FACTSHEET H 1

ERGONOMIC HAZARDS

Our bodies normally recover from the wear and tear of

work after a period of rest. But if the stresses continue
day after day without time to recover, the damage can
lead to ergonomic injuries.

Many different terms are used to describe these

ergonomic injuries. For example:
• Cumulative trauma disorders (CTDs). Ergonomic
injuries involve strain that may develop, or
accumulate, over time.
• Repetitive strain injuries (RSIs). Ergonomic injuries
are often caused by repeating the same motions
over and over.
• Musculoskeletal disorders (MSDs). Ergonomic injuries
affect the muscles, bones, tendons, nerves, and
tissues.

These terms do not necessarily refer to different

conditions. Many ergonomic injuries can be
described in all three ways.

These disorders include a number of specific diseases such

as carpal tunnel syndrome, bursitis, and tendinitis. Back
injuries are the most common and most costly MSD.

Symptoms of these disorders are most common in the back, hands, arms, wrists,
elbows, neck, and shoulders. They include:

• Soreness or pain (aching or

• Numbness
sharp)
• Tingling (as though the area is “asleep”)
• Stiffness
• Unexplained weakness
• Swelling
• Loss of coordination

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If your work exposes you to any of the ergonomic risk factors described on page 3 of this
factsheet, these symptoms may be signs that you have an MSD.

It is important to seek medical care if these symptoms:

• Last for more than a week
• Bother you so much that you restrict activities or take
time off to recover

If You Believe You Have an MSD

• Seek early treatment. The longer you have symptoms without getting help, the harder
they can be to treat successfully.
• Find a doctor who understands work-related health problems. Don’t be afraid to
educate your doctor about the possible causes of your MSD.
• If your problem is work-related, report it to your supervisor. You may be eligible to
file a workers’ compensation claim to cover lost work time and/or medical costs.
• It is best not to return to the same working conditions that caused your problem.
Work with others at your workplace to ensure that the equipment or activities that
contributed to your injury are changed.
• Finding the right doctor, getting effective treatment, and improving your work
environment take persis-tence and energy. Don’t hesitate to ask for help and don’t
give up until the problem is solved.

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Risk Factors for Ergonomic Injuries

The field of ergonomics examines the fit between employees and their jobs. Ergonomics looks
at:
• What body movements and positions people use when they work
• What tools and equipment they use
• The physical environment (temperature, noise, lighting, etc.)
• The organizational environment (deadlines, teamwork, supervision)
• Whether any of these factors may place an employee at risk of injuries or illnesses

The goal of ergonomics is to fit workplace conditions and job demands to the capabilities of the
individual worker, instead of making the worker fit the job.

To prevent injuries, ergonomic risk factors must be identified. Ergonomic risk factors are
workplace situations that cause wear and tear on the body and can cause injury. Once
these have been identified, you can work on finding ways to eliminate them.

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Ergonomic Risk Factors

RISK FACTORS DEFINITION POSSIBLE SOLUTIONS

Repetition Making the same motion over and Redesign task to reduce
over. repetitions; increase rest time
between repetitions; rotate
among tasks with different
motions.
Awkward Posture Prolonged bending, Redesign tasks, furniture, and
reaching, kneeling, equipment to keep the body
squatting, or twisting any in more “neutral” positions
part of your body. and minimize reaching
bending and
twisting.
Forceful Motion Excessive effort needed to do Redesign task to reduce the
tasks such as pulling, exertion needed; assign more
pounding, pushing, and lifting. staff; use mechanical assists.

Stationary Position Staying in one position too Redesign task to avoid

long, causing fatigue in muscles stationary positions; provide
and joints. opportunities to change
position.
Direct Pressure Prolonged contact of the Improve tool and
body with a hard surface or equipment design or
edge. layout to eliminate
pressure; provide
cushioning
material.
Vibration Using vibrating tools or Insulate the hand or body
equipment. from vibration; keep tools or
equipment in good condition
to reduce excessive vibration.

Extreme Temperature Working where it is too hot or Control temperature where

too cold. Cold reduces feeling, possible; insulate the body
blood flow, and strength. Heat against cold by wearing
increases fatigue. gloves and warm clothing;
provide breaks and fresh
water in hot environments.
Work Stress Includes machine-paced work, Establish reasonable
inadequate breaks, workload, provide sufficient
monotonous tasks, multiple breaks and vary tasks.
deadlines, poor work
organization, or poor

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supervision.

• The more risk factors you face, the greater your chance of injury.
• The longer you are exposed to a risk factor, the greater your chance of injury.
• By reducing or eliminating risk factors, the chance of injury can be decreased.

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Identifying Risk Factors

Below are some ways to identify ergonomic risk factors.

TALK TO EMPLOYEES: SURVEYS OR INTERVIEWS

Employees are often the best source of information on the
potential problems posed by their jobs. You can conduct a
written survey or talk to people individually.

LOOK AT JOBS: INSPECTIONS AND JOB

EVALUATIONS
Conduct a walk around inspection of the work environment
to see which jobs or tasks may pose ergonomic
problems. Those jobs can then be evaluated to identify
specific risk factors. When evaluating a job, break the
work down into the smallest pieces possible so that you
can be specific and detailed.

Once you have watched people do their work and asked them
about it, use a checklist or similar form to record risk factors as
well as to track your progress in resolving a problem.

Below are some tips for conducting job evaluations.

A job evaluation should include three parts:

• Discussion. Talk to the people doing the job. Ask whether they
experience pain or discomfort while performing the job and what specific activities seem to
trigger that pain. Understanding the relationship between pain and specific activities
can help you pinpoint tasks, workstations, equipment, or tools which may be causing
or aggravating injuries.
• Job description. Collect information that fully describes each specific task, job,
workstation, tool, and/ or piece of equipment that you evaluate. Include information
about work pace and work schedule, including break times. See if there is a written job
description available and supplement
it with your own notes.
• Observation and measurement. Use direct observation, videotapes, photos, and
sketches to identify risk factors. Use a checklist to record specific risk factors, including
the weights of objects, how long they are held, or how far they are moved.

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Controlling Ergonomic Hazards

There are many ways to reduce ergonomic risk factors and help fit the workplace to
the worker. Solutions can be grouped into three main categories: eliminate the
hazard, improve work policies and procedures, and provide personal protective
equipment. Often the best solution involves a combination of approaches.

Eliminate the Hazard

The most effective way to control ergonomic hazards is to eliminate the risk factors
altogether. Sometimes you can change the tools, equipment, job design, or work area to
remove the hazard completely. This is called using “engineering controls.”

These are some examples of engineering controls:

• Redesign workstations and work areas to eliminate reaching, bending, or other awkward postures.
• Provide adjustable tables and chairs that can be used by employees with a range of
sizes and shapes, and that allow neutral postures.
• Provide carts for transporting material and mechanical hoists to eliminate lifting.
• Use tools that fit the hand, have no sharp edges, and eliminate awkward hand and wrist positions.
• Change where materials are stored to minimize reaching.
• Design containers with handles or cutouts for easy gripping.

Improving the workplace is the

heart of ergonomics: changing
the work to fit the worker. The
design should accommodate
the wide range of people
assigned to the task.

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Improve Work Policies and Procedures

The next most effective solution is to develop work policies, procedures, and
practices that change how the job is done. This is called using “administrative
controls.”

These are some examples of administrative controls:

• To the extent possible, rotate employees among different tasks to rest the various
muscle groups of the body, reduce repetition, and ease mental demands.
• Improve work scheduling, if possible, to reduce risk of fatigue.
• Increase staffing to reduce individual workloads.
• Provide sufficient breaks, since adequate recovery time can reduce fatigue.
• Assign more staff to lifts of heavy objects.
• Encourage proper body mechanics and use of safe lifting techniques (see box on next
page).
• Require all loads to be labeled with their weight.
• Store heavy objects at waist height.
• Follow good housekeeping practices. Keep floors free of slipping or tripping hazards.
Maintain power tools properly to reduce vibration. Keep cutting and drilling tools
sharp to reduce the force required.
• Provide workers with training on safe working postures, lifting techniques,
ergonomics policies and procedures, and the safe use of lifting and carrying
devices.

Training is a critical element of

nearly any solution and provides
an important opportunity for
employee participation.
However, it is not a substitute for
reducing risk factors and should
be used in combination with
engineering and administrative
controls.

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ERGONOMIC HAZARDS

SAFE LIFTING TECHNIQUE

Lifting can put great strain on your back. Lifting from the floor can be particularly
risky. For example, lifting a 25-pound box from the floor requires about 700 pounds
of back muscle force, even when you bend your knees. Below are some tips that can
help protect your back when you need to lift heavy objects.
• Try out the load first. If it is too bulky or heavy, get help.
• Avoid lifts that require stretching or bending to reach the load.
Redesign the work area so objects you lift are close to the
body and at waist height.
• Don’t lift awkward objects such as long pipes or large boxes
by yourself. Get help or use mechanical assists.
• When lifting, keep your back straight and lift with your legs.
• Lift slowly and carefully and don’t jerk the load around.
• Keep the load as close to your body as possible while lifting it.
• Don’t twist or turn your spine while carrying the load.
• Make sure your path is clear while carrying
the object. Remove obstacles that could
cause you to trip.

A program to teach employees how to lift properly should be used in combination with
workplace redesign that reduces the amount of lifting needed. Remember, if materials
are too heavy or awkward to lift and carry safely, get help, redesign the materials to be
lighter and easier to handle, or use mechanical assists such as carts.

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Provide Personal Protective Equipment

While more permanent solutions are being found and implemented, or if you are
unable to redesign the job or equipment to eliminate risks, personal protective
equipment (PPE) can be used.

PPE that can help address ergonomic problems includes:

• Knee pads for kneeling tasks

• Shoulder pads to cushion loads carried on the shoulder
• Gloves to protect against cold, vibration, or rough surfaces
A CAUTION ABOUT BACK BELTS
Back belts are sometimes provided as PPE. Back belts have been studied extensively, and
experts
have concluded that they are not effective in preventing back injuries. Some believe that,
in fact, they may cause injury by encouraging workers to lift heavier objects or by making
muscles weaker. Most importantly, they do not make workers stronger or more able to
perform a lift that is awkward or too heavy. The National Institute for Occupational
Safety and Health (NIOSH) recommends that employers not rely on back belts to
protect workers. Instead, it recommends that employers implement a comprehensive
ergonomics program that includes workplace assessment, hazard reduction, and worker

Establish a Comprehensive Ergonomics Program

Workplaces should establish an ergonomics program to minimize
musculoskeletal disorders. Elements of a good program include:
• Management commitment
• Employee involvement
• An organizational structure to get the work done, such as an ergonomics team or
committee
• Training and education of employees and supervisors
• Job evaluation to identify risk factors
• Hazard prevention and reduction or elimination of risk factors
• Early detection and treatment of ergonomic injuries, and medical management of injury
cases
• A system for employees and supervisors to report ergonomic problems,
symptoms, and injuries without reprisal
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• Ongoing evaluation of the ergonomics program

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California’s Ergonomics Standard

Cal/OSHA has an Ergonomics Standard which requires employers to take action to prevent
repetitive motion injuries when two or more employees doing the same type of work are
diagnosed with a repetitive motion injury (RMI). Every employer subject to this regulation is
required to establish and implement
a program designed to minimize RMIs. The program must include a worksite evaluation,
control of exposures which have caused RMIs and training of employees.

The regulation can be found in Title 8, California Code of Regulations, General Industry Safety Orders
§5110.

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Inspection Checklist for Ergonomic Risk Factors

Date: Time: Employee observed:

Job title: Task:

Task description:

Found In
RISK FACTORS Cause/Description Possible Solutions
This Task

Repetition

Repeated forceful or awkward motions

Little or no rest

Using same body part repeatedly

Awkward Posture

Bending or leaning forward

Reaching or lifting below knee level

Twisting or bending to the side

Reaching above chest level

Bending wrist frequently

Twisting hands or forearms

Raising arms to side or forward

Bending neck

Forceful Motion

Lifting, pushing, or
pulling more than 50
pounds
Lifting more than six pounds with one
hand
Forceful gripping of material or tools

Handling tools or material in pinch

grip

(Continued on next page)

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Inspection Checklist for Ergonomic Risk

Factors
(continued from previous page)

Found In
RISK FACTORS Cause/Description Possible Solutions
This Task

Stationary Position

Working in one position for long

periods
Standing for long periods

Sitting for long periods

Direct Pressure

Tool or equipment pressing on hand or

body
Seat or table pressing on leg or body

Vibration

Using vibrating hand tools

Operating vibrating heavy equipment

(including large vehicles)

Temperature and Environment

Temperature too hot or too cold

Workplace poorly lit

Walkways obstructed or slippery

Work stress

Pace of work is machine-controlled

Piece work is used as production

incentive
Insufficient work breaks

Poor supervision

Inspection checklist was adapted from: NIOSH “Elements of Ergonomics Program,” Tool box Tray 5-A,
www.cdc.gov/niosh/ eptbtr5a.html, and “Working Without Pain Train the Trainer Program,” Hunter College Center
for Occupational and Environmental Health.

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