring proper PPE is worn and lockout/tagout steps are followed. In the event of an incident, rapid video review pinpoints procedural gaps. Real-time alerts flag unsafe practices—like entering an energized area without authorization.

4. Heat-Related Illness and Environmental Exposure

Scenario:
A crew working on exposed pipeline segments during midsummer begins to show signs of heat exhaustion. One worker collapses before help arrives.

Root Causes & Impact:
Heat illness and environmental exposures now account for at least 8 serious incidents, with climate change expanding high-heat days by 22% in pipeline regions since 2010 (Source: OSHA Heat Illness Prevention Study, 2025; OSHA Workplace Injury Analysis: Pipeline Transportation Industry). Insufficient acclimatization, lack of hydration, and prolonged sun exposure during maintenance all contribute. The cost? Hospitalizations, lost workdays, and—tragically—fatal heat stroke.

How video intelligence helps:
AI cameras can monitor outdoor crews, flagging when workers show signs of distress (swaying, sitting, or removing gear). They ensure required hydration and rest breaks are being observed, and help supervisors spot risky environmental conditions early.

5. Hazardous Material Exposure

Scenario:
During pipeline cleaning, a vapor cloud escapes from a valve. Workers are slow to recognize the hazard, leading to acute toxic exposure before the area is evacuated.

Root Causes & Impact:
Exposure to hazardous substances—like hydrogen sulfide or chemical vapors—makes up 15% of pipeline-related injuries (Source: NIOSH Pipeline Sector Report, 2023). These events are particularly dangerous during confined space entries or emergency response scenarios. Inconsistent gas monitoring and bypassed safety steps are common factors.

How video intelligence helps:
Video analytics can verify PPE compliance, monitor confined space entries, and detect when unauthorized personnel enter hazardous zones. Reviewing incidents helps teams retrain on hazard recognition and emergency protocols. Real-time alerts can notify supervisors if workers remove respirators or enter restricted areas.

Challenges and Impact of the Injuries

How Technology Strengthens Injury Prevention

Struck-By and Caught-In/Between Equipment

Safety challenge: Heavy machinery, moving pipes, and dense worksites create constant risk of crush injuries—especially where visibility is poor or procedures are rushed.

Tech solution: AI video analytics automatically watch for workers entering danger zones or bypassing safety barriers. Real-time alerts notify supervisors instantly, so they can intervene before an incident. Spot AI’s platform helps safety managers quickly review footage, spot patterns, and adjust training—turning every camera into a proactive safety partner.

Falls—Same-Level and from Heights

Safety challenge: Slippery, uneven ground and improper ladder/platform use make falls a persistent threat, particularly during maintenance and inspections.

Tech solution: Video intelligence monitors walkways, platforms, and access points. It flags clutter, spills, or improper ladder use. Supervisors get alerts if workers skip harnesses or enter restricted areas without protection. After a fall, reviewing footage provides clear, actionable insights for fixing the underlying issue.

Burns—Thermal and Electrical

Safety challenge: Arc flash, hot work, and hazardous substance handling require strict PPE and lockout/tagout compliance—but busy crews may cut corners.

Tech solution: Cameras equipped with AI can verify that all workers in high-risk zones are using appropriate PPE and following lockout/tagout steps. If a worker enters a hazardous area without protection, instant alerts prompt supervisor action. Video review after any incident makes root cause analysis fast and reliable.

Heat-Related Illness and Environmental Exposure

Safety challenge: Long hours outdoors, extreme temperatures, and missed breaks put crews at risk for heat illness—especially as climate change pushes more days into the danger zone.

Tech solution: Video analytics monitor crews for signs of distress and verify rest/hydration breaks. Supervisors can spot risky behavior—like removing gear or skipping shade breaks—and intervene before anyone gets sick. Detailed video records help refine heat illness prevention plans.

Hazardous Material Exposure

Safety challenge: Confined space entries and emergency cleanups are high-risk for toxic exposures—especially if PPE is skipped or gas monitoring is inconsistent.

Tech solution: AI-powered cameras verify PPE compliance and track who enters/exists confined spaces. Real-time alerts warn if workers remove respirators or violate entry protocols. Incident footage streamlines investigations and tailors future training.

Practical Implementation of Safety Technology

Rolling out new safety technology in pipeline transportation isn’t about starting from scratch. The best solutions, like Spot AI’s platform, are designed to work with existing camera systems and integrate with your current safety protocols. Here’s what works:

• Plug-and-play integration: Modern video intelligence can bridge legacy and new cameras, so you maximize past investments.

• Support for unlimited users: Make video insights accessible to everyone on your safety, operations, and compliance teams.

• Open APIs: Seamlessly connect video analytics data with your other safety management systems.

• Compliance first: Look for solutions that help you document adherence to OSHA and PHMSA standards, making incident investigations and audits faster and more transparent.

When evaluating a solution, ask: Will it help me spot the root cause of our top injury risks? Can it provide real-time alerts to prevent incidents, not just record them? And does it make my team’s job easier so we can focus on safety—not on managing technology?

Ready to Build a Safer Pipeline Transportation Operation?

Safety in pipeline transportation is about more than checking boxes—it’s about sending every worker home safe, every day. Today’s video intelligence platforms are more than just cameras—they’re a frontline safety partner that helps you catch hazards before they become tragedies, avoid costly penalties, and build a best-in-class safety culture.

If you want to see how your existing safety program can be strengthened with real-time video insights, book a safety consultation. Our experts will help you assess your risks, design practical solutions, and empower your team to shine. Book a consultation.

Frequently asked questions

What are the most common injuries in pipeline transportation?

The leading injuries include struck-by and caught-in/between incidents (especially involving heavy equipment), falls from the same level or height, burns from thermal or electrical sources, heat-related illness, and hazardous material exposures. Amputations and fractures are unfortunately prevalent, especially during maintenance and material handling (Source: OSHA Workplace Injury Analysis: Pipeline Transportation Industry).

How can video intelligence help prevent injuries on a pipeline site?

Modern video intelligence platforms monitor worksites in real time. They can identify unsafe behaviors, verify PPE compliance, spot near-misses, and alert supervisors to hazards before they lead to injuries. Reviewing incident footage also accelerates root cause analysis and training improvements.

What are key challenges in implementing safety technology for pipeline operations?

Challenges include integrating new tech with legacy camera systems, ensuring data security, and training teams to use video analytics effectively. The best platforms offer plug-and-play hardware, unlimited user seats, and open APIs for seamless integration with existing safety programs.

How does technology support regulatory compliance?

Video intelligence helps document adherence to OSHA and PHMSA requirements, simplifies incident investigations, and provides an auditable record for safety protocols, PPE use, and access control. This can be crucial during audits or after a reportable event.

What’s the best way to start with video safety technology in pipeline transportation?

Start by identifying your top injury risks and reviewing your current camera infrastructure. Then, choose a video intelligence platform that can bridge your existing systems, deliver real-time alerts, and offer user-friendly incident review tools. Consult with safety technology experts to tailor the solution to your specific operational needs. Book a safety consultation to get started.

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.