Every year, countless workers suffer serious injuries due to pinch point hazards, areas where a body part can get caught between moving objects or equipment. 

A moment of inattention near a conveyor belt, a press machine or a closing door can lead to painful crush injuries, fractures, or even amputations.

Workplace injuries related to machinery and equipment in Canada remain a significant concern. 

According to the Association of Workers' Compensation Boards of Canada (AWCBC), over 14,000 lost-time claims are filed annually due to contact with objects and equipment. Many of these involve pinch points, making it clear why proper safety measures are essential.

Recognizing and managing pinch point hazards is key to preventing life-changing injuries. Employers and workers must prioritize hazard awareness, proper safety training, and the use of protective equipment to reduce risks. 

Machine guarding, lockout/tagout procedures, and clear safety protocols are critical in keeping workers safe.

This article will explore the common causes of pinch point injuries, high-risk industries, and the best strategies to prevent accidents. Whether you're an employer or a worker, understanding these risks can help create a safer work environment.

What Are Pinch Points?

A pinch point is any area where a body part—such as fingers, hands, feet, or limbs—can become trapped between two objects, one or both of which are moving. 

These hazardous areas are commonly found in workplaces with heavy machinery, conveyor belts, assembly lines, and power tools. 

Pinch points can also occur between stationary objects and moving equipment, like closing doors, heavy materials, or rotating machine parts.

Why Are Pinch Points Dangerous?

Pinch point hazards can lead to severe workplace injuries, including crushed bones, amputations, lacerations, and nerve damage. Because many pinch points involve high-force equipment, injuries are often irreversible, resulting in permanent disability. 

Even minor pinch point injuries can cause pain, swelling, and reduced mobility, impacting a worker's ability to perform their job effectively.

According to the Canadian Centre for Occupational Health and Safety (CCOHS), a significant number of workplace injuries are related to caught-in or caught-between hazards, including pinch points. 

Many of these incidents occur due to improper machine guarding, lack of awareness, or inadequate training.

Examples of Pinch Point Incidents in Different Industries

1. Manufacturing: A worker's hand gets caught in an unguarded conveyor belt, resulting in a fractured wrist.
2. Construction: A laborer's fingers are crushed while handling materials between a wall and a heavy steel beam.
3. Warehousing: A forklift operator's foot is trapped between the vehicle and a loading dock, causing severe bruising and fractures.
4. Agriculture: A farmworker's hand is pulled into a power take-off (PTO) shaft, leading to a traumatic amputation.

Understanding pinch point hazards is essential for preventing these incidents. Employers and workers must take proactive steps, such as installing machine guards, implementing lockout/tagout procedures, and ensuring proper training to minimize risks.

What Are the Types of Pinch Points?

Pinch point hazards exist in many workplaces, mainly where workers interact with machinery, heavy materials, or vehicles. 

Pinch points can be found in various work environments, including manufacturing plants, construction sites, warehouses, and even office settings with mechanical equipment.

Understanding the different types of pinch points is essential for identifying risks and implementing effective safety measures. 

Below are the most common categories of pinch point hazards and how they can cause injuries.

1. Machinery and Equipment Pinch Points

Many machines have moving parts that create pinch points, especially if they lack proper guarding. Workers can get caught between:

1. Rotating gears, pulleys, and rollers, which can trap hands or clothing.
2. Conveyor belts, which can catch fingers if guards or emergency stops are not in place.
3. Presses and stamping machines, where forceful mechanical movements pose a risk of crushing injuries.

Without machine guards or proper training, workers can easily suffer serious injuries, including amputations and crushed bones. Regular maintenance and lockout/tagout (LOTO) procedures are crucial for preventing these hazards.

2. Material Handling Pinch Points

Moving heavy materials creates pinch points, especially in warehouses, construction, and manufacturing settings. Workers are at risk when:

1. Stacking materials or handling heavy pipes, beams, or pallets, where shifting loads can trap hands or feet.
2. Using forklifts, cranes, or hoists to move heavy items, as improper positioning can result in body parts being caught between objects.
3. Working in tight spaces, such as between walls and large equipment, where sudden movements can lead to crushing injuries.

To reduce risks, workers should use mechanical lifting aids when handling heavy objects and always keep their hands clear of pinch-point zones.

3. Doors, Lids, and Covers

Pinch points aren't limited to machinery, doors, lids, and covers can also be a threat. Workers can get fingers or hands caught when:

1. Closing heavy doors, such as warehouse or industrial facility doors.
2. Operating machine covers and enclosures, where fingers can get caught between panels.
3. Handling vehicle hatches or maintenance panels, which can suddenly close due to mechanical force.

Ensuring that doors and covers have slow-close mechanisms and proper warning labels can help reduce injuries.

4. Vehicle and Mobile Equipment Pinch Points

Workers who operate or work near vehicles and mobile equipment face a high risk of pinch point injuries. These risks are common in construction sites, warehouses, and transportation hubs, where:

1. Workers can get caught between trailers, moving trucks, or heavy machinery.
2. Body parts can become trapped in vehicle hinges, tailgates, or articulating equipment.
3. Equipment with extendable parts (e.g., scissor lifts or boom lifts) can create crush points if not properly controlled.

Proper vehicle safety protocols, clear communication, and high-visibility clothing are essential to prevent these incidents.

Recognizing the different types of pinch point hazards is the first step toward prevention. To reduce risks, employers must enforce safety measures such as machine guarding, safe material handling practices, and worker training. 

By implementing effective safety protocols, workplaces can significantly lower the chances of serious injuries related to pinch points.

How to Recognize Pinch Points?

Recognizing pinch point hazards is essential for preventing workplace injuries. Many accidents occur because workers are unaware of the risks around them. 

These hazards exist in areas where workers frequently interact with equipment and materials that can shift, rotate, or close unexpectedly.

Workers and supervisors must actively identify and assess high-risk areas to reduce the risk of pinch point injuries. Below are key strategies to recognize and mitigate pinch point hazards.

1. Train Workers to Identify High-Risk Areas

Employees should be trained to recognize where pinch points are most likely to occur, including:

1. Machinery with moving parts, such as conveyor belts, rollers, gears, or presses.
2. Areas where materials are stacked, lifted, or transported, as shifting loads can create pinch points.
3. Vehicles and mobile equipment, including forklifts, scissor lifts, and articulated machinery.

Training should emphasize real-world scenarios where pinch point injuries have occurred, helping workers understand the risks associated with their specific tasks.

2. Be Aware of Body Positioning

Workers must stay mindful of their hands, feet, and clothing when working near pinch points. Common risky behaviors include:

1. Reaching into moving machinery to remove an obstruction.
2. Placing hands or feet in tight spaces where equipment or materials might shift.
3. Standing between moving vehicles or heavy objects, creating a crush hazard.

Encouraging safe work habits, such as keeping hands away from pinch zones and using tools instead of hands to clear jams, significantly reduces injuries.

3. Conduct Pre-Job Inspections

Before starting work, supervisors and employees should perform pre-job safety inspections to detect potential pinch points. This includes:

1. Checking if machine guards are in place and functional.
2. Inspecting work areas for loose materials or unstable loads that could shift.
3. Ensuring vehicles and heavy equipment are properly maintained and have clear visibility.

A Job Hazard Analysis (JHA) can help identify pinch point risks for specific tasks, ensuring preventive measures are in place before work begins.

A proactive approach to workplace safety ensures that workers stay alert, informed, and protected from these hidden hazards.

10 Effective Safety Measures to Prevent Pinch Point Injuries

Pinch point injuries are among the most preventable workplace accidents, yet they continue to cause serious harm in industries like manufacturing, construction, warehousing, and transportation. 

These injuries often result in fractures, crushed bones, amputations, or severe soft tissue damage, leading to lost workdays and long-term disabilities. The good news is that workers can significantly reduce their risk of injury with effective safety measures.

To protect employees from pinch point hazards, workplaces must adopt a comprehensive safety approach, combining engineering controls, proper training, and strict enforcement of safety protocols. 

Below are ten highly effective strategies to eliminate or mitigate pinch point risks.

1. Install Proper Machine Guarding

Machine guards are the first line of defense against pinch point hazards. They block access to dangerous moving parts, preventing accidental contact with rollers, gears, conveyors, or presses.

Types of Machine Guards

1. Fixed guards: Permanently attached barriers that cover hazardous machine parts.
2. Interlocked guards: Automatically stop the machine when the guard is removed or opened.
3. Adjustable guards: Can be positioned based on the specific task while still providing protection.
4. Presence-sensing devices: Use light curtains or sensors to detect a worker’s presence near the machine and stop its operation.

Best Practices for Machine Guarding

1. Conduct regular inspections to ensure guards are properly installed and functioning.
2. Train workers on the purpose and importance of machine guards.
3. Never bypass or remove guards while machinery is running.
4. Replace damaged guards immediately to maintain effectiveness.

Proper machine guarding is a non-negotiable safety measure that prevents serious injuries by keeping workers' hands, fingers, and clothing away from dangerous pinch points.

2. Implement Lockout/Tagout (LOTO) Procedures

LOTO procedures prevent accidental machine startup during maintenance or servicing. Workers performing repairs must ensure all energy sources are deactivated and locked out before beginning work.

Steps of a Proper LOTO Procedure

1. Shut down the machine completely.
2. Isolate all energy sources (electrical, hydraulic, pneumatic, mechanical).
3. Apply lockout devices and secure them with a personal padlock.
4. Attach a tagout label indicating that the equipment is out of service.
5. Verify energy isolation by testing the machine before maintenance begins.
6. Remove locks/tags only after all work is complete and workers are safely positioned.

Importance of LOTO Training

1. Educate workers on why LOTO is critical for preventing injuries.
2. Provide hands-on demonstrations of proper LOTO procedures.
3. Enforce strict LOTO compliance with zero-tolerance policies for bypassing locks/tags.
4. Conduct periodic refresher training to reinforce LOTO practices.

Without LOTO, workers are at high risk of unexpected machine activation, leading to severe pinch point injuries. Proper LOTO training saves lives and ensures compliance with workplace safety standards.

3. Provide Anti-Pinch Gloves and Protective Gear

Personal Protective Equipment (PPE) plays a crucial role in reducing the risk of pinch point injuries.

Specialized gloves and protective gear offer an extra layer of defense, particularly in industries where workers handle heavy machinery, tools, or materials.

Anti-Pinch Gloves: Features and Benefits

1. Impact-resistant materials: Absorb shocks and pressure to minimize hand injuries.
2. Reinforced knuckles and fingers: Provide protection against crushing forces.
3. Flexible design: Maintains dexterity for precision work while offering safety.
4. Cut and abrasion resistance: Prevents injuries from sharp edges or rough surfaces.

PPE Best Practices for Pinch Point Safety

1. Ensure a proper fit: Loose gloves or clothing can increase risks by getting caught in moving parts.
2. Select job-specific gloves: Different tasks require different levels of protection.
3. Regularly inspect PPE: Damaged gloves should be replaced immediately.
4. Provide PPE training: Workers must understand how to use and maintain their protective gear effectively.

Proper use of PPE is not a substitute for engineering controls, but it adds an essential layer of protection in high-risk environments.

4. Use Two-Hand Control Systems for Machines

Many industrial machines, such as hydraulic presses and stamping machines, pose a high risk of pinch point injuries. 

Two-hand control systems require operators to use both hands simultaneously to activate the machine, ensuring hands are clear of danger zones before operation begins.

How Two-Hand Controls Work

1. Both hands must engage the controls before the machine cycle starts.
2. If one hand is removed, the machine stops immediately to prevent injury.
3. Controls are placed at a safe distance from the machine’s pinch points.

Benefits of Two-Hand Control Systems

1. Prevents accidental hand placement in hazardous areas.
2. Reduces risk of injury caused by distraction or sudden machine activation.
3. Enhances worker focus by requiring intentional engagement with controls.

Best Practices for Two-Hand Control Implementation

1. Install two-hand control on all high-risk machinery, such as stamping presses, shears, and bending machines.
2. Ensure controls cannot be bypassed or overridden by workers.
3. Train workers on the correct use of two-hand control panels.
4. Conduct routine inspections to verify proper functionality.

Two-hand controls are a simple yet highly effective safety measure that ensures workers keep their hands out of dangerous pinch points during machine operation.

5. Conduct Regular Pinch Point Hazard Assessments

A proactive approach to workplace safety requires frequent assessments to identify and control pinch point hazards. 

Regular hazard assessments help prevent injuries before they occur by ensuring workplaces remain compliant and up to date with safety regulations.

Key Steps in a Pinch Point Hazard Assessment

1. Identify all pinch points: Inspect machinery, conveyors, and material handling areas.
2. Assess the level of risk: Determine the chance and severity of injuries.
3. Examine machine modifications: Any changes in equipment can introduce new hazards.
4. Evaluate safety controls: Check if guards, LOTO procedures, and warning labels are in place and functional.

When to Conduct a Hazard Assessment

1. Before introducing new machinery or equipment.
2. After an accident or near-miss incident.
3. During routine safety inspections.
4. Whenever work processes change.

Improving Workplace Safety through Hazard Assessments

1. Engage workers in assessments: Employees who operate machines daily can provide valuable insight into potential risks.
2. Document findings: Keep records of assessments and corrective actions taken.
3. Act on identified hazards immediately: Delays in addressing hazards increase injury risks.

Conducting regular hazard assessments is one of the most effective ways to prevent pinch point injuries. By staying proactive, workplaces reduce accidents, improve compliance, and enhance overall safety culture.

6. Enforce Proper Hand and Body Placement Training

Proper hand and body placement is critical in preventing pinch point injuries. Many incidents occur when workers unintentionally place their hands, fingers, or other body parts in dangerous areas without realizing the risk. 

Comprehensive training helps employees develop safe habits and use the correct techniques when working near pinch points.

Key Training Topics for Hand and Body Placement

1. Keeping hands away from moving parts: Train workers to always be aware of hand placement and avoid placing hands near machinery, conveyor belts, or rotating equipment.
2. Using tools instead of hands: Encourage the use of push sticks, tongs, or other tools to handle materials near hazardous areas.
3. Maintaining a proper stance: Teach workers how to position their bodies safely when working near moving equipment.
4. Avoiding distractions: Reinforce the importance of staying focused to prevent accidents caused by inattention.

Best Practices for Reinforcing Safe Hand and Body Placement

1. Integrate training into onboarding for new hires.
2. Provide hands-on demonstrations to show correct techniques.
3. Conduct refresher training sessions to reinforce safety behaviors.
4. Use visual aids like posters and safety videos to reinforce key concepts.

By teaching and enforcing proper hand and body placement, workplaces can significantly reduce the risk of pinch point-related injuries.

7. Maintain a Safe Distance from Heavy Machinery and Moving Parts

Workers should always maintain a safe distance from heavy machinery and moving equipment to prevent pinch point injuries. 

Establishing physical barriers and visual cues ensures that employees understand where it is safe to stand or work.

Creating Exclusion Zones Around Pinch Point Hazards

1. Define high-risk areas: Identify zones where machinery operates and materials move.
2. Use physical barriers: Install railings or guardrails to prevent workers from stepping into hazardous zones.
3. Train workers on restricted areas: Ensure all employees understand where they should not enter during machine operation.

Visual Markings and Safe Zone Indicators

1. Use high-visibility floor tape to define safe working areas.
2. Install warning signs near pinch points to remind workers to stay clear.
3. Color-code zones: Different colors can indicate safe, caution, and danger zones.

Maintaining a safe distance from moving machinery is an effective way to reduce the risk of serious injuries, especially in high-traffic industrial settings.

8. Implement Automatic Safety Shutoff Mechanisms

Technology plays a key role in preventing workplace injuries. Automatic safety shutoff mechanisms help reduce pinch point risks by stopping machinery when a worker is detected in a hazardous zone.

Types of Safety Shutoff Systems

1. Emergency stop buttons (E-stops): Allow workers to quickly halt operations in case of an emergency.
2. Proximity sensors: Detect when a worker or object enters a danger zone and automatically shut down the machine.
3. Light curtains: Use infrared sensors to stop machinery if an obstruction is detected.
4. Pressure-sensitive mats: Stop machine operation when someone steps on a designated danger area.

Benefits of Automatic Shutoff Systems

1. Provides immediate response to prevent serious injuries.
2. Reduces human error by automatically halting operations.
3. Enhances overall workplace safety when combined with proper training and procedures.

Investing in automatic shutoff mechanisms ensures that workplaces have an added layer of protection against pinch point injuries.

9. Display Pinch Point Warning Signs and Labels

Clear warning signs and labels are essential for alerting workers to the presence of pinch point hazards. Proper signage helps increase awareness, reducing the chance of machinery-related accidents.

Types of Pinch Point Warning Signs

1. Standardized hazard labels: OSHA and CSA-compliant warning signs should be placed near all pinch points.
2. Multilingual signs: In diverse workplaces, use multiple languages to ensure understanding.
3. Pictograms and symbols: Use universally recognized symbols like WHMIS pictogram to communicate hazards visually. 

Where to Place Pinch Point Warning Signs

1. On machinery with moving parts: Ensure signs are visible before operation.
2. At entry points to hazardous areas: Remind workers to be cautious before entering.
3. Near high-traffic work zones: Alert workers about potential risks in shared spaces.

Proper signage is a simple yet powerful tool in maintaining workplace safety and preventing avoidable accidents.

10. Conduct Frequent Safety Drills and Reinforcement Training

Regular safety drills and ongoing training ensure that workers remain aware of pinch point hazards and know how to respond in case of an emergency.

Importance of Safety Drills

1. Helps workers recognize risks in real-world scenarios.
2. Prepares employees to respond quickly in case of an emergency.
3. Reinforces safety protocols through hands-on practice.

Best Practices for Reinforcement Training

1. Hold monthly or quarterly safety meetings focused on pinch point awareness.
2. Simulate emergency response scenarios to train workers on injury prevention and first aid.
3. Encourage employee feedback to improve safety procedures.

By conducting regular drills and training, workplaces can build a strong safety culture and reduce the risk of pinch point-related injuries.

Conclusion

Recognizing pinch points and understanding their risks are critical to ensuring workplace safety. These hazards, often found in machinery and equipment, can cause severe injuries if not properly addressed. 

By taking proactive measures, businesses can significantly reduce the chance of accidents and create a safer environment for workers.

Key strategies include implementing machine guarding to prevent access to dangerous areas, following Lockout/Tagout (LOTO) procedures to control hazardous energy, and providing appropriate personal protective equipment (PPE). 

Comprehensive safety training is equally essential to ensure workers understand the risks and know how to operate equipment safely. Proper work practices, such as maintaining a clean and organized workspace, are vital in minimizing hazards.

However, safety is not a one-time effort, it requires ongoing commitment. Businesses must prioritize continuous education, regularly review and update safety protocols, and encourage worker engagement in safety initiatives. 

By promoting a culture of safety, companies can prevent injuries and improve productivity and morale.