How often these injuries happen
OSHA recorded 26 severe cases involving hydraulic systems, where fractures account for 38% of all reported injuries. These incidents often involve high-pressure releases or crushing forces that cause immediate, life-altering damage to you.
The severity of these accidents is reflected in the high rate of amputations, which make up 35% of all hydraulic-related injuries. Fingers are the most frequently affected body part, accounting for 48% of incidents, often suffering permanent loss due to the immense force exerted by pressurized cylinders and equipment components.
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Check My BenefitsHow these injuries happen
Injuries involving hydraulic systems typically occur when you are struck by falling objects, which accounts for 43% of incidents, or propelled components, which accounts for 30%. In many cases, a sudden loss of pressure or a mechanical failure causes heavy cylinders to drop or lines to whip violently. These accidents often happen during maintenance or alignment tasks where you are caught between heavy components that shift unexpectedly.
| 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 severe hydraulic injuries, as high-volume production environments rely heavily on pressurized machinery. You face constant exposure to hydraulic cylinders and lines that require rigorous inspection and maintenance to prevent catastrophic mechanical failure.
Real cases like yours
Common patterns in these reports involve you performing routine maintenance or equipment alignment when a hydraulic component shifts or a line ruptures. Whether it is a finger caught during pin installation or a face injury from a pressurized line failure, these incidents frequently stem from inadequate lockout or improper equipment handling. 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.