Hydraulic systems are a cornerstone of modern industrial machinery, widely used in construction, manufacturing, and agriculture. Despite their efficiency and power, these systems pose significant risks, particularly hydraulic injection injuries. While these injuries might appear minor initially, they can quickly escalate into life-threatening medical emergencies if not treated properly.
In this article, we’ll explore what hydraulic injection injuries are, their dangers, and the best practices for dealing with them. Let’s also look at how you can prevent these injuries in the workplace.
What Is a Hydraulic Injection Injury?
A hydraulic injection injury occurs when high-pressure fluid from a hydraulic system punctures the skin and enters the body. These injuries often happen when a worker handles equipment that operates at pressures exceeding 2,000 to 4,000 psi (pounds per square inch). At such pressures, even a pinhole-sized leak can eject fluid with enough force to penetrate protective gloves and skin.
Common causes of hydraulic injection injuries include:
- Leaks in hydraulic hoses or fittings.
- Accidental disconnection of pressurized lines.
- Improper maintenance or handling of hydraulic systems.
Why Are Hydraulic Injection Injuries Dangerous?
The danger of hydraulic injection injuries lies in their deceptive nature. The entry wound may appear small or superficial, leading workers to underestimate the severity. However, the injected fluid can cause:
- Tissue damage: Hydraulic fluid spreads rapidly, damaging nerves, muscles, and tissues.
- Infections: Contaminated fluids introduce harmful bacteria, increasing the risk of infection.
- Toxic reactions: Hydraulic fluids often contain toxic substances that can lead to severe chemical burns or systemic poisoning.
- Amputations: Delayed treatment can result in severe necrosis (tissue death), potentially leading to amputation.
According to OSHA, hydraulic injection injuries require immediate medical attention, as irreversible damage can occur within hours.
What to Do If a Hydraulic Injury Occurs
1. Stop Work Immediately
As soon as an injection injury occurs, shut down the hydraulic equipment and isolate the area to prevent further injuries.
2. Seek Immediate Medical Attention
Time is critical. Even if the injury seems minor, call emergency medical services (EMS) or go to the nearest hospital immediately. Inform the medical team that it’s a hydraulic injection injury, as specialized treatment is required.
3. Do Not Delay Treatment
Avoid the temptation to wait and see if the injury worsens. Hydraulic injection injuries are medical emergencies, and delays in treatment can lead to amputation or even death.
4. Avoid Self-Treatment
Do not try to squeeze out the fluid, clean the wound, or apply home remedies. These actions can worsen the injury or spread the fluid further into the tissue.
5. Provide Information to Medical Personnel
When you arrive at the hospital, share as much information as possible about the hydraulic system and fluid involved. This helps doctors determine the appropriate treatment, including surgery or specific antidotes for toxic substances.
Preventing Hydraulic Injection Injuries
Prevention is always better than cure. Here are some proactive measures to minimize the risk of hydraulic injection injuries:
1. Regular Maintenance of Hydraulic Equipment
- Inspect hoses, fittings, and components regularly for wear, cracks, or leaks.
- Replace damaged parts immediately, even if the equipment seems functional.
2. Use Proper Personal Protective Equipment (PPE)
- Wear gloves, safety glasses, and protective clothing designed to withstand hydraulic fluid exposure.
- Ensure PPE meets industry standards for puncture and chemical resistance.
3. Train Employees
- Provide comprehensive training on the operation and maintenance of hydraulic systems.
- Teach workers how to identify potential hazards, such as leaking hoses or improperly connected fittings.
4. Depressurize Systems Before Maintenance
- Always release hydraulic pressure before inspecting, disconnecting, or replacing components.
- Use manufacturer-recommended tools and procedures for depressurization.
5. Avoid Direct Contact with Pressurized Lines
- Never place your hands or body near suspected leaks or pressurized lines.
- Use a piece of cardboard or wood to detect leaks instead of your hands.
Injury Treatment Overview
Medical treatment for hydraulic injection injuries often involves:
- Immediate debridement: Removing dead or contaminated tissue to prevent further damage.
- Antibiotics: Administering antibiotics to prevent or treat infections.
- Surgical intervention: In severe cases, surgery may be required to remove injected fluid and repair damaged tissues.
- Long-term care: Physical therapy and follow-ups may be necessary for recovery and to regain mobility.
Conclusion
Hydraulic injection injuries are rare but highly dangerous, requiring immediate and specialized medical attention. Understanding the risks and knowing how to respond can save lives and prevent severe complications. Employers must prioritize training, proper maintenance, and the use of protective equipment to create a safer workplace.
By fostering a strong safety culture and adhering to OSHA guidelines, you can minimize the risks associated with hydraulic systems and ensure the well-being of your workforce.
Less than 1% of hydraulic systems are fitted with devices that make it possible for workers to detect and or diffuse stored energy post lockout.
I strongly urge OSHA to remove “hydraulics” from the Control of Hazardous Energies standard.