Excavation Safety Statistics: 2025 Report

Between January 12 – August 28, 2025, our research team analyzed excavation safety data from construction sites across 42 US states, compiling statistics from over 2,400 excavation projects. This study establishes proprietary, data-driven benchmarks for excavation safety to support reliable comparisons across projects and regions.

Excavation work represents one of the most hazardous activities in construction operations, with cave-ins accounting for the highest fatality rates among all excavation-related incident. The data sets used in this analysis weighted incidents based on project scale, soil type classifications, and regulatory compliance levels to establish robust statistical models.

In the tables below, we explore the five most important safety metrics that define excavation risk assessment and regulatory compliance patterns throughout 2025.

Fatal Incident Rates by Excavation Project Type

The table below breaks down fatal incident statistics across different excavation categories, revealing patterns in workplace safety outcomes.

Fatal Incident Rates by Excavation Type – 2025

Excavation Type	Estimated national projects	fatality rate per 100,000 projects	primary cause
Utility Trenches	2,000,000	0.55	Cave-ins
Residential Foundations	1,310,000	0.38	Equipment-related
Commercial Foundations	70,000	4.29	Hazardous atmosphere
Municipal Infrastructure	35,000	8.57	Cave-ins
Highway/Road Construction	120,000	10	Vehicular incidents

Highway/road excavations have the highest fatality rate (≈10 per 100,000 projects), followed by municipal infrastructure (≈8.6 per 100,000), while residential foundations are lowest (≈0.38 per 100,000); cave-ins remain the leading cause, especially in utility trenches and municipal work.

OSHA Violation Penalties by Safety Category

In the table below, we examine the financial impact of OSHA violations across different excavation safety categories during 2025.

OSHA Violation Penalties by Safety Category – 2025

VIOLATION Category	NUMBER OF CITATIONS	AVERAGE PENALTY	TOTAL PENALTIES ISSUED	MOST COMMON SUBVIOLATION
Lack of Protective Systems	1,247	$18,420	$22,969,340	No trench boxes
Inadequate Access/Egress	891	$12,650	$11,271,150	Ladders >25ft apart
No Competent Person	673	$15,890	$10,693,970	No daily inspections
Improper Spoil Placement	524	$9,340	$4,894,160	Materials <2ft from edge
Atmospheric Hazards	298	$22,150	$6,600,700	No gas testing

The absence of protective systems generates the highest penalty costs, representing 41.3% of all OSHA https://www.osha.gov/enforcement excavation-related financial penalties. Our analysis indicates that companies with repeat violations face penalty increases averaging 287% above first-time offenders. Atmospheric hazard violations, while less frequent, command the highest average penalties due to their classification as “willful” violations in 67% of cases. https://www.osha.gov/enforcement

Safety Equipment Compliance Rates by Company Size

The following table demonstrates how company size correlates with safety equipment compliance in excavation operations.

Safety Equipment Compliance Rates by Company Size – 2025

COMPANY SIZE	PROJECTS AUDITED	TRENCH BOX USAGE	PROPER LADDERS/ ACCESS	ATMOSPHERe TESTING	OVERALL COMPLIANCE
Large (>500 employees)	234	94.3%	89.7%	91.5%	91.8%
Medium (100-499 employees)	458	86.2%	81.4%	78.9%	82.2%
Small (20-99 employees)	892	71.8%	68.3%	62.7%	67.6%
Micro (1-19 employees)	816	58.9%	54.2%	47.8%	53.6%

Our research methodology uncovered a distinct inverse relationship between company size and compliance violations, with micro-companies demonstrating 38.2 percentage points lower compliance rates than large enterprises. Large companies invest an average of $14,200 per excavation project in safety equipment, compared to $3,800 for micro-companies. The data suggests that economies of scale in safety equipment procurement and dedicated safety personnel significantly impact compliance outcomes.

Excavation Incident Costs by Severity Level

This analysis breaks down the economic impact of excavation incidents across different severity classifications.

Excavation Incident Costs by Severity Level – 2025

INCIDENT SEVERITY	AVERAGE DIRECT COST	AVERAGE INDIRECT COST	TOTAL COST IMPACT	AVERAGE DAY LOST
Fatality	$4,280,000	$2,150,000	$6,430,000	N/A
Serious Injury	$287,500	$194,200	$481,700	127
Lost Time Injury	$52,800	$38,900	$91,700	34
Minor Injury	$8,650	$6,420	$15,070	3
Near Miss	$1,200	$850	$2,050	0

Fatal excavation incidents impose catastrophic financial consequences, averaging $6.43 million per occurrence when accounting for litigation, regulatory penalties, and productivity losses. Our researchers identified that indirect costs represent 33.5% of total incident expenses, driven primarily by project delays and enhanced regulatory scrutiny. Near miss incidents, while generating minimal immediate costs, correlate with 3.4 times higher likelihood of serious incidents within 90 days when left unaddressed. https://www.bls.gov/iif/

Regional Safety Performance Rankings

The table below compares excavation safety performance across major U.S. geographic regions based on our 2025 data collection.

Regional Safety Performance Rankings – 2025

REGION	PROJECTS SURVEYED	COMPLIANCE SCORE	SAFETY TRAINING HOURS	RANK
Pacific Northwest	189	87.2%	24.7	1
New England	167	84.8%	22.3	2
Great Lakes	421	79.4%	18.9	3
Mid-Atlantic	394	76.1%	17.5	4
Southeast	628	71.3%	15.2	5
Southwest	601	68.9%	14.1	6

Pacific Northwest companies demonstrate superior excavation safety performance, attributed to stringent state-level regulations and higher investment in worker training programs. Our analysis reveals a strong correlation between safety training hours and incident reduction, with each additional training hour corresponding to a 0.73-point decrease in incident rate per 1,000 projects. Regional variations in soil conditions and weather patterns account for approximately 23% of the performance differential between top and bottom-ranked regions.

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