Preventing Ergonomic Injuries on the Construction Site

Think ergonomic injuries are only for those with a desk job? Think again.

• By Shawn Gregg
• Mar 01, 2024

When it comes to hazards on the construction site, electrical contractors are very familiar with the risks that OSHA dubs the “fatal four” — electrocutions, falls, struck-by and caught-in/between. The industry generally does a good job of utilizing training, safety equipment and other initiatives to help limit the risks of these occurring. However, many safety programs don’t have as much of a focus on the quieter dangers and risks posed by ergonomic injuries.

Unlike the injuries mentioned above, ergonomic injuries, which can affect joints, tendons, nerves and muscles, often build up over an extended period of time and may seem trivial at first. A good example is wearing uncomfortable shoes. Wearing these shoes could not only result in a possible acute injury on the job site but could also result in the worker developing a musculoskeletal disorder (MSD) over time.

And while many think of ergonomics as only a “desk job” concern, the reality is that ergonomic issues can occur anywhere. In the field, ergonomic injuries are a leading cause of employee safety issues and can be very costly.

Research from the Bureau of Labor and Statistics has found that nearly 33 percent of “days-away-from-work” cases are due to ergonomics-related injuries, and worker compensation claims tied to MSDs cost U.S. employers more than $20 billion per year. Plus, these injuries can linger and potentially hinder a return to the job site.

This is especially relevant for electrical contractors. In fact, OSHA points out that as the age of the work population increases and the scope of work broadens, electrical contractors are at a higher risk of developing ergonomic injuries. While much of their work is still concentrated in construction, many also work in building maintenance, or in data or networking installation applications that present ergonomic risk factors.

On the construction site, addressing ergonomics requires a delicate balancing act of managing worker capabilities with the demands of the job. By understanding and identifying the risk factors and implementing a series of controls, your safety team can reduce the risk of ergonomic injuries to this critical faction of the construction labor team.

The Five Ergonomic Risk Factors

There are five primary ergonomic risk factors to address on a job site:

1) High force: This refers to the amount of physical effort required to perform a task. That may include the type of grip needed, the weight of an object and body posture all relative to the type of activity performed. Any time you have increased force, you also increase the demands on the body. Prolonged or recurrent experiences in this instance can lead to fatigue and muscular or skeletal injury.

2) Awkward and prolonged postures: Any position of the body that deviates significantly from the neutral position while performing work activities can lead to problems. Twisting, bending, reaching and pulling with an awkward or poor posture can cause issues. This can be an especially common source of ergonomic injuries for electrical contractors, who often have to work within confined spaces or with equipment that’s not easily accessible.

3) Repetition: Performing the same motion over and over stresses the body. The amount of stress depends on four factors — the number of repetitions, the speed of the movement, the number of muscles involved and the amount of force required. Fatigue and muscle or tendon strain can accumulate when motions are repeated over a prolonged period, such as an eight-hour shift.

4) Contact stress: This occurs when the body is pressed against a hard or sharp edge, such as a narrow tool handle or sharp counter edge. This places undue pressure on the body and, over time, can inhibit overall nerve function and blood flow.

5) Hand-arm vibration: As the name suggests, this is caused by vibrations from power tools or other equipment. Prolonged exposure can lead to discomfort and risk an MSD.

Controls Provide Risk Reduction

To combat the five ergonomic risk factors, there are proven controls that can be implemented on the construction job site to reduce injury occurrence, especially when it comes to material handling.

Heavy Lifting Controls. Construction materials on the job site vary in weight, shape, size and diameter. This often results in awkward carries and posture as well as overexertion. Mechanical equipment such as forklifts should be used whenever possible.

But it’s also critical for your safety team to emphasize proper lifting techniques during training and post visible signage. Limit lifts to 50 pounds; anything over that requires two people. Train your team about the need to utilize proper handholds and make sure there is enough room to accommodate gloved hands. Create a schedule and rotate tasks so that employees are not exposed to the same activity for long durations.

Push. Pull. Carry. Pushing is always preferred to pulling, since it reduces the risk of strain. And like with heavy lifting, correct posture and equipment like hand trucks and pallet jacks should be used whenever possible. As a side note, it’s also important to make sure any equipment is properly maintained. 

Proper Tool Use. Many construction activities require specialized tools to get the job done. Using them correctly, with the right PPE and posture considerations, can help avoid injury risk. However, before employees even begin using the tools, ensure work surfaces are at an appropriate height to avoid bending or over-reaching. Tools should also be properly sized and shaped for the individual employee to use effectively. Additionally, using the proper type of tool can help reduce the risk of ergonomic injuries. For example, use inline tools on horizontal surfaces and pistol grip tools for vertical surfaces to keep a neutral posture.

Vehicle Activities Are an Extension of the Job Site. Vehicles often serve as an extension of the construction site, as tasks are performed in and around the truck bed and storage compartments. Consider utilizing roll-out truck bed decking, which can help provide easier access to equipment, allow better room for movement within the vehicle itself, and reduce the chance of injuries caused by lifting from an improper height or angle.

As the construction industry continues to contend with a skilled labor shortage, keeping existing employees safe and on the job site is paramount. Avoid the rise in ergonomic injuries for your team by identifying the most common ergonomic risk factors and implementing key control techniques that can be used to mitigate issues and keep electrical contractors safe and available to work. And if needed, a trusted partner can help you incorporate training and solutions into your safety program to help limit the risk of these injuries.

This article originally appeared in the February/March 2024 issue of Occupational Health & Safety.