James had been working in construction for over 20 years. He thought he’d seen everything. He’d spent plenty of time navigating busy sites, working on scaffolding, and operating heavy machinery. He always took safety seriously. One afternoon, he lost his balance on some scaffolding and fell four floors. Despite immediate medical attention, James didn’t survive.
Stories like James’ are far too common in high-risk industries like Construction, Manufacturing, and Utilities. In 2023/2024, the construction sector recorded 51 fatalities – the highest of any industry in the UK – while manufacturing saw 16 deaths. With the fatal injury rate in construction nearly five times the all-industry average, it’s clear that every precaution must be taken to keep workers safe.
As a safety manager, being aware of the common causes of workplace fatalities is essential. It’s the only way you can mitigate risks and create a safer workplace. In the following blog post, we’ll cover some of the common causes of workplace fatalities across construction, manufacturing, and utilities.
Falls
In the construction industry, falls from a height were the cause of 52% of the 51 fatal incidents in 2023/2024. The nature of construction work makes the industry prone to these types of incidents. Construction sites are busy places. Workers may fall due to unsafe ladders, scaffolding failures, or human error.
In manufacturing, falls from a height accounted for 21% of the 21 fatalities in 2024. Slips, trips, and falls from platforms occur frequently. Uneven or slippery surfaces coupled with poor housekeeping make manufacturing sites prime locations for falls. In 2016, Volvo was fined £900k after a worker fell from a worn step ladder and had to be placed in a medically induced coma for two weeks. The worker still suffers from complications.
Utilities workers can experience falls during their routine maintenance work. Activities near power lines, poles, and substations leave utilities professionals vulnerable to these types of injuries.
Struck-By Incidents
Struck-by incidents occur when a worker comes into forcible contact with an object or piece of equipment. In the manufacturing sector, struck-by incidents are tied with falls for the most common cause of workplace fatalities. In 2024, they made up 21% of fatalities.
Why could this be? Risks are especially rife in fast-paced production environments. With plenty of moving equipment on the job, there’s potential for disaster around every corner. Robotic arms, forklifts, and other heavy machinery create constant hazards. Falling objects, moving conveyor belts, or improperly secured loads leave plenty of room for danger.
Busy construction sites also create the perfect storm for struck-by incidents. Heavy moving machinery and falling debris places workers at risk. Struck-by incidents were the third most common cause of fatalities within the construction industry in 2024, accounting for 11% of deaths.
Workers in the utilities sector are also threatened by the nature of their job. Falling tools, equipment, or debris are common causes of workplace fatalities here.
Machinery and Equipment Accidents
Machinery and equipment accidents are a leading cause of injury in the manufacturing and utilities sectors. These incidents stem from improper use, malfunction, or lack of safeguarding on machines. In 2024, 16% of fatal injuries and 12% of non-fatal injuries in the manufacturing sector were due to contact with moving machinery.
In the utilities industry, machinery-related incidents are commonplace. Workers face risks from high-powered equipment that can be treacherous to operate or even get near to.
Confined Space Hazards
There are risks of confined space hazards across the construction, manufacturing, and utilities sectors. Confined spaces pose significant risks due to limited oxygen flow and inadequate ventilation. A restricted space also makes it harder for workers to escape in an emergency.
A lack of fresh air can lead to dangerous conditions. Poor air quality can damage the lungs and increase the risk of heart disease, stroke, and certain cancers. The nature of the work within the construction, manufacturing, and utilities industries also means workers may be coming into contact with dangerous dusts, gases, vapours, smoke, and fumes. Studies have found that 50% of demolition workers, 40% of insulation installers, 30% of pipefitters, and 20% of electricians are exposed to dangerous asbestos while completing their duties.
Employees in the utilities and construction sectors are at risk due to their work, which may take them into sewers, tunnels, underground, in electrical vaults, or other confined spaces. Trenching and excavation tasks are also hazardous.
Manufacturing often produces oxygen-deficient environments. Warehouses that aren’t fitted with the proper filtration systems expose workers to toxins. Warehouse equipment may also entrap workers in a location where it’s difficult to get out.
Electrical Hazards
Electricity is all around us, so electrical incidents can happen across all sectors. However, some of the activities performed within the construction and utilities sectors can make these accidents more prevalent. Electrical injuries include electric shock, electrical burns, loss of muscle control, and thermal burns. A voltage as low as 50 volts can have an impact on the body.
In construction and utilities, workers run the risk of electrical hazards from working with things like exposed wiring, power lines, improper grounding and faulty equipment. Contact with electricity or electrical discharge accounted for 5% of all fatal injuries within the construction sector in 2024.
Caught-In or Between Accidents
In construction, 11% of all fatal injuries 2024 were caused by being trapped by something collapsing/overturning. Construction and utilities workers must face risks associated with operating heavy machinery, working on unstable structures, or even being trapped by trench collapses.
In manufacturing, workers may get entangled with machines, or suffer from conveyor belt accidents. Even if an injury isn’t fatal, the risk of losing limbs or dealing with crushed body parts is high.
Smarter safety starts with EcoOnline
While the above may be the most common causes of workplace fatalities, this list is by no means exhaustive. It’s essential for companies to continuously stay on top of their safety responsibilities for the sake of everyone in their workforce.
EcoOnline’s cloud-based EHS solution makes this easy to do by offering unparalleled health and safety visibility across your organisation. Say goodbye to reactive safety and hello to a frictionless system that gives you all the insights you need to make the smartest safety decisions for your people. Because everyone deserves a safe place to work.
