A lack of maintenance or poor-quality maintenance causes thousands of on-the-job accidents every year. Maintenance workers face significant risks associated with their jobs.
According to Bureau of Labor Statistics reports, deaths related to poor maintenance have increased in some years and remain a significant concern.
Accidents from maintenance can result from falls when working at height, confined spaces or harsh environments when accessing equipment, shocks and burns if power is not properly isolated, injuries from moving machine parts, musculoskeletal strain from awkward postures, and exposure to asbestos or hazardous chemicals.
Types of maintenance
- Routine or preventive maintenance keeps equipment working — such as a scheduled overhaul or replacement.
- Corrective maintenance gets broken equipment up and running again.
- Predictive maintenance uses tests to identify when maintenance is or will soon be needed.
How to make maintenance safer
- Emphasize planning and scheduling for every maintenance task.
- Invest in affordable technology, such as a thermographic camera to detect temperature variations that can reveal failing motors or bearings.
- Ensure supervisors convey the right message consistently. Employees should understand that shortcuts, like failing to lock out equipment before maintenance, increase accident risk.
- Teach workers to intervene. Reporting unusual noises or unsafe conditions helps prevent incidents before they happen.
- Get employees engaged and accountable. A safety culture makes everyone responsible for safe maintenance, not just the safety or maintenance department.
For guidance on reducing liability and workers compensation claims through proper maintenance, see Importance of Proper Maintenance in Reducing Liability and Workers Compensation Claims.
For industry-specific guidance on vehicle and equipment service operations, see Reducing Liability and Workers Compensation Claims through Proper Maintenance.
For more information on maintaining your safety maintenance program, just ask an agent.
Frequently Asked Questions
What are the most common hazards during maintenance?
Common hazards include falls, electrical shocks, burns, contact with moving parts, musculoskeletal strain from awkward positions, and exposure to hazardous materials.
How does lockout/tagout help prevent maintenance injuries?
Lockout/tagout procedures isolate energy sources and prevent unexpected equipment startup, significantly reducing the risk of shocks, burns, and crush injuries.
When should predictive maintenance be used instead of routine maintenance?
Use predictive maintenance when monitoring equipment condition (like vibration or temperature) can identify impending failures, allowing targeted repairs and avoiding unnecessary downtime.
What should I ask an insurance agent about maintenance-related risks?
Ask about coverage for maintenance operations, common exclusions, risk-control resources, and whether loss-prevention programs affect premiums or claims handling.