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Hydraulic Safety 101: Preventing High-Pressure Injection Injuries
- PSI Hydraulics
- Jul 1
- 3 min read
Hydraulic systems are powerful, precise, and essential across industries—from construction to manufacturing and beyond. But with that power comes risk. One of the most severe and often misunderstood dangers is the high-pressure injection injury. This type of injury can occur in a split second and lead to long-term, life-altering consequences if not treated properly.
Understanding these hazards—and how to prevent them—is not optional. It’s critical. At PSI Hydraulics, safety is built into every solution we provide. This guide covers what high-pressure injection injuries are, how they happen, and, most importantly, how to protect your team and your equipment.
What Is a High-Pressure Injection Injury?
A high-pressure injection injury occurs when a fluid under extreme pressure is accidentally injected into a person’s skin. Unlike typical puncture wounds, these injuries may look minor on the surface but can cause extensive internal damage. In hydraulic systems, this often involves oil or other hydraulic fluids forced through tiny breaches or pinhole leaks in hoses or fittings.
These injuries can happen at pressures as low as 100 PSI—but most hydraulic systems operate at pressures far greater than that, often exceeding 3,000 PSI. The combination of speed, force, and fluid type makes these incidents especially dangerous.
How Do High-Pressure Injection Injuries Happen?
Most often, these injuries occur during maintenance or troubleshooting. Common causes include:
Pinhole leaks in pressurized hoses
Damaged or worn seals and fittings
Improper or rushed repairs
Contact with pressurized components during testing
In many cases, the injured person doesn’t realize the severity until it’s too late. The fluid can penetrate deep into tissues, causing chemical burns, tissue necrosis, or systemic toxicity. Immediate medical attention is always required.
Warning Signs and Immediate Response
Recognizing a potential injection injury is key to mitigating damage. Look for:
A small puncture wound, often painless at first
Swelling, numbness, or a tingling sensation
Stiffness or limited mobility
If an injection injury is suspected:
Do not delay—seek emergency medical attention.
Do not try to squeeze or cut the wound.
Inform medical personnel that it’s a hydraulic fluid injection.
How to Prevent High-Pressure Injection Injuries
1. Conduct Regular Equipment Inspections
Check hoses, fittings, seals, and all pressurized components regularly. Look for signs of wear, cracking, or damage. Replace components at the first sign of degradation.
2. Use Proper Protective Equipment (PPE)
Face shields, gloves, and long sleeves provide critical protection—especially when testing or working near live systems. Ensure PPE is rated for the pressures and materials involved.
3. Depressurize Before Servicing
Always depressurize the hydraulic system before performing any maintenance. Don’t rely on visual cues alone; use system gauges to verify pressure levels.
4. Use Leak Detection Tools Safely
Never use hands to check for leaks. Use a non-conductive piece of cardboard, wood, or a specialized tool to detect pinhole leaks safely.
5. Provide Ongoing Training
Train all operators and technicians on the risks and response protocols for high-pressure injection injuries. Refresh this training regularly to maintain awareness.
Why Regular Maintenance Matters
Preventative maintenance is your first line of defense against high-pressure hazards. A well-maintained hydraulic system is not just more efficient—it’s safer. Proactive service prevents unexpected failures, protects your personnel, and extends equipment lifespan.
At PSI Hydraulics, we don’t just repair—we inspect, test, and verify. Our team looks beyond the obvious to identify risk factors before they become injuries.
Partner with a Shop That Prioritizes Safety
When you choose PSI Hydraulics, you’re choosing a partner that understands the stakes. Our full-service shop is built around precision, safety, and reliability. From cylinder repair to custom hose kits and on-site service, we bring decades of expertise to every job.
We don’t cut corners, and we don’t guess. We engineer solutions that perform safely under pressure.
Stay Safe. Stay Operational.
High-pressure injection injuries are preventable—with the right knowledge, habits, and partners. Make hydraulic safety a non-negotiable part of your operation.
Need a second set of eyes on your system? Let’s talk. Contact PSI Hydraulics today to schedule a safety-focused inspection or consultation.
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