The Dangers of Using Chainsaws

Chainsaw Hazards and Tips to Stay Safe

Chainsaws are indispensable tools for a variety of professionals, from arborists to landscapers to forestry workers. While they offer unmatched efficiency in cutting through wood, they also pose significant risks when used improperly or without the necessary safety precautions.

Many homeowners, farmers, and small wood lot landowners also use chainsaws for cutting trees or clearing brush. Cutting your own firewood is a common reason for Pennsylvania residents to use a saw. But far too often, we see non-professionals using chainsaws improperly, and unfortunately, this can lead to very serious injuries.

The national statistics on chainsaw-related injuries are quite sobering. From 2018 to 2022, nearly 128,000 people were treated in a US emergency department for chainsaw-related injuries. Over the study period, an estimated 70 patients per day presented to a U.S. emergency department with a chainsaw-related injury.

Previous research at Penn State illustrated the dangers to loggers and landscapers of felling trees with chainsaws. We recently conducted an additional study that examined the incidence of chainsaw-related injuries and fatalities across a five-year period (2018-2022). Those data are presented below, along with some recommendations for safe practices that should be followed by anyone using a chainsaw. Understanding the hazards associated with chainsaws and implementing safety measures is vital to preventing injuries and fatalities. This article explores the dangers of using chainsaws, common injury mechanisms, and practical methods to mitigate these risks.

Hazards of Using Chainsaws

Chainsaws are powerful machines that can cause serious harm if not handled with care. Most professionals are well-trained and aware of the hazards, but new employees and occasional users of saws may not be as aware. Below are some of the primary hazards associated with chainsaw use:

Contact Injuries

The most immediate and severe hazard when using a chainsaw is the risk of contact with the moving chain. A chainsaw chain rotates at high speeds, making it capable of causing deep lacerations or amputations if it makes contact with skin or bones. Cutting teeth on the chain are designed for efficiency in cutting wood, but they are equally effective at inflicting serious injury.

Kickback

Kickback occurs when the tip of the chainsaw blade comes into contact with an object or is suddenly stopped. This causes the chainsaw to forcefully "kick back" toward the user. Kickback is a leading cause of chainsaw-related injuries. It can happen unexpectedly, especially when cutting overhead, making it difficult for practitioners to avoid.

Recoil

Recoil is related to kickback but is less abrupt. It happens when a chainsaw jerks backward or to the side while being used. This movement can be enough to cause the operator to lose control, potentially leading to an injury. Recoil is often caused by the saw not being properly braced, resulting in instability.

Debris and Wood Chips

The powerful rotation of the chain sends sawdust, chips, and other debris flying. These flying particles can cause eye injuries, and inhaling wood dust over extended periods can also lead to respiratory issues.

Location-Specific Hazards

Working in certain environments—such as on sloped ground, near power lines, or in dense forests—poses additional risks. Uneven surfaces can cause the operator to lose footing, while nearby trees or branches can fall unpredictably. In confined spaces, the risk of getting struck or trapped by a falling tree is increased.

Carbon Monoxide Exposure

Chainsaws, particularly gas-powered models, produce carbon monoxide (CO) as a byproduct of combustion. Using saws for longer periods or in areas with poor ventilation can lead to exposure to CO, a colorless and odorless gas that can cause serious health issues such as dizziness, nausea, and weakness.

Physical Limitations

Using a chainsaw can be physically challenging, especially for those who are older or not in good physical condition. Users can easily get tired while cutting and that can lead to mistakes that might otherwise have been avoided.

Injury Statistics

Our research shows that from 2018 to 2022, an estimated 127,944 people were treated in an emergency department for chainsaw-related injuries; these represented both occupational and non-occupational victims. The national mean age estimate in this population was 47 years old, with the oldest patient being 91 years old. Most of the patients were male, and almost 65% of them were white. It was interesting that occupational chainsaw injuries went down in the first year of the pandemic (2020), while the number of non-occupational injuries was nearly 50% higher than the longer-term average.

Occupational Injuries

The number of occupational victims was low relative to the total number seen in an ER; there were 202 non-fatal and 57 fatal occupational chainsaw-caused injuries during 2018-2022. All victims were male.

Landscaping incurred the highest number (n=33) of both fatal and non-fatal (n=92) injuries. By contrast, the agriculture and forestry sectors incurred 24.6% (n=14) of all fatal occupational injuries and 7.4% (n=15) of nonfatal injuries. The construction industry sector reported 8.8% (n=5) of fatal and 18.3% (n=37) of nonfatal injuries. Pennsylvania had the third highest number of occupational chainsaw injuries of all states.

It is noteworthy that while chainsaws were responsible for the highest number of incidents overall (53.3%), with a significant proportion being nonfatal (63.9%), there are a variety of additional hazards that saw users must be aware of. For example, "trees, tree limbs, and logs" hitting an operator accounted for a high percentage of fatal incidents. Falls from a tree were also significant as an additional cause of injuries and fatalities (notable for tree care professionals but rare with non-occupational victims). Even exposure to electricity was a source of fatalities for chainsaw users.

Occupational fatalities from chainsaw use were fairly even across the year, although January was statistically the most hazardous month. Nonfatal injuries followed a similar pattern. In contrast, the non-occupational data show that most injuries occurred from March through October. Users in winter months must be aware of cold-related hazards (e.g., numb hands) that could contribute to injuries, while users in hot summer months must be aware of hazards exacerbated by overheating or dehydration.

Non-Occupational Injuries

Nearly 95% of non-occupational victims were male, and the vast majority were white. More than half of the incidents occurred at the victim’s residence.

The most common injury was an open wound (76%), followed by fractures (7%) and other soft tissue injuries (5%). The upper and lower extremities were the two most injured body parts, accounting for more than 80% of the patients. Head and neck injuries were often fatal and accounted for more than 10% of injuries.

Preventing Injuries: Safety Precautions and Practices

Given the many hazards associated with chainsaw use, it is essential for practitioners to adopt comprehensive safety measures. Penn State Extension produced a helpful Chainsaw Safety Tips video that highlights chainsaw safety tips.

Below are key strategies to reduce the risk of injury and ensure safe chainsaw operation. These are especially relevant to non-professionals who may not have received any formal training in safe saw operation:

Proper Training

Before operating a chainsaw, users should undergo training to learn proper handling techniques, safety protocols, and maintenance. In many jurisdictions, certification is required for professional tree surgeons, arborists, and other chainsaw operators. Proper training ensures operators understand not only how to use the equipment but also how to anticipate and respond to hazards.

Personal Protective Equipment (PPE)

PPE is essential to mitigate the severity of potential injuries. The following items should always be worn when operating a chainsaw:

• Chainsaw helmet with face shield and ear protection: Protects against flying debris and reduces the risk of hearing damage from the high decibel levels produced by chainsaws.
• Heavy-duty gloves: Designed to protect hands from cuts, they also improve grip and reduce hand fatigue.
• Chainsaw chaps or pants: Made from a strong, cut-resistant material, these protect the legs in the event of accidental contact with the chain. Given that our data showed legs being a common point of contact with a running saw, this is an easy way to prevent many injuries.
• Steel-toed boots: Heavy-duty boots with steel caps provide protection to the feet and ankles in case the chainsaw or a heavy object falls onto the operator.
• The Chainsaw PPE Protects People video from Penn State Extension provides an excellent overview of PPE use.

Routine Equipment Inspection and Maintenance

Regular inspection and maintenance of your chainsaw is essential for safe and effective operation. Before each use, the chainsaw should be checked for:

• Chain tension: The chain should not be too loose or too tight.
• Sharpness of the chain: A dull chain requires more force to cut and is more likely to cause kickbacks.
• Oil levels: Sufficient lubrication prevents overheating and reduces wear on the chain.
• Safety features: The chainsaw should be equipped with safety features such as a chain brake, throttle lock, and anti-vibration systems. Do not use an older saw without a chain brake!

Proper Body Positioning

Maintaining the correct body position is critical for controlling the chainsaw and avoiding kickback or recoil. Operators should stand with their feet shoulder-width apart, ensuring stability and balance. It is generally recommended that non-professionals avoid cutting overhead.

Safe Cutting Techniques

There are several techniques that can help avoid accidents when using a chainsaw:

• Maintain a firm grip: Both hands should always be firmly on the chainsaw, with the left hand gripping the front handle and the right hand on the rear handle (there are no left-handed chainsaws).
• Avoid cutting above shoulder height: Overhead cutting increases the risk of kickback and recoil.
• Proper stance and control: When making a cut, keep both hands on the chainsaw and ensure your feet are planted firmly on the ground. Avoid leaning or overreaching, as this can destabilize your stance.
• Plan the cut: Always plan your cuts carefully to avoid sudden pinching of the chainsaw chain or trapping the saw. Make sure the area is clear of obstacles, and if felling a tree, anticipate how it will fall once it is cut. Plan an escape route that includes at least two paths away from a falling tree.

Choosing a Safe Environment

Whenever possible, work in clear, open spaces. Avoid operating chainsaws near power lines, in poorly lit areas, or during windy weather, which can reduce visibility and increase the risk of accidents. In addition, ensure that bystanders are kept at a safe distance (at least a distance greater than the height of the tree being cut) from the work area. Always be aware of possible snags or other overhead hazards.

Avoiding Fatigue

Operating a chainsaw for extended periods can lead to fatigue, which significantly reduces the operator’s reaction time and attention – being exposed to CO gas increases fatigue. Take regular breaks, stay hydrated, and limit the duration of each session. If you feel fatigued, rest before continuing.

Conclusion

Chainsaws are essential tools in both occupational settings and for non-professionals, but their inherent dangers require constant vigilance. Many of the 25,000 injuries caused annually by a chainsaw could have been easily prevented. By understanding the hazards and following the best practices outlined above, chainsaw operators can minimize the risk of injury and maintain a safe working environment. Proper training, personal protective equipment, regular maintenance, and adherence to safe operating procedures are all essential components of chainsaw safety.

By prioritizing safety, chainsaw users can continue to benefit from the efficiency and power that chainsaws provide while protecting themselves and others from harm. While chainsaws are a common source of serious injury, users should always remember that it's not just the saw that can hurt you! For example, falling limbs are a common cause of serious injury that should always be considered when felling a tree.

Safety training is a key component of learning to properly fell trees, clear brush, or even cut firewood with a saw. Penn State Extension offers chainsaw safety training that can upgrade your skills and keep users from becoming a statistic. We recommend this or other training before anyone starts using a saw for the first time or as a refresher for those with experience.