Every utility system construction project—whether it’s laying water mains, installing power lines, or upgrading communications—carries risk. In 2023 alone, utility construction accounted for 18% of severe workplace injuries across all industries (Source: OSHA Form 300A, 2023). The dangers are real: falls, struck-by incidents, electrocutions, trench collapses, and heat stress continue to send workers home injured or worse (Source: OSHA Utility System Construction Injury Analysis).
But here’s the good news: a majority of these incidents are preventable. The industry’s most common—and most severe—injuries often stem from lapses that are both visible and addressable with the right mix of practical safety protocols and modern technology. When video intelligence platforms like Spot AI are added to the safety toolbox, they don’t just record what happened—they help you stop it before it happens.
In this guide, we’ll break down the top 5 injuries that put utility system construction workers at risk, why they happen, how to prevent them, and where video analytics can tip the scales toward a safer site.
The Cost of Safety Negligence in Utility System Construction
Utility system construction is high-stakes. When safety slips, the financial penalties are steep—sometimes devastating. In 2024, the average penalty for a major safety violation in utility construction was $23,032, with a median of $10,808 and a maximum of $204,400 (Source: OSHA Penalty Data, 2025). These are just the direct consequences—before factoring in lost productivity, retraining, or the human impact.
These tragedies—and the penalties that follow—are not inevitable. Proactive, visible safety practices, supported by technologies like AI-powered video monitoring, can help prevent them. The goal isn’t just to avoid fines, but to protect people and keep every project on track.
The Top 5 Preventable Injuries in Utility System Construction
1. Falls (From Heights, Trenches, or Structures)
Scenario: A crew member is working atop a transformer pad, reaching for a tool. There’s no guardrail. In a split second, he loses his balance and falls six feet to the ground.
Root Causes & Impact: Falls are the leading cause of fatalities in construction, making up 37.5% of deaths (Source: Kryder Law Group Report, 2025). In utility construction, this includes not just roofs, but poles, ladders, and open trenches. Unprotected edges, inadequate fall arrest systems, and rushed protocols are frequent culprits—especially for workers new to the job (20% of fatal falls involve those in their first two months; Source: EDGE Fall Protection, 2025).
How video intelligence helps: AI cameras can monitor elevated work areas, spot missing harnesses, and alert supervisors if someone enters a hazardous zone without proper protection—before an accident happens.
2. Struck-By Incidents (Vehicles, Equipment, or Falling Objects)
Scenario: A backhoe swings a load of pipe overhead. A worker steps into the exclusion zone, unseen by the operator. In an instant, he’s struck.
Root Causes & Impact: Struck-by incidents cause 28% of severe injuries and are a top driver of fatalities, especially involving cranes and moving vehicles (Source: OSHA Utility System Construction Injury Analysis). Poor visibility, lack of barriers, and failure to use spotters or signal systems are frequent factors (Source: OSHA Crane Safety Statistics, 2025).
How video intelligence helps: AI-powered cameras define and enforce exclusion zones, detect unauthorized entries, and issue real-time alerts—helping crews react before disaster strikes.
3. Electrocutions
Scenario: A field tech is positioning a steel support truss. The truss touches an overhead power line. There’s an arc flash—and a life is changed forever.
Root Causes & Impact: Electrocutions account for 8.6% of construction deaths and often result in severe burns or amputations (Source: Costello HSE, 2025). Missed lockout/tagout, incomplete utility locating, and unsafe distances from live wires are the usual suspects.
How video intelligence helps: Video analytics can monitor for work near energized lines, flag missing PPE (like arc flash suits), and provide instant playback after incidents for root cause analysis and targeted retraining.
4. Caught-In/Between (Trench Collapses, Machinery)
Scenario: A worker climbs into a 10-foot trench to retrieve a dropped tool. The walls aren’t shored. Seconds later, the trench collapses.
Root Causes & Impact: Caught-in/between injuries—especially trench collapses—cause 17% of severe injuries and remain a stubborn killer, despite decades of OSHA enforcement (Source: OSHA Utility System Construction Injury Analysis). Unstable soil, lack of trench boxes, and unsafe behaviors like entering unprotected trenches are to blame.
How video intelligence helps: AI cameras can enforce entry protocols, monitor trench shoring compliance, and alert when workers access hazardous areas without proper safeguards.
5. Heat Stress
Scenario: It’s 98°F on site. A worker skips his hydration break to stay on schedule. Mid-afternoon, he collapses from heat stroke.
Root Causes & Impact: Heat stress is an invisible threat, responsible for an increasing share of utility construction incidents. In 2023, temperatures above 86°F reduced productivity by 14% and caused 55 worker deaths across industries (Source: National Bureau of Economic Research, 2025; NSC Heat Stress Report, 2025). Skipped breaks and lack of shaded rest areas are common issues.
How video intelligence helps: AI video can monitor work/rest cycles, flag workers lingering in sunny zones, and verify that cooling stations are being used—protecting crews when the temperature soars.
Challenges and Impact of Injuries
Injury Type | Challenges | Impact | Role of data & technology |
|---|---|---|---|
Falls | Gaps in fall protection, rushed work, missed PPE checks | Serious injuries, fatalities, project delays | AI cameras monitor elevated work, enforce harness/guardrail use |
Struck-by | Poor visibility, ignored exclusion zones, moving vehicles | Trauma, amputations, fatalities, insurance hikes | Video analytics create/enforce exclusion zones, real-time alerts for breaches |
Electrocutions | Unmarked lines, missed lockout/tagout, missed PPE | Burns, deaths, lost time, regulatory penalties | Cameras flag unsafe work near live wires, missing PPE, enable event review |
Caught-in/Between | Unsafe trenches, lack of shoring, unauthorized entry | Crush/asphyxiation injuries, fatalities | AI verifies shoring, monitors trench entry, flags protocol violations |
Heat Stress | Skipped breaks, unmonitored exposure, no cooling areas | Heat illness, lost productivity, increased incidents | Video monitors rest cycles, hydration, use of cooling stations |
How Technology Strengthens Injury Prevention
Falls
Safety challenge: Inconsistent use of harnesses and guardrails, especially in fast-moving crews or when deadlines loom.
Tech Solution: AI video platforms like Spot AI monitor elevated work, detect when harnesses aren’t worn or guardrails are missing, and send real-time alerts to supervisors. This closes the gap between policy and practice—every shift, every site.
Struck-By Incidents
Safety challenge: Exclusion zones around heavy equipment are hard to enforce, especially when sites are busy or visibility is poor.
Tech Solution: Video analytics define digital boundaries. If a worker or vehicle enters a danger zone, the system issues an immediate alert. Cameras also capture near-misses, giving safety teams the proof and insight needed to update procedures.
Electrocutions
Safety challenge: Workers sometimes bypass lockout/tagout or work too close to energized lines, often due to unclear marking or rushed schedules.
Tech Solution: Spot AI can monitor for presence near live electrical hazards, flag missing PPE, and verify that lockout/tagout protocols are followed. When incidents occur, video evidence helps retrain and prevent repeat events.
Caught-In/Between
Safety challenge: Trench safety protocols are often violated when crews are under pressure, or when “just a quick check” turns into disaster.
Tech Solution: AI video monitors trench shoring and entry points, ensuring only authorized and properly equipped workers enter. Real-time alerts flag when trenches are accessed without proper protection.
Heat Stress
Safety challenge: Heat illness is often missed until it’s too late—especially when workers skip breaks to meet deadlines.
Tech Solution: Video analytics can track scheduled breaks, monitor worker locations (to ensure use of shaded or cooled areas), and verify that hydration stations are accessed. Combined with wearable sensors, this provides a proactive approach to heat safety.
Practical Implementation of Safety Technology
Integrating AI-powered video into utility system construction isn’t about replacing people—it’s about making your safety program smarter and more responsive.
Here’s how to get started:
Build on what works: AI video should layer onto existing safety protocols—think of it as a second set of eyes that never blinks.
Integrate with current systems: Most solutions (like Spot AI) can use your existing camera infrastructure, minimizing disruption and cost.
Customize alerts: Set up real-time notifications for your top risks—falls, exclusion zone breaches, missing PPE—so supervisors get actionable information, not just more footage.
Review and improve: Use video analytics to review near-misses and incidents, identify root causes, and tailor retraining where it matters.
Train your team: Make sure everyone understands how video supports—not replaces—their safety role.
When evaluating options, look for platforms that are easy to deploy, offer flexible alerting, and provide simple video search tools. And above all, choose tools that empower your frontline teams to act fast and decisively.
Protect Your Crew, Your Project, and Your Reputation
Utility system construction can be made safer—and smarter—when people and technology work together. Proactive safety measures, supported by AI-powered video, help you see risks before they become tragedies. The result? Fewer injuries, smoother operations, and a reputation as a leader in safety.
Want practical guidance on building a high-performance safety program that leverages the latest technology? Book a consultation with our experts to see what’s possible.
Frequently asked questions
What are the main safety challenges in utility system construction?
Utility construction sites are dynamic and hazardous. The biggest challenges are enforcing exclusion zones, ensuring consistent PPE use (especially for falls and electrical work), preventing trench collapses, and monitoring for heat stress in changing weather conditions. Fast-moving crews, complex environments, and deadline pressures make these risks hard to control without real-time monitoring.
How does video intelligence help prevent injuries on utility construction sites?
Video analytics platforms can monitor high-risk areas 24/7, detect unsafe behaviors (like missing harnesses or exclusion zone breaches), and alert supervisors in real time. This allows for immediate intervention—often before an incident occurs. Video also provides context for incident investigations and safety training.
How can AI cameras be integrated with our current safety program?
Most AI video solutions can use your existing camera infrastructure. Integration involves connecting cameras to the analytics platform, defining alert rules for your key risks, and training your team to respond to alerts and use video for incident review. The goal is to make technology a seamless extension of your safety protocols.
Are there best practices for using video analytics on utility projects?
Yes: Focus on your highest risks (falls, struck-by, electrical, trenches, heat). Customize alerts so they’re actionable, not overwhelming. Use video reviews for targeted retraining after incidents or near-misses. And involve workers in the process—make it clear that technology is there to keep everyone safe.
What should we look for when choosing a video analytics platform for safety?
Look for easy deployment, compatibility with your current cameras, customizable alerts, user-friendly video search, and strong support. The best platforms empower your team with timely, actionable insights—not just more video to sift through.
About the author
Joshua Foster, IT Specialist, Spot AI
Joshua Foster is an IT Specialist at Spot AI with hands-on experience in deploying, maintaining, and troubleshooting security camera systems for enterprise environments. He is passionate about helping businesses optimize their video surveillance for maximum uptime, safety, and operational insight.
