Do you work with hydraulic high-pressure tools? Their power comes from using pressurised hydraulic fluid to move extremely heavy loads. However, that same power also presents serious risks—especially when damaged equipment is used. One of those risks is a hydraulic injection injury. In this article, you'll learn what it is, why it happens and, most importantly, how to prevent it.
You may not realise it, but the hydraulic oil in these tools is pressurised to 700 bar (10,000 psi). To put that into perspective, the water pressure from a household tap is around 4 bar, while a typical pressure washer operates at approximately 100 bar. The video below clearly demonstrates what these pressures mean in practice.
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Power Comes with Risk: Hydraulic Oil Can Escape Under Extreme Pressure
The extremely high operating pressure of 700 bar (10,000 psi) poses a serious safety risk. If you're working with a damaged hydraulic cylinder or hose, hydraulic oil can escape at extremely high speed. Damage to a cylinder is not always visible from the outside, and hose damage can be difficult to detect. Yet the risk is significant: escaping hydraulic oil can reach speeds of up to 400 m/s.
Seek Emergency Medical Attention Immediately
Because of the pressure and velocity, hydraulic oil can penetrate the skin and enter the body—for example through an arm or leg. This is known as a hydraulic injection injury. The body cannot break down the injected oil, and it may spread through the surrounding tissue or even enter the bloodstream.
A hydraulic injection injury is a medical emergency. Even if the wound appears small or painless, seek immediate treatment at the emergency department of a specialist hospital. Early diagnosis and surgical treatment are essential to minimise permanent damage.
The Consequences Can Be Severe
The consequences of a hydraulic injection injury can be life-changing. Without prompt and appropriate medical treatment, the injury can lead to permanent tissue damage, loss of function, amputation or, in rare cases, even death. Many victims are unable to return to their normal work or can only do so with lasting physical limitations.
Reducing the Risk Starts with Awareness
Fortunately, the risk of hydraulic injection injuries can be significantly reduced by following a few essential safety measures.
1. Raise Awareness
Employers should ensure that both operators and equipment managers understand how to use hydraulic tools safely.
Provide training on:
Correct and safe operation of hydraulic equipment
Proper storage and handling
The risks associated with high-pressure hydraulic systems
Recognising damaged equipment before use
A dedicated hydraulics safety toolbox talk is an effective way to increase awareness throughout the organisation.
2. Carry Out Regular Inspections
Hydraulic equipment should be inspected and maintained at regular intervals to identify defects before they become hazardous.
Routine inspections help you:
Detect wear and hidden damage at an early stage
Replace unsafe equipment before failure occurs
Improve employee safety
Reduce unplanned downtime and unnecessary operating costs
3. Perform Dynamic Testing
In addition to routine inspections, hydraulic equipment should undergo dynamic testing.
Unlike a static pressure test, dynamic testing evaluates the equipment under realistic operating conditions at its maximum rated capacity. This allows hidden defects to be detected across the full stroke or working range of the tool—issues that may remain unnoticed during static testing alone.
Work Safely—Prevent Hydraulic Injection Injuries
Safe working practices, regular inspections and proper maintenance are essential when using hydraulic tools. By raising awareness and ensuring equipment is correctly maintained, employers and operators can greatly reduce the risk of hydraulic injection injuries and other serious accidents.
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What should you look out for? What are the risks? How can you prevent accidents—and avoid unnecessary downtime in your daily operations?
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Knowledge file hydraulics
Hydraulic high-pressure tools deliver tremendous force. But with that power comes responsibility. What should you look out for? What are the risks? How can you prevent accidents and avoid unnecessary downtime in your daily operations?
In this white paper, Holmatro and Mennens share practical advice, expert insights and best practices to help you work safely and confidently with hydraulic equipment.
