In 1991, Blue Cross Blue Shield of Kansas (BCBSKS) faced a growing problem: employees performing data entry were suffering repetitive strain injuries. That year, the company had 103 repetitive stress injury claims, costing over half a million dollars in compensation.
Their previous approach involved managing the claims as they came in, but that didn’t slow down the number of claims. They then shifted their strategy to focus on safety and prevention: educating employees, redesigning workstations, and paying closer attention to comfort, posture, and movement.
The results of this shift were overwhelmingly positive. A decade later, the number of claims dropped to 52, and total costs had fallen to just $137,000.
This is just one of countless success stories published by the Occupational Heath and Safety Administration (OHSA). Across numerous industries, companies successfully implemented measures to reduce ergonomic injuries in the workplace, and you can do the same.
In this article, we’ll cover what ergonomic injuries are, give examples of ergonomic hazards, and provide tips on how to avoid ergonomic injuries in the workplace.
What are ergonomic injuries?
When we think of ergonomic injuries in the workplace, the first image that may come to mind is a worker lifting something heavy with their back instead of their legs. That’s certainly a common ergonomic injury, but it’s not the only one.
Ergonomic injuries impact workers across different industries and sectors, including office workers, and typically result from performing repetitive tasks or working in an awkward posture.
So, what exactly is an ergonomic injury?
It is an injury that happens when a person’s work environment, tasks, or tools don’t align well with how the body naturally moves and functions. Over time, this misalignment can cause stress, inflammation, and pain, and tend to affect the hands, wrists, shoulders, back, or neck.
Ergonomic injuries are often categorized as:
- Cumulative Trauma Disorders (CTDs): Injuries that build over time from repetitive motion or sustained awkward positions.
- Repetitive Strain Injuries (RSIs): A type of CTD caused by repeated tasks like typing, lifting, or twisting.
- Musculoskeletal Disorders (MSDs): A broader term that covers injuries to muscles, nerves, tendons, and joints.
Common symptoms include:
- Tingling or numbness (especially in hands or fingers)
- Stiffness or reduced range of motion
- Soreness, swelling, or inflammation
- Weak grip strength or fatigue
- Chronic discomfort that worsens with activity
In general, ergonomic injuries are not one-time incidents. They develop gradually and can impact long-term productivity and quality of life if not addressed early.
Risk Factors for Ergonomic Injuries
Certain work conditions can increase the chances of ergonomic injuries. Here are some examples of ergonomic hazards:
- Poor workstation setup (chairs, desks, monitors)
- Repetitive motion without rest
- Awkward or static body postures
- Forceful exertions (like heavy lifting)
- Lack of training or awareness
- Inadequate tools or equipment
- Cold or hot environments (which reduce flexibility and circulation)
All of these risk factors can be addressed through the right mix of adequate training, education, and equipment.
How can you prevent ergonomic injuries in the workplace?
Some number of injuries will always occur despite your best intentions and efforts. While some injuries may be unavoidable, many are preventable with the right approach. Being proactive means assessing risks and hazards early before they cause injuries. You need to prioritize employee well-being and design a safe workplace that promotes it.
1. Start By Identifying Risk Factors & Hazards
You can’t prevent injuries if you don’t know what causes them or where they’re happening. That’s why prevention starts with observation. Regularly inspect your workplace. Conduct routine ergonomic assessments of workstations, job tasks, and workflows to identify potential hazards. Consider bringing in a certified ergonomics professional or occupational health expert to provide tailored recommendations.
While performing these kinds of audits, ask yourself questions like:
- Where are people experiencing discomfort?
- Which roles involve repetitive motion or awkward positions?
- Are tools or machines contributing to poor posture?
- Are workers using proper technique when carrying out their work?
Speak with workers and gather their feedback. Since they’re often the first to spot the warning signs, it’s a good idea to document common challenges in this way. Another great source of insight is injury records, which can tell you exactly what is currently causing ergonomic injuries.
Remote employees should also be included. Make sure they know how to set up a safe and supportive home workspace.
Once you have identified risks and hazards, you can tackle them head-on. This will involve redesigning the workplace where possible to eliminate hazards and providing workers with the right training and education to address ergonomic issues.
Related: OHSA | Identify Problems
2. Provide Proper Training and Education for Employees
Prevention starts with awareness. Provide regular training on body mechanics, posture, lifting techniques, and how to recognize early symptoms of strain. Teach employees how to adjust their workspace and encourage them to speak up when something doesn’t feel right.
Many times, workers are not using proper lifting techniques or are performing hazardous activities simply because they have not received training or instruction. A little training can go a long way. For example, by implementing ergonomic training, United Airlines reduced back injuries by 63% in less than a year.
A great place to start is OHSA’s training and assistance resources. They can give you a great overview of what kind of training to provide.
3. Make Things Safer By Redesigning the Workplace
Even the best ergonomic training in the world will be useless if workers are still working in hazardous conditions. When a job requires workers to reach too far, bend too often, or stay in a fixed position, even basic tasks can cause long-term stress on muscles and joints. Consider how physical spaces, tools, and job duties interact with the human body, and then make intentional changes to reduce strain and support healthier movement.
Redesigning the workplace can involve small changes like giving office workers adjustable chairs and monitor stands, to more complex processes like avoiding manual lifting with a drum mover in shipyards. It’s also not just about equipment and involves structuring tasks to reduce overuse, vary motion, and eliminate unnecessary strain.
Ergonomic redesign may involve:
Adjusting computer workstations: Chairs, desks, monitors, and keyboards should support neutral body positions. That means feet flat on the floor, knees at a 90-degree angle, wrists straight, and the top of the monitor at or just below eye level. For standing roles, counters should be at elbow height to avoid hunching or shoulder strain.
Repositioning tools and materials: Frequently used items, like scanners, staplers, controls, or components, should be within easy reach to avoid excessive stretching or twisting. Storage systems can be raised or lowered to reduce bending and overhead reaching.
Providing ergonomic equipment: Tools should match the task and fit the user. Ergonomic keyboards, vertical mice, lifting aids, adjustable carts, anti-fatigue mats, and grip-friendly hand tools are just a few examples of equipment that can reduce physical stress.
Reconfiguring workflows: Sometimes, the way a job is structured creates unnecessary repetition or awkward movement. Rotating tasks, changing work pacing, or adjusting team responsibilities can reduce the repetitive load on workers.
Redesigning the workplace goes hand-in-hand with identifying risk factors. It’s not something you perform once and then never have to think about. It’s a continuous process that requires listening to employees, evaluating job demands, and staying responsive to changes in the workplace.
4. Encourage Breaks to Move and Stretch
Even with a redesigned workplace that’s been ergonomically optimized, the body isn’t built to stay in one position for long periods. Whether sitting at a desk or standing on a production line, static postures limit circulation, strain muscles, and contribute to discomfort over time. That’s why it’s essential to build movement into the workday.
Encourage employees to take short, regular breaks. These can be short 1-2 minute breaks every 30-60 minutes to stand, stretch, walk, or simply change positions. Moving in this way helps reset posture, loosen stiff joints, and reduce mental fatigue.
Consider incorporating stretching routines or reminders into shift schedules or team meetings, especially in roles that involve repetitive motion or fixed positions.
5. Provide Personal Protective Equipment (PPE)
Depending on the job or task, PPE plays an important role in preventing ergonomic injuries.
Examples of ergonomically supportive PPE include:
- Anti-vibration gloves for workers using power tools;
- Wrist supports for those doing repetitive hand tasks;
- Knee pads for frequent kneeling;
- Back braces for lifting or standing work.
However, PPE should never be a substitute for redesigning the task itself. It’s most effective when used as part of a broader ergonomics program, not as a quick fix. Equipment must also be properly fitted and regularly evaluated to ensure it still meets the worker’s needs as tasks or conditions change.
Prevention Pays Off
An ounce of prevention is worth a pound of cure couldn’t be truer than when it comes to ergonomic-related injuries in the workplace. Left unchecked, ergonomic hazards and risks can lead to higher workers’ compensation claims, lost productivity, and long-term disability.
But when you shift the focus from managing to preventing injuries, you can build a healthy and safe workplace. You can reduce costly claims and foster an environment where employees can do their best work without pain getting in the way.
If you’ve suffered an ergonomic injury at work, you have the right to workers’ compensation. At Ransom, Gilbertson, Martin & Ratliff, we help workers navigate the workers’ compensation process and make sure they get the compensation they’re entitled to.
Contact us today to schedule a free consultation and learn how we can help.
Mike grew up in a military family and attended Northwestern School of Law in Oregon, where he graduated with honors. He began practicing workers’ compensation law in 1991 and became a founding partner of Ransom & Gilbertson in 1995. With decades of experience, Mike is known as a top 1% workers’ compensation attorney and has earned Martindale-Hubbell’s highest AV rating for skill and ethics. Outside the office, he enjoys rafting, fishing, going to the beach, and spending time with his dog, Sahalie.