The top 5 preventable injuries in construction (and how video intelligence helps)
Every construction site is unique, but the leading causes of serious injury are remarkably consistent. Here are the five types of preventable injuries that every safety manager should have on their radar—with actionable tips and the role video intelligence plays in stopping them.1. Falls from Heights
ScenarioA worker steps onto a scaffold on the third floor. There’s no guardrail at the edge—just a piece of caution tape. In the rush to finish before weather moves in, he leans to reach a tool, loses his balance, and falls 15 feet to the ground.
Root Causes & ImpactFalls remain the #1 killer on construction sites, accounting for 39.2% of all industry fatalities in 2023 (Source: U.S. Bureau of Labor Statistics, Porter Law Group). Most falls happen due to unprotected edges, unstable surfaces, and improper ladder or scaffold use. In 2023, 109 fatalities involved ladders alone (Source: Porter Law Group). A shocking 52% of workers admit to bypassing fall protection protocols when supervisors aren’t actively engaged (Source: Associated Builders and Contractors).
These incidents don’t just end lives—they cause severe injuries like fractures and amputations, with 90.71% of reported fall injuries resulting in hospitalization (Source: OSHA Data).
How video intelligence helpsAI-powered cameras can continuously monitor high-risk areas, detecting when guardrails are missing or workers are not wearing harnesses. Real-time alerts prompt supervisors or safety officers to intervene immediately—closing the gap when human attention lapses. Video records also provide evidence for incident investigation and training.
2. Struck-by Incidents (Vehicles, Tools, or Equipment)
ScenarioA laborer crosses a busy work zone, unaware that a forklift is reversing with a pallet of bricks. The operator’s view is blocked. In seconds, the worker is struck, suffering multiple fractures.
Root Causes & ImpactStruck-by incidents accounted for 8% of construction fatalities in 2023, with highway work zones seeing 63% of such deaths from vehicle strikes (Source: CPWR, U.S. Bureau of Labor Statistics). Causes include falling tools from above, moving vehicles, and flying debris. The risks rise dramatically in high-traffic zones with poor visibility and insufficient barricading. Alarmingly, 60% of equipment operators do not check their blind spots before moving (Source: NIOSH).
Injuries often involve multiple body parts and can lead to fractures, amputations, or worse. Each incident disrupts site operations and can have lifelong consequences for the worker.
How video intelligence helpsModern video systems with AI analytics can detect unauthorized personnel in equipment zones, alert operators to blind spot intrusions, and flag non-compliance with high-visibility PPE protocols. These systems also provide footage to retrain teams on safe movement patterns and incident root causes.
3. Electrocutions
ScenarioAn electrician works near an exposed temporary power line. A supervisor walks by but doesn’t notice the missing lockout tag. A crane’s boom, unnoticed by the ground crew, swings into the line. The resulting electrocution is catastrophic.
Root Causes & ImpactElectrocutions made up 8% of construction fatalities in 2023 (Source: U.S. Bureau of Labor Statistics). Most are traced to contact with live wires, faulty equipment, or failure to enforce lockout/tagout (LOTO) procedures. Wet conditions and metal ladders add to the risk.
Electrocution injuries are severe—burns, cardiac trauma, and fatalities are common. Each incident has far-reaching effects, with some resulting in lifelong disability and significant operational disruption.
How video intelligence helpsAI cameras can monitor critical zones for unauthorized entry during electrical work, verify the presence of lockout devices, and detect when workers use unsafe equipment (like metal ladders near power lines). Video records help safety teams spot recurring LOTO non-compliance and address training gaps on the spot.
4. Caught-In/Between (Trenches, Machinery)
ScenarioA crew is laying pipe in a trench. The trench box is 10 feet away—removed to allow equipment access. A supervisor leaves to get more materials. The unstable soil collapses, trapping a worker.
Root Causes & ImpactCaught-in/between incidents caused 5.4% of construction worker fatalities in 2023 (Source: U.S. Bureau of Labor Statistics). They stem from trench collapses, machinery entanglement, and unguarded moving parts. Common causes include missing trench shields, ignored soil stability checks, and tight workspaces.
These incidents are often severe, leading to crushing injuries, amputations, or death. They also account for a significant portion of OSHA citations and are among the most expensive workplace injuries to manage (Source: ElectroIQ).
How video intelligence helpsVideo analytics can monitor trench activity, detect the absence of protective barriers, and alert supervisors when equipment or unauthorized personnel enter “no-go” zones. Continuous visual records also support enforcement of machinery guard protocols and help pinpoint exactly when and how unsafe acts occur.
5. Overexertion and Musculoskeletal Injuries
ScenarioA concrete finisher spends hours bending, lifting, and moving heavy formwork to stay ahead of schedule. Short on staff, he skips his break. Days later, he is sidelined with a severe back injury.
Root Causes & ImpactOverexertion injuries—especially to the back—are common and costly, with over 10,000 reported cases in 2020 alone (Source: ComplianceSigns). Factors include repetitive heavy lifting, poor posture, and skipped breaks. Work conditions—like assembling cement structures—often require prolonged bending and awkward positions.
While not always fatal, these injuries cause lost time, higher insurance costs, and long-term health issues for workers.
How video intelligence helpsAI cameras analyze body mechanics and patterns of work, flagging cases where workers repeatedly lift beyond safe limits or skip designated rest breaks. Supervisors can use video for ergonomic assessments and to reinforce safe lifting protocols during toolbox talks.
Challenges and impact of the injuries
Let's break down how each injury type affects your jobsite—and how data and technology can make a difference:
| Injury Type | Challenges | Impact | Role of Data & Technology |
|---|---|---|---|
| Falls from Heights | Unprotected edges, missed harness checks, busy areas | Severe injuries, lost time, OSHA citations, fatalities | AI cameras flag missing guardrails/harnesses in real time |
| Struck-by Incidents | Blind spots, poor visibility, unauthorized access | Fractures, amputations, equipment downtime, investigations | Video detects zone intrusions, supports coaching |
| Electrocutions | LOTO non-compliance, exposed wiring, tool misuse | Fatalities, burns, project shutdowns, legal liabilities | Video verifies LOTO, detects unsafe equipment use |
| Caught-In/Between | Unprotected trenches, machine access, tight spaces | Crushing injuries, amputations, major regulatory fines | AI flags missing trench boxes, monitors machine zones |
| Overexertion / MSDs | Repetitive strain, skipped breaks, poor ergonomics | Chronic injuries, lost productivity, higher comp claims | Video analyzes postures, flags unsafe lifting patterns |
How technology strengthens injury prevention in construction
Modern construction safety is about more than just hard hats and hazard signs. Here’s how video intelligence fits into the prevention strategy for each injury type:Falls from Heights
Safety challengeGuardrails get moved. Harnesses are left in the trailer. In the rush of daily work, fall protection is easy to overlook—until it’s too late.
Tech SolutionAI-powered cameras monitor scaffolds, roofs, and elevated workspaces 24/7. They flag missing guardrails, unsecured ladders, and workers not using fall protection. Real-time alerts go to supervisors’ phones or radios, so someone always has eyes on the most dangerous spots—even during shift changes or busy periods. Spot AI, for example, makes it simple to review footage for compliance and quickly pull video after a near-miss to drive home training points.
Struck-by Incidents
Safety challengeForklifts, dump trucks, and tower cranes all move with limited visibility. Pedestrians and vehicles share the same space, and even the best-trained operators can’t see everything.
Tech SolutionVideo intelligence can track people and vehicles, sending instant alerts when someone enters a high-risk zone or an operator’s blind spot. AI can also monitor high-traffic areas for missing barriers and flag non-compliance with high-visibility PPE. Reviewing near-miss footage helps safety teams coach both operators and crews on safer practices.
Electrocutions
Safety challengeLOTO tags get skipped, temporary lines are exposed, and it only takes a moment’s inattention for disaster to strike.
Tech SolutionCameras verify that access controls and LOTO tags are in place, even in off-hours. AI can be trained to spot when workers are using metal ladders near electrical panels or entering unauthorized electrical enclosures. If a risk is detected, supervisors get instant notifications—allowing for rapid intervention and improved compliance documentation for OSHA.
Caught-In/Between
Safety challengeTrench boxes are sometimes removed “just for a minute.” Machine guards are bypassed for quick fixes. Workers enter tight spaces to retrieve tools without thinking twice.
Tech SolutionVideo analytics continuously check that trench boxes are in use and unauthorized personnel stay out of danger zones. AI can also monitor for missing machine guards or unsafe equipment operation. Reviewing video after close calls helps identify and eliminate unsafe shortcuts before they lead to tragedy.
Overexertion and Musculoskeletal Injuries
Safety challengeMuscle strains, repetitive lifting, and skipped breaks are common—especially when teams are short-handed or under deadline pressure.
Tech SolutionAI-powered video can monitor body mechanics and flag repetitive unsafe lifting or bending. Supervisors use this data to adjust workflows, rotate jobs, and reinforce proper technique during toolbox talks. Video also helps demonstrate the need for ergonomic equipment or job rotation, making the business case to leadership crystal clear.
Practical implementation of safety technology
Bringing AI-powered video intelligence onto a construction site doesn’t mean starting from scratch. Here’s how to make it work for your safety program:
- Integrate with what you have: Modern video intelligence platforms, like Spot AI, work with most existing camera systems—no need for a full rip-and-replace.
- Support, not replace, your team: Technology is a second set of eyes, not a substitute for boots-on-the-ground safety walks and toolbox talks. Use AI alerts to empower supervisors, not overwhelm them.
- Customize for your risks: Every jobsite is different. Focus cameras and analytics on your highest-risk zones—scaffolds, trenches, equipment crossings, and electrical panels.
- Get buy-in across the team: Show how video intelligence makes everyone’s job safer and easier, from the apprentice to the project manager.
- Choose solutions that scale: Look for platforms that are easy to deploy, simple to search, and provide actionable data—not just endless hours of footage.
The best technology works quietly in the background, catching what people might miss, and helping your team do their jobs better. For more guidance, book a safety consultation to evaluate what fits your workflow and goals.
Drive safer outcomes on every construction site
Ready to cut preventable injuries and make your site a place where everyone goes home safe? Spot AI partners with construction leaders to build smarter, safer jobsites—combining real-world know-how with powerful, easy-to-use technology. Our goal: empower your team, reduce incidents, and keep projects moving.
Book a safety consultation to see how you can make video intelligence a seamless part of your safety program: Book a safety consultation.
Frequently asked questions
How can I prevent falls from heights on my construction site?
The most effective steps are installing guardrails, enforcing harness use, and conducting daily toolbox talks focused on fall hazards. Supplement these with video intelligence to monitor high-risk areas—AI cameras can alert your team in real time if guardrails are missing or harnesses aren’t used, closing the gap when supervisors are busy elsewhere (Source: ABC Health and Safety Report, Associated Builders and Contractors).
What’s the best way to reduce struck-by incidents with vehicles or equipment?
Separate workers from moving vehicles using barricades and clear walkways. Use high-visibility PPE and, for added protection, deploy AI-powered cameras that detect when someone enters a vehicle’s blind spot or a restricted area, sending instant alerts before an incident can occur (Source: CPWR).
How do I ensure lockout/tagout (LOTO) compliance for electrical safety?
Train your team on LOTO protocols and use checklists before work begins. AI video analytics can verify that LOTO tags are in place and flag attempts to access energized equipment, providing an extra layer of oversight and documentation for compliance (Source: OSHA).
How can I use video intelligence to prevent caught-in/between injuries?
Position cameras to monitor trenches, excavation sites, and machinery. AI can identify when trench boxes or guards are missing and alert supervisors if anyone enters a hazardous zone. This supports your team's vigilance and helps maintain compliance with site safety rules.
What ergonomic risks can video intelligence help address?
AI video can analyze lifting techniques, posture, and repetitive motion—flagging unsafe practices like heavy lifting without assistance or skipping scheduled breaks. This data helps supervisors adjust workflows and reinforces safe habits through targeted training.
How do I integrate AI cameras into my existing construction safety program?
Choose a video intelligence platform that works with your current cameras and workflows. Start by focusing coverage on your highest-risk areas, and use alerts to supplement—not replace—your in-person safety processes. Engage your team early and use video insights to drive continuous improvement.
About the author
Amrish KapoorVP Technology, Spot AI
Amrish Kapoor leads Spot AI’s technology and engineering teams, driving innovation in AI-powered video analytics for workplace safety. With deep expertise in system architecture, machine learning, and scalable cloud infrastructure, Amrish has helped hundreds of organizations in high-risk industries like construction implement smarter, simpler safety solutions. His mission: make safety technology as practical, accessible, and effective as possible for every frontline team.
