How often these injuries happen
OSHA recorded 26 severe cases involving hydraulic systems and pressurized components. Fractures are the most common injury type, appearing in 38% of all reported incidents. These injuries often result from sudden equipment failure or unexpected pressure release.
The severity of these incidents is driven by the high force involved in hydraulic operations. Fingers are the most frequently affected body part, often suffering from crush injuries or amputations when components shift or collapse during maintenance.
How these injuries happen
Injuries involving hydraulic systems typically occur when you are struck by falling or propelled objects. Many incidents involve components like cylinders or lines that shift unexpectedly during assembly or repair. When pressure vessels or lines rupture, the sudden release of energy can propel parts or fluid with enough force to cause severe fractures or thermal burns.
| Cause | Incidents | |
|---|---|---|
| 1 | Struck by falling object | 10 |
| 2 | Struck by propelled object or substance | 7 |
| 3 | Caught or wedged between objects— nonrunning | 2 |
| 4 | Explosion of pressure vessel, piping, or tire | 2 |
| 5 | Flash fire | 1 |
| 6 | Struck by propelled, falling, or suspended object— unspecified | 1 |
Where injuries happen most
Manufacturing accounts for 35% of all reported hydraulic injuries. This high rate is driven by the constant use of heavy machinery and the frequent need for maintenance on pressurized systems. Construction and other service industries also see significant injury rates due to the reliance on mobile hydraulic equipment and the complexity of field repairs.
Real cases like yours
Common patterns in these reports involve you performing routine maintenance or alignment tasks when a hydraulic component shifts or a line releases pressure. Many incidents occur because equipment was not properly locked out or secured before you placed your hands in a danger zone. If any of these scenarios sound like what happened to you, an attorney can help you review the specifics of your incident.
| Year | State | Industry | Incident summary | |
|---|---|---|---|---|
| 2025 | MO | Manufacturing | "Two employees were working together to insert a pin into a hydraulic cylinder. One employee was holding the cylinder in place to align it with the pinhole, while the injured employee was inserting the pin. The injured employee was aligning the pin and moved to determine whether the hole alignment was too high or low. At that moment, the crowbar being used to assist with alignment slipped and his left index fingertip was pinched between the cylinder and the housing, resulting in an amputation just below the fingernail." | |
| 2025 | TX | Other Services | "Two employees were working at the hydraulic shop refilling a square dump truck cylinder. While pushing the piston back on top, the cylinder fell onto the injured employee's little finger. The employee sustained an amputation of the finger to the distal knuckle." | |
| 2025 | FL | Wholesale Trade | "Employees were installing a hydraulic cylinder on a compactor. The injured employee completed rigging of the hydraulic cylinder and directed another employee to move the cylinder into place. At the same time, a third employee was preparing the cylinder pin for installation. The injured employee went to align the pin on the cylinder. The hydraulic cylinder shifted and pinched his left index finger between the cylinder and the compactor, resulting in amputation of the fingertip. " | |
| 2025 | PA | Other Services | "An employee was braising a copper elbow on a refrigeration line as part of a repair. The copper line exploded and fire came out of the line. The employee sustained burns to their face and neck." | |
| 2025 | UT | Public Administration | "An employee was servicing equipment and had disconnected a 4-inch line. A proportional control air valve on the equipment actuated, releasing a large volume of air at 99 psi into the 4-inch braided stainless steel line hanging down from the valve. The sudden release of pressure caused the line to whip and strike the employee's face. He was hospitalized due to an orbital bone fracture requiring surgery. The equipment was not locked out/tagged out at the time. " | |
| 2025 | MS | Other Services | "An employee was removing a hydraulic cylinder from a baler. As he removed the bolts, the cylinder came down and fractured his left middle finger." | |
| 2025 | CO | Manufacturing | "An employee was unscrewing the accumulator from an agricultural tractor. When he released the line during disassembly, it sprung apart and crushed his thumb. In addition, oil that was under pressure in the line shot underneath the skin of his thumb, resulting in right thumb lacerations and fractures, as well as oil injected under the skin." | |
| 2025 | PA | Manufacturing | "An employee was helping to lift a cylinder assembly with a remote-controlled overhead crane when the cylinder slipped out of the basket hitch and pinched the employee's right hand, resulting in amputation of their index and middle fingertips." | |
| 2025 | IL | Manufacturing | "An employee was unclogging product from a railcar hose using air pressure from a valve. The air hose coupling went out of control in the employee's right hand and struck the employee's right shin, resulting in a fractured tibia. The employee was hospitalized." | |
| 2024 | TX | Manufacturing | "Employees were working to re-install a 500-pound shear cylinder (20 x 40 ). They took the cylinder off a pallet and laid it vertically on the ground. Using nylon straps, they rigged the cylinder through eyelets to lift it with a forklift and place it back in the machine. The injured employee grabbed the cylinder and went to rotate it. The cylinder tipped over and landed on the injured employee's leg, fracturing bones in their lower leg and foot. The employee was hospitalized and required surgery." |
Source: OSHA Severe Injury Reports. Narratives are verbatim from filings; identifying details may have been redacted by OSHA.
Frequently asked questions
Seek immediate medical attention for any wound, especially if pressurized fluid may have entered your skin. Report the incident to your employer immediately and document the equipment involved. An attorney can help you determine if the equipment failure was due to improper maintenance or lack of safety protocols.
Employers are required to maintain equipment in safe working order and provide proper training for all hydraulic operations. If an injury occurred because a machine was not locked out or lacked proper guarding, your employer may be liable for your damages. An attorney can help you evaluate whether your employer met these safety obligations.
Yes, amputations resulting from workplace accidents are typically covered under Workers' Compensation. These benefits are intended to cover medical expenses and lost wages during your recovery. An attorney can help you ensure your claim accurately reflects the severity of your injury and the long-term impact on your ability to work.
OSHA requires employers to follow strict machine guarding and pressure vessel safety standards to prevent accidental contact or release. Failure to comply with these regulations often serves as evidence in a Workers' Compensation or personal injury claim. An attorney can help you identify if your employer violated these critical safety standards.