Struck-by incidents are one of the most common and dangerous hazards in Canadian workplaces, especially in industries like construction, manufacturing, and warehousing.

These incidents occur when workers are hit by falling, flying, swinging, or rolling objects, often leading to serious injuries or even fatalities. 

For example, a tool dropped from a height, a vehicle backing up unexpectedly, or debris flying from machinery can all have life-altering consequences.

In Canada, struck-by incidents are a leading cause of workplace injuries. According to the Association of Workers’ Compensation Boards of Canada (AWCBC), being struck by an object or equipment accounted for nearly 15% of all lost-time injuries in recent years. 

These incidents impact workers and their families and cost businesses $5.3 billion annually in lost productivity and compensation claims.

The good news is that many struck-by incidents can be prevented. Proper training, awareness, and safety measures can significantly reduce the risks.

Employers and workers must prioritize safety by using protective gear, securing tools and materials, and following established protocols. 

Understanding how these incidents happen and taking proactive steps can create safer workplaces for everyone.

In this blog, we’ll explore practical ways to protect workers from struck-by incidents, ensuring they can return home safely at the end of each day. Let’s work together to make workplace safety a top priority.

What Are Struck-By Incidents?

Struck-by incidents occur when a worker is injured by forcible contact with an object. These incidents are a major safety concern across various industries, particularly in construction and warehousing, where heavy equipment, tools, and materials are constantly in use.

 Struck-by hazards can be grouped into four main types:

1. Falling Objects: Tools, materials, or debris dropped from heights can strike workers below. For example, a wrench falling from scaffolding or unsecured materials on a high shelf can cause serious harm.
2. Flying Objects: Debris or particles propelled by power tools, compressed air, or machinery can hit workers. Think of wood chips from a saw or nails from a nail gun.
3. Swinging Objects: Loads being moved by cranes, hoists, or other equipment can swing unexpectedly and strike workers nearby. This is a common hazard associated with construction sites where heavy materials are lifted and transported.
4. Rolling or Moving Objects: Vehicles, forklifts, or heavy machinery in motion can hit workers, especially in busy warehouses or industrial settings.

These hazards pose significant risks to workers, often leading to injuries like fractures, concussions, or even fatalities. 

In industries like construction and warehousing, where such hazards are prevalent, understanding and addressing these risks is critical to ensuring worker safety. 

By recognizing the types of struck-by incidents and their causes, employers and workers can take steps to prevent them and create a safer work environment.

Key Risk Factors for Struck-By Incidents

Struck-by incidents don’t happen by chance, they often result from specific risk factors that can be identified and addressed. Understanding these risks is the first step toward preventing injuries and fatalities in the workplace. 

By recognizing the conditions and behaviors contributing to struck-by hazards, employers and workers can take proactive measures to reduce the likelihood of accidents.

1. Unsafe Work Environments

A poorly managed worksite is one of the biggest contributors to struck-by incidents. When tools, materials, or equipment are not properly stored or secured, they can become serious hazards. For example:

1. Tools or materials that are left unsecured on elevated surfaces, such as scaffolding or ladders, can fall and strike workers below.
2. Power tools like saws and grinders can propel particles or fragments at high speeds, increasing the risk of eye injuries or blunt force trauma.
3. Heavy machinery, such as cranes and hoists, often move large objects that can swing unexpectedly, hitting nearby workers.
4. Forklifts, trucks, and other moving vehicles pose a risk if proper traffic controls and pedestrian safety measures are not in place.

Additionally, poor lighting, cluttered workspaces, and inadequate warning systems make it harder for workers to spot hazards in time to react. 

Creating safer environments starts with routine inspections, securing loose objects, maintaining clear walkways, and implementing traffic control measures to separate pedestrians from moving equipment.

2. Lack of Proper Training and Awareness

One of the biggest contributors to struck-by incidents is inadequate worker training. Many accidents happen simply because workers do not recognize hazards or are unaware of best safety practices. 

Without proper training, employees may mishandle tools, position themselves in dangerous areas, or fail to use protective equipment correctly.

For example, a worker operating near a crane may not fully understand the risk of a swinging load, or a new employee may not know how to identify a high-risk zone where falling objects are a concern. 

Safety training, including hazard identification training, is essential to ensure that workers can spot and avoid struck-by risks before they lead to injuries.

Employers must invest in regular training sessions that cover:

1. Recognizing common struck-by hazards in different work environments.
2. Safe handling and storage of tools and materials to prevent falling and flying objects.
3. Proper use of personal protective equipment (PPE), such as hard hats, face shields, and safety glasses.
4. Situational awareness training to help workers stay alert in high-risk areas.

By increasing safety awareness, organizations can reduce the number of struck-by incidents and create a more proactive safety culture.

3. Poor Visibility and Communication

Limited visibility on a worksite significantly increases the risk of struck-by incidents. Workers may not see an approaching vehicle, a suspended load, or flying debris in time to react. Common visibility issues include:

1. Dimly lit work areas, especially in warehouses, construction zones, and nighttime operations.
2. Dust, fog, or other environmental conditions that obscure vision.
3. Blind spots around heavy machinery, where operators may not see nearby workers.

Beyond visibility challenges, poor communication is another major risk factor. Many workplaces lack clear safety signals, warning signs, or proper communication protocols between workers and machine operators. 

When workers do not receive proper alerts about incoming hazards, the likelihood of accidents increases.

Employers can improve visibility and communication by:

1. Ensuring high-visibility PPE, such as reflective vests, is worn in all hazardous areas.
2. Using spotters and flaggers in areas with heavy equipment movement.
3. Installing clear signage and warning lights around high-risk zones.

Implementing standard hand signals and radio communication protocols for equipment operators and ground workers.

4. Equipment and Machinery Hazards

Heavy machinery plays a crucial role in industries like construction, warehousing, and manufacturing, but it also introduces significant struck-by risks. 

Forklifts, cranes, trucks, and power tools create movement-related hazards that can lead to severe injuries or fatalities.

Common equipment-related risks include:

1. Forklift and vehicle strikes: Workers walking near forklifts, trucks, or other moving vehicles may not be visible to operators, leading to collisions.
2. Crane and hoist accidents: Loads suspended in the air can swing unexpectedly, striking workers if they stand too close.
3. Flying debris from power tools: Saws, grinders, and drills can propel metal, wood, or other materials at high speeds, causing serious injuries.
4. Malfunctioning or poorly maintained machinery: Faulty brakes, broken safety features, or unstable equipment increase the likelihood of incidents.

To minimize these risks, companies must:

1. Perform routine equipment maintenance to prevent malfunctions.
2. Provide forklift operator training to better control the situation. 
3. Train operators on safe machinery handling and emergency procedures.
4. Enforce strict exclusion zones around active machinery.
5. Require proper PPE, such as safety goggles and helmets, to protect against flying debris.

By addressing these equipment hazards, workplaces can significantly reduce the risk of struck-by injuries and create a safer environment for workers.

Strategies for Preventing Struck-By Incidents

Preventing struck-by incidents requires a proactive approach that includes engineering controls, administrative policies, worker training, and proper use of personal protective equipment (PPE).

Since these incidents are among the leading causes of workplace injuries and fatalities, employers must take strategic steps to eliminate or reduce risks.

The following are effective strategies that can help prevent struck-by incidents.

1. Implementing Engineering Controls

Engineering controls are the first line of defense against struck-by hazards because they involve modifying the physical environment to reduce risks. 

Unlike administrative controls, which rely on worker behavior, engineering controls create permanent solutions that protect workers even if mistakes occur.

Some of the most effective engineering controls include:

1. Installing protective barriers and guardrails: Placing sturdy barriers around high-risk areas (such as construction zones or machine workstations) prevents workers from entering dangerous zones.
2. Using safety nets and debris containment systems: On multi-level work sites, these can catch falling objects and prevent them from striking workers below.
3. Securing tools and materials at height: Using tethering systems and tool lanyards prevents tools from accidentally falling from scaffolding, ladders, or elevated work platforms.
4. Machine guards and enclosures: Installing protective shields around moving parts reduces the risk of flying debris from machinery like saws, grinders, and presses.
5. Vehicle and equipment safety features: Installing backup alarms, automatic braking systems, and collision warning sensors on forklifts and heavy equipment can prevent vehicle-related struck-by incidents.

Employers can eliminate many struck-by hazards at the source by prioritizing engineering controls, making workplaces significantly safer. However, engineering solutions should always be combined with training and administrative measures to ensure maximum protection.

2. Enhancing Safety Training and Awareness

Training is one of the most effective ways to prevent struck-by incidents. It ensures that workers recognize hazards and know how to protect themselves. 

Many injuries occur due to a lack of awareness, improper equipment use, or failure to follow safety protocols. Employers must prioritize regular safety training sessions to keep safety in mind.

Key training components include:

1. Conducting routine safety training on struck-by hazards: Workers and supervisors should regularly attend training sessions that cover common risks, recent incidents, and best practices for prevention.
2. Providing PPE training: Workers must know how to properly wear and maintain personal protective equipment (PPE) like hard hats, face shields, and safety goggles. Providing PPE training to the worker can help them select and maintain personal protective equipment easily. 
3. Emphasizing situational awareness: Regular toolbox talks should focus on hazard identification and risk assessment. Training on WHMIS (Workplace Hazardous Materials Information System) is also essential for recognizing and managing workplace hazards. 

When equipped with the right knowledge, workers can make safer decisions and actively contribute to injury prevention.

3. Strengthening Communication and Signage

Clear and effective communication prevents struck-by incidents, especially in high-risk work zones. Many accidents happen because workers fail to see, hear, or understand warnings before an impact occurs.

To enhance communication:

1. Use spotters, flaggers, and standardized hand signals: These measures are essential for guiding equipment operators and warning nearby workers about moving machinery.
2. Install high-visibility warning signs: Proper signage should be placed in high-risk zones, such as areas where cranes, forklifts, or heavy equipment operate.
3. Require two-way radios or other communication devices: Workers near moving vehicles or in noisy environments should use radios, horns, or alarms to maintain real-time communication with co-workers and equipment operators.

Improved communication helps workers stay alert and avoid dangerous areas, reducing the risk of struck-by incidents.

4. Safe Worksite Practices and Policies

Creating and enforcing strict safety policies ensures that everyone on-site follows best practices to prevent struck-by injuries. Without clear policies, workers may take unnecessary risks or fail to recognize potential hazards.

Essential worksite safety practices include:

1. Establishing exclusion zones: Workers must avoid designated danger zones where cranes, forklifts, and other moving equipment operate.
2. Enforcing load securing procedures: Loose materials and equipment can become deadly projectiles if not properly secured. Employers should require strict load tie-down and lifting procedures.
3. Requiring pre-job hazard assessments: Before any work involving elevated loads, heavy machinery, or moving objects, a safety review must be conducted to identify risks and implement controls.

A well-defined safety policy creates a culture of accountability, ensuring all workers understand and follow the necessary precautions.

5. Personal Protective Equipment (PPE) Requirements

While PPE alone does not eliminate struck-by hazards, it is a critical last line of defense against serious injuries. Proper PPE can significantly reduce the severity of an impact when an incident occurs.

Employers must ensure:

1. Workers wear the correct PPE for the job: Hard hats, high-visibility clothing, steel-toe boots, and impact-resistant eye protection are essential for struck-by hazard protection.
2. Regular PPE inspections and replacements: Damaged or worn-out equipment must be replaced immediately to maintain effectiveness.
3. PPE policies are tailored to specific job hazards: Different tasks may require specialized protection, such as face shields for grinding work or reinforced gloves for material handling.

By enforcing strict PPE policies, employers help workers stay better protected in high-risk environments.

Tools and Technologies for Workplace Safety

Technology is crucial in reducing workplace injuries and fatalities, especially when it comes to struck-by incidents. 

Advances in wearable safety devices, automated systems, and AI-driven monitoring have significantly improved hazard detection and prevention. 

By integrating these tools into daily operations, employers can proactively protect workers from struck-by incidents and create a safer work environment.

The following technologies are helping prevent struck-by injuries and enhance workplace safety:

1. Wearable Safety Technology

Wearable technology is becoming a game-changer in workplace safety, helping protect workers in high-risk environments. 

Sensor-equipped vests, helmets, and armbands can alert workers in real-time when they are near moving equipment, falling objects, or restricted zones.

The following are the key benefits of wearable safety technology:

1. Proximity alerts: Wearables with sensors warn workers if they get too close to hazardous areas or moving vehicles.
2. Fatigue monitoring: Smart helmets can detect signs of fatigue or drowsiness, reducing the likelihood of accidents caused by exhaustion.
3. Real-time tracking: GPS-enabled wearables help supervisors monitor workers’ locations and ensure safe movement within job sites.

By integrating wearables, employers can significantly reduce struck-by incidents and enhance overall site safety.

2. Automated Safety Systems

Automation is an essential tool in minimizing human error and preventing workplace accidents. 

Collision avoidance technology and motion sensors help reduce the risk of struck-by incidents by detecting hazards before an impact occurs.

This is how automated safety systems improve workplace safety:

1. Collision avoidance technology: Installing collision detection systems on forklifts, cranes, and heavy machinery prevents accidents by alerting operators of nearby obstacles or workers.
2. Motion sensors and alarms: These systems detect unauthorized entry into high-risk zones and automatically trigger alerts to warn workers.
3. Automatic shutdown mechanisms: Some machinery is now equipped with auto-stop features, which immediately shut down operations if a worker enters a danger zone.

By integrating automation, companies can prevent accidents before they happen, ensuring a safer worksite for all employees.

3. Smart Worksite Planning and AI-Based Monitoring

Artificial intelligence (AI) is revolutionizing workplace safety by analyzing risks in real-time and identifying dangerous behaviors before an accident occurs. 

AI-powered systems use advanced monitoring tools to improve safety enforcement and compliance.

Here is how AI-driven monitoring improves safety:

1. AI-powered cameras: These cameras can detect unsafe behaviors such as workers not wearing PPE, stepping into high-risk areas, or standing too close to moving equipment.
2. Data-driven safety analysis: AI can analyze workplace incidents and identify patterns in near-misses. This helps employers make data-backed decisions to strengthen safety protocols. Modern incident investigation training also uses data-driven safety analysis to provide real-life examples of possible accidents. 
3. Predictive analytics: AI-based tools assess risk factors and anticipate potential hazards before injuries occur.

By adopting AI-powered safety solutions, companies can significantly reduce workplace hazards, improve response times, and enhance worker protection.

Conclusion

Struck-by incidents remain one of the most significant challenges to worker safety, particularly in industries like construction, manufacturing, and warehousing. 

These incidents, caused by falling, flying, swinging, or rolling objects, often result in severe injuries or fatalities, impacting workers, their families, and businesses alike. 

The key risk factors such as unsafe work environments, lack of training, poor visibility, and equipment hazards, highlight the need for proactive measures to protect workers from struck-by incidents.

To reduce these risks, workplaces must prioritize safety through comprehensive training, proper use of personal protective equipment (PPE), and the implementation of engineering controls like barriers and guardrails. 

Technology, such as proximity sensors on machinery and improved communication tools, can also play a vital role in preventing accidents. However, safety is not a one-time effort, it requires a culture of continuous improvement and worker engagement.

By promoting a safety-first mindset and encouraging workers to actively participate in hazard identification and reporting, industries can create safer environments for everyone.

Protecting workers from struck-by incidents is not just a regulatory obligation; it’s a moral responsibility. Let’s work together to ensure every worker goes home safely at the end of the day.