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Construction sites are inherently dangerous, but not all risks are immediately visible. Some quietly accumulate over time or seem to appear out of nowhere, often leading to musculoskeletal disorders, and potentially even long-term disability.
The three leading causes of ergonomic injuries in the construction industry are heavy lifting and forceful material handling, awkward postures, and repetitive motion.
In this article, we explore the impact of these risks on workers and projects, and provide practical strategies construction companies can implement to prevent injuries, protect their workforce, and maintain productivity on site.
Why it’s essential to combat common ergonomic injuries on construction sites
Ergonomic injuries (MSDs) account for roughly 77% of all reported non-fatal injuries in US construction1.
Based on OSHA data, in 2025, injuries in the construction industry caused damages of around $11.5 billion on average, with the majority related to non-fatal injuries.
What’s more, according to data from the NSC, workers between the ages of 25 and 35 are the most likely to be injured on a construction site. This means a key segment of your workforce, one that brings a good balance of strength, endurance, and experience to the table, is at higher risk of being sidelined, potentially impacting both productivity and the quality of work delivered on site.
OSHAs stats also highlight that, for every dollar invested in workplace safety, construction companies saved between $4-$6.
1. Heavy Lifting and Forceful Material Handling
A CPWR report showed that overexertion from lifting and lowering was responsible for roughly 30% of reported work-related musculoskeletal disorders (WRMSD) in construction. Other forms of forceful materials handling, such as pushing, pulling, holding, carrying, and catching accounted for a further 37% of MSDs among construction workers.
These injuries most commonly affect the lower back, shoulders, and knees, but can also impact wrists and hands when lifting awkward or heavy tools and materials.
Explore the impact of masculine culture on materials handling risks.
It’s important to note that forceful handling is often compounded by awkward postures, repetitive movements, and limited recovery time, which together increase the risk of chronic injury. Even short-term overexertion can lead to long-term musculoskeletal issues if repeated daily.
Practical examples on site include:
- Lifting rebar or lumber without mechanical assistance
- Carrying heavy materials over uneven surfaces
- Pushing or pulling wheelbarrows or carts loaded beyond recommended limits
- Catching or guiding falling objects or loads
2. Awkward postures
The National Safety Council (NSC) reports that awkward postures are the second-most common cause of MSDs at work across all industries. However, with a DART (days away from work) case rate of 10.6 per 10,000 workers, they’re far more common in the construction industry than in others.
“Awkward postures” refers to:
- Twisting
- Bending
- Working overhead
- Prolonged reaching
- Kneeling
- Squatting
- Holding any fixed position for an extended period
- Pinch grips
These movements place excessive strain on muscles, tendons, and joints, especially when combined with forceful exertion or repetition. For example, overhead electrical work strains the shoulders and neck, while prolonged kneeling during flooring or tiling jobs places damaging pressure on the knees and lower back.
Over time, these postures can lead to chronic pain, reduced mobility, and long-term musculoskeletal disorders.
3. Repetitive motion
According to CPWR research, in 2023, 8.8% of construction workers reported a repetitive strain issue (RSI) related to their work. That’s roughly 1.2 million workers before even considering unreported cases.
Repetitive motion injuries develop from tasks like constant reaching, sawing, screwing, or repetitive lifting, leading to conditions such as tendonitis, bursitis, or carpal tunnel syndrome.
These injuries often appear minor at first: stiffness, tingling, or mild discomfort. But without intervention, they can progress to chronic musculoskeletal disorders that require extended time off work.
How to prevent materials handling, awkward posture, and repetitive motion injuries on construction sites
General prevention principles
These strategies apply across all types of ergonomic risks:
- Rotate tasks and allow recovery
- Alternate high-strain activities with lower-strain tasks.
- Implement micro-breaks to allow muscles and tendons to recover.
- Provide ergonomic training and awareness
- Conduct toolbox talks and practical demonstrations on safe lifting, posture, and tool use.
- Encourage reporting of early warning signs such as stiffness, tingling, or discomfort.
- Redesign workflows
- Organize materials and tools within easy reach.
- Plan routes and workflows to reduce unnecessary bending, twisting, or carrying.
Risk-specific prevention tips
- Heavy lifting and forceful material handling
- Use mechanical aids: hoists, cranes, pallet jacks, lift-assist devices.
- Break down heavy loads into smaller, manageable parts.
- Employ team lifts for bulky or awkward items.
- Train workers on proper lifting techniques – see our materials handling eLearning course.
- Awkward Postures
- Adjust work heights and positions to reduce strain.
- Use adjustable platforms, scaffolds, or lifts for overhead work.
- Supply long-handled tools and padded knee supports for floor-level or kneeling tasks.
- Pre-fabricate components at ground level where possible to avoid prolonged overhead work.
- Repetitive Motion
- Use powered tools to reduce manual repetition.
- Encourage micro-breaks and stretching exercises during shifts.
- Maintain tools properly — dull or inefficient tools force extra strain.
Learn more about injury prevention and wellness in the construction industry.
Protect your construction team from MSDs with Cardinus
We offer a variety of ergonomics solutions designed specifically for non-office work environments like construction sites.
From motion capture technology and interactive eLearning to a comprehensive industrial ergonomics platform, our flexible solutions are designed to fill the gaps in your ergonomics program and deliver measurable improvements in employee wellbeing and productivity.
Explore our industrial ergonomics solutions, or contact Cardinus today to discuss your requirements.
