Overview
Crush injury at work
A machinery crush incident occurs when a body part is compressed by moving equipment, a closing mechanism, a load or stored energy. The evidence must identify the precise trapping surfaces, movement source, controls and duration rather than rely on the general word “crush”.
General information only. It is not legal advice for your individual matter, and past outcomes do not guarantee future results.
How this accident commonly happens
Crush injury at work can occur through a press, gate, ram, clamp, roller or attachment closes unexpectedly and stored hydraulic, pneumatic, gravitational or mechanical energy is released. The incident history should identify the task, equipment, location and sequence of events rather than relying on the job title alone.
A worker clears, aligns or adjusts material within a danger zone.
Guarding, interlock, isolation or communication does not control movement.
People commonly exposed
People commonly exposed include machine operators, process workers and packers and maintenance, cleaning and fault-response workers. Employment records should identify each person's task, employer and position in the work area when the incident occurred.
Warehouse, construction and agricultural workers handling plant, loads or attachments.
Common injuries from this accident type
Medical records after a crush injury at work may identify hand, finger, foot and limb crush injury and fracture, tendon, nerve, vascular and compartment injury. Each diagnosis should be linked to the event or exposure and to the worker's actual functional change.
Amputation, scarring and complex pain consequences.
Psychological symptoms after entrapment or serious bodily threat.
Evidence that may help
For a crush injury at work, the first evidence to preserve includes machine and trapping-point photographs or diagrams after safe isolation and guarding, interlock, emergency stop and control-system records. It is most useful when dates, people, equipment, duties and later medical histories tell a consistent account.
- Lockout, isolation and stored-energy procedures.
- Maintenance, fault, production and prior incident records.
- CCTV, witness accounts and measurements of the movement.
- Hospital, surgical, hand therapy, rehabilitation and capacity evidence.
Common insurer disputes
After a crush injury at work, an insurer may dispute the accepted injury is limited to a wound and omits nerve, tendon or complex consequences and the mechanism is disputed because the machine was reset before inspection. The written decision should be answered with evidence directed to those stated reasons.
Ongoing surgery, therapy, prosthetic or pain treatment is challenged.
Duties are said to be suitable despite dexterity, sensation, lifting or machinery-exposure limits.
Treatment, rehabilitation, and surgery issues
Urgent care may involve vascular, crush, fracture, wound, tendon, nerve or compartment assessment. Long-term treatment may include surgery, hand therapy, scar, pain, prosthetic, rehabilitation or psychological care. If treatment is disputed after a crush injury at work, the request should explain the accepted diagnosis, expected functional benefit and reasonable alternatives.
Reports should describe function, not only appearance or pain.
Duties should address machinery, bilateral hand use, pace, lifting and medication.
Weekly payments and work capacity
Work capacity after a crush injury at work may turn on grip, sensation, dexterity, standing, lifting and safe machine control may be affected and production roles can remain unsuitable even when described as light because of pace and hazard exposure. Proposed duties must be compared with the real task demands and the worker's ability to sustain them for the proposed hours.
Weekly-payment decisions should compare actual output and hours with medical restrictions.
Permanent impairment and lump sum issues
Stable limb, digit, nerve, scarring, amputation or psychological impairment may require separate NSW methods. Crush severity and surgery do not by themselves set WPI. Any WPI assessment after a crush injury at work occurs after stabilisation under the NSW method for the accepted body system; the accident or surgery alone does not determine a percentage.
Objective sensory, motor, motion and structural findings may be relevant depending on diagnosis.
Primary psychiatric impairment is assessed separately from physical impairment under the NSW Guidelines. A psychological condition secondary to a physical injury is not assessed for permanent impairment.
Other claim pathways that may need investigation
A manufacturer, host business or maintenance contractor may raise another recovery issue. TPD insurance may be separate and relevant to lasting total incapacity. These issues are separate from workers compensation and depend on the particular facts.
If the event met the Work Health and Safety Act definition of a notifiable incident, sections 38 and 39 may result in notification and site-preservation records. Those safety records may assist the facts, but they do not determine workers compensation entitlement.
How NSW Work Injury Claim can help
For a crush injury at work, assistance may involve identify the trapping surfaces and energy source and preserve controls, fault and maintenance evidence. The purpose is to identify the disputed decision and the evidence needed for the next step, not to promise an outcome.
Check every diagnosed consequence and functional restriction.
Organise treatment, work capacity and impairment evidence.
Common questions about crush injury at work claims
Why is “crush injury” not a complete diagnosis?
It describes a mechanism. Medical evidence should identify the resulting fracture, nerve, tendon, vascular, scarring, amputation or other condition.
What if the machine was repaired immediately?
Maintenance, control data, photographs, witnesses and prior fault records may still assist. A prompt preservation request is useful.
Can pain treatment be disputed?
Yes. The request should explain diagnosis, clinical findings, prior treatment, expected benefit and the insurer’s reasons.
Are one-handed duties automatically suitable?
No. The real task, pace, safety, dominant hand, bilateral requirements and hours must match restrictions.
Does a crush event guarantee lump sum compensation?
No. Any lump sum issue depends on stable accepted permanent impairment and the applicable legal requirements.
Workers compensation help by location
We assist workers across NSW. Choose a location guide for contact options, appointment information and links to the claim issues discussed on this page.
- warehouse and logistics injury claims in Blacktown
- work injury assistance for Liverpool transport workers
- manual handling and plant incident guidance for Fairfield workers
Browse NSW workers compensation location guidesRead how IRO and ILARS funding is assessed
Need help after a NSW workplace accident?
If you have an insurer decision, unclear capacity certificate or treatment dispute after a workplace accident, we can help identify the issue and organise the evidence. Where ILARS funding is approved, eligible legal costs and necessary disbursements may be covered.
Related injury guides
Related accident mechanisms
Later or multiple conditions after the incident
Related NSW workers compensation guides
Official sources
- SafeWork NSW: factory machinery crush incident
- Workers Compensation Act 1987 (NSW), including sections 9 and 9A
- Workplace Injury Management and Workers Compensation Act 1998 (NSW), section 4 and Schedule 1 worker provisions
- Work Health and Safety Act 2011 (NSW), sections 35-39 on notifiable incidents and site preservation
- SIRA: weekly payments and work capacity
- SIRA: medical, hospital and rehabilitation expenses
- SIRA: NSW Guidelines for the Evaluation of Permanent Impairment
- SafeWork NSW: plant, machinery and equipment
Last reviewed: 19 July 2026
