Severe thigh injuries are on the rise
OSHA has recorded 2,256 severe incidents involving the thigh, with fractures accounting for 78.0% of all reported cases. These injuries often require extensive surgical intervention and prolonged rehabilitation to restore basic mobility.
The thigh contains the femur, the strongest bone in the human body, meaning any injury significant enough to cause a fracture often involves high-impact trauma. Such damage frequently results in permanent limitations that prevent workers from returning to physically demanding roles.
Over the last decade, reported thigh injuries have increased by 97.6%, signaling a persistent gap in workplace safety protocols. Falls on the same level remain the primary driver, accounting for 41.2% of all incidents as workers navigate hazardous surfaces.
Manufacturing and construction industries lead the reporting, collectively accounting for over 40% of all cases. These environments often involve heavy machinery and elevated work surfaces that create high-risk conditions for lower-body trauma.
Top causes based on OSHA incident reports
Most thigh injuries stem from preventable falls and contact with heavy equipment. When a worker falls on the same level, which accounts for 41.2% of cases, or is struck by a falling object, the force is frequently transferred directly to the upper leg.
| Cause | Incidents | |
|---|---|---|
| 1 | Fall on same level | 907 |
| 2 | Other fall to lower level | 446 |
| 3 | Struck by falling object | 175 |
| 4 | Struck by propelled object or substance | 80 |
| 5 | Injured by object handled by person | 73 |
| 6 | Pedestrian struck by vehicle in nonroadway area | 65 |
| 7 | Nonroadway collision with object other than vehicle | 36 |
| 8 | Nonroadway noncollision incident | 33 |
Employers are legally required to maintain safe walking and working surfaces under 29 CFR 1910.22. When these surfaces are obstructed or poorly maintained, resulting in a fall that fractures a femur, the employer may be in violation of federal safety standards.
Where these injuries occur most frequently
Manufacturing accounts for 23.6% of all thigh injuries, followed closely by construction at 17.2%. These sectors rely heavily on powered industrial vehicles and complex machinery that, when not properly guarded or operated, pose a constant threat to the lower body.
Under 29 CFR 1910.178, employers must ensure the safe operation of powered industrial trucks to prevent workers from being struck or crushed. Additionally, 29 CFR 1910.141 requires that floors be kept clean and dry to prevent the slips and trips that lead to severe thigh fractures.
From actual OSHA investigation files
Reported incidents frequently involve workers performing routine maintenance or navigating warehouse floors who suffer catastrophic fractures due to inadequate fall protection or improper equipment operation. These narratives highlight a recurring failure to secure heavy loads and maintain clear, safe walkways.
"An employee was airing up a trailer tire in the gas station parking lot. When he stepped backward, he tripped over an elevated fuel riser and suffered a fractured right femur."
"On July 31, 2025, an employee was walking when they fell on the concrete floor. The employee sustained a fractured right femur."
"An employee was sitting with a client in a dental exam room. When she stood up at the end of the appointment, her foot got caught on a cord that operates the dental hand pieces, causing her to trip and fall to the floor on her right side. The employee was hospitalized with a fractured femur and required surgery."
"On July 25, 2025, at 11:21 a.m., an employee was sitting underneath the forks of a forklift while performing maintenance on the forklift when the forks dropped onto them, resulting in a broken femur."
"An employee was standing on the forks of a forklift adjusting a pallet on a storage rack in the warehouse. The employee fell from the forklift, landing on the ground and suffering a broken femur."
"An employee was walking down a hallway In front of offices when she tripped over a door mat and fell to the floor. The employee sustained a fractured left femur."
"An employee was walking up a set of three steps that lead out of a pit. Water that had leaked from a valve was on his boots and he slipped and fell backward to the floor. The employee sustained an injury to his L5 vertebra and a ruptured hamstring that required surgery."
"An employee was taking care of a client inside their home. The employee tripped and fell to the ground while walking, resulting in hospitalization with a fractured right femur."
"An employee was using a manual pallet jack to pull dairy products to the dairy cooler. He slipped and fell on absorbent matting near the dairy cooler. He sustained a fractured left femur."
"An employee was walking down a hallway when they stepped on a small puddle of liquid and fell backward onto their left leg, resulting in a broken left femur."
The ClaimsBoost Research Team aggregates official government data to help workers understand workplace injury trends and their coverage options.
ClaimsBoost is not a law firm and does not provide legal advice. ClaimsBoost is not affiliated with, endorsed by, or connected to any government agency. Performance scores, rankings, and statistics displayed on this site are calculated by ClaimsBoost using publicly available government data from OSHA severe injury reports. Individual results may vary. Nothing on this site should be construed as legal advice or a guarantee of benefits. If you need legal help, we can connect you with licensed attorneys in your area.Some written content on this page was created with the assistance of AI to help interpret and explain the data. AI can make mistakes — all content has been reviewed for accuracy, but we encourage you to verify any information that is important to your situation.