Injury and Fall Prevention in the Workplace: Protecting Workers and Reducing Costs

Workplace injuries, particularly slips, trips, and falls, are among the most common and costly incidents affecting employers and employees alike. According to the U.S. Bureau of Labor Statistics (BLS), falls, slips, and trips accounted for nearly 16% of all nonfatal work injuries involving days away from work in 2022.1 These events are more than safety statistics—they disrupt lives, hinder productivity, and inflate workers’ compensation costs. Fortunately, proactive injury and fall prevention strategies can dramatically reduce these incidents.

The Cost of Injuries and Falls

Injuries and falls are financially devastating for many businesses. The National Safety Council (NSC) reports that the average cost per medically consulted injury in 2023 was $43,000, while a workplace fatality cost an average of $1.46 million.2 Direct costs—such as medical bills, rehabilitation, insurance claims, and administrative expenses—are just the beginning. Indirect costs, including lost productivity, training replacements, OSHA fines, and decreased employee morale, compound the financial burden.

For employers covered by workers’ compensation insurance, higher injury rates often lead to increased premiums. A company’s Experience Modification Rate (EMR), which influences workers’ compensation insurance premiums, is directly impacted by its injury history. High EMRs can not only raise insurance costs but also make a business less competitive when bidding for contracts, especially in industries like construction and manufacturing.

For injured employees, falls and musculoskeletal injuries can result in long-term disability and reduced quality of life. Time away from work often leads to loss of income, reduced job satisfaction, and increased stress. Additionally, some injuries result in chronic pain or require surgical interventions, which can sideline workers for months or even permanently.

Prevention Strategies

A core component of fall and injury prevention is environmental safety. Employers must regularly inspect and maintain flooring, lighting, stairways, and high-traffic areas. Installing non-slip surfaces, railings, and proper signage is critical. In industrial settings, ensuring that cables are secured and that storage systems are stable helps prevent trip hazards and falling objects.

Beyond the physical environment, employers should develop and enforce safety policies, conduct regular training, and implement a safety culture that encourages reporting hazards without fear of reprisal. Safety audits and safety incentive programs are effective tools to maintain employee engagement and accountability.

One of the most effective administrative strategies is the implementation of a Job Hazard Analysis (JHA). This is a systematic evaluation of job tasks that identifies risks and determines safe procedures to circumvent those risks.

The Physical Therapist’s Role in Prevention and Recovery

Physical therapists are often thought of as post-injury providers, helping employees recover after accidents. However, PTs can offer far more—particularly in injury prevention, early intervention, ergonomic assessments, post offer employment testing, and workforce education.

Pre-Injury Services

Ergonomic Assessments

PTs can assess workstations, workflows, and job demands to identify physical stressors that increase injury risk. Their understanding of biomechanics allows them to recommend modifications tailored to the individual and task, reducing repetitive stress and overexertion injuries.

On-Site Injury Prevention Programs

Many employers now utilize PTs in “triage therapist” or “industrial athlete” models. These PTs screen for early signs of strain or injury and provide guidance before symptoms escalate. Research has shown that early intervention can reduce the severity and duration of musculoskeletal injuries.3

Employee Education

PTs can lead workshops on body mechanics, safe lifting techniques, stretching, and warm-up routines. Employees who understand how to move safely and recognize the signs of strain are less likely to be injured.

Post Offer Employment Testing

Numerous studies have shown that pre-employment physical ability screening reduces the frequency of work-related injuries.4, 5, 6 These pre-screening tests ensure that workers are physically capable of performing essential functions of a job (based on a job demands analysis). Not only do these programs reduce injuries, but they positively impact the financial considerations associated with workplace injuries. One study highlighted an 18:1 return on investment following implementation of pre-employment screening.5

Conclusion

Employers who prioritize injury and fall prevention benefit from healthier workers, lower costs, and improved operational efficiency. As the American Physical Therapy Association (APTA) emphasizes, “Physical therapists are movement experts… and key partners in occupational health”.7 By integrating PTs into workplace safety and wellness programs, companies gain a powerful ally in their mission to reduce injuries and create a culture of safety.

To learn more about how Upstream Rehabilitation and our family of brands can assist with Workers’ Compensation and how physical therapy plays an effective role in helping injured workers return to work, contact our Workers’ Compensation team today!

 

  1. U.S. Bureau of Labor Statistics. (2023). Employer-Reported Workplace Injuries and Illnesses, 2022. https://www.bls.gov
  2. National Safety Council. (2023). Work Injury Costs. https://injuryfacts.nsc.org/work/costs/work-injury-costs/
  3. Gellert, R. J., Mizrahi, J., & Eldar, R. Early intervention in work-related musculoskeletal disorders: long-term outcomes. Occupational Medicine, (2002); 52(6), 327-332.
  4. Rosenblum, K. E, Shankar A. A Study of the effects of isokinetic pre-employment physical capability screening in the reduction of musculoskeletal disorders in a labor-intensive work environment. Work. (2006); 26 (2):215-28
  5. Littleton M. Cost Effectiveness of a pre-work screening program for the university of Chicago physical plant. Work. 2003; 21(3): 243-250
  6. Anderson C, Briggs J. A study on the effectiveness of ergonomically based functional screening tests and their relationship to reducing worker’s compensation injuries. Work. (2008); 31 (1); 27-37
  7. American Physical Therapy Association. (2021). Role of PTs in Occupational Health. https://www.apta.org
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