Caught-in/between hazards are unique in their speed: a rotating shaft or pinch point can pull in a limb before a worker can react. Unlike struck-by incidents where a worker can sometimes dodge, caught-in incidents provide zero margin for error. Understanding where these hazards exist — machinery, equipment swing zones, trenching, and excavation — and maintaining absolute separation from them is the only reliable protection.
- Never enter the operating radius of heavy equipment. Assume the operator cannot see you unless you have confirmed direct eye contact.
- Never reach into running machinery, even to clear a jam. De-energize and lockout/tagout first — every time, no exceptions.
- Keep hair, loose clothing, and gloves away from rotating equipment. Rotating parts can catch loose material faster than any human reaction.
- Lockout/Tagout (LOTO) is mandatory before any maintenance, cleaning, or unjamming of equipment that stores or uses energy.
- Trench and excavation cave-ins: never enter an unprotected excavation over 5 feet deep. At 4+ feet, the competent person must evaluate cave-in potential before any entry.
- Establish and enforce clear exclusion zones around heavy equipment during active operations.
- If a coworker is caught in a machine, do NOT attempt to pull them out. Cut power, call 911, and wait for emergency services. Attempting extraction can cause additional injury.
Talk topic: Caught-In/Between Hazards | Date: _________________ | Supervisor: _________________
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Recommended Gear for This Talk
Hand-picked PPE and supplies that match this safety topic. Links go to Amazon search results.
Lockout / Tagout Kit
Includes hasps, padlocks, tags, and labels. One kit per crew minimum for any machinery maintenance or clearing jams.
ANSI Class 2 Hi-Vis Vest
Required near heavy equipment exclusion zones so operators can identify ground workers at all times.
Non-Contact Voltage Tester
Verify equipment is fully de-energized before any lockout/tagout procedure begins. Test before touch.
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