Annual incident rates are currently decreasing
OSHA recorded 259 severe incidents involving bodily motion or positioning between 2015 and 2025. These events frequently result in fractures, which account for 27.8 percent of cases, and sprains or strains, which make up 17.8 percent of reported injuries.
The back is the most vulnerable area, with 24.4 percent of injuries affecting unspecified musculoskeletal structures and 13.2 percent specifically impacting the lumbar region. These injuries often lead to long-term mobility issues and require extensive medical intervention.
Over the past ten years, reported cases of overexertion have decreased by 58.5 percent. Despite this downward trajectory, the 13.3 percent increase observed over the last five years indicates that physical strain remains a persistent risk in modern workplaces.
Manufacturing leads all sectors with 22.4 percent of cases, followed by health care at 12.4 percent and transportation at 12 percent. These environments often demand repetitive physical tasks that place significant stress on the musculoskeletal system.
Top causes based on OSHA incident reports
These injuries occur when the natural movement of a worker leads to sudden trauma, such as reaching for products on high shelves or bending to retrieve dropped items. The source of these injuries is exclusively the worker's own bodily motion or position, which often becomes hazardous when combined with heavy lifting or awkward postures in cramped workspaces.
| Injury Type | Incidents | |
|---|---|---|
| 1 | Fractures | 72 |
| 2 | Traumatic injuries or exposures— unspecified | 65 |
| 3 | Sprains, strains, tears | 46 |
| 4 | Dislocations | 25 |
| 5 | Hernias | 17 |
| 6 | Soft tissue injuries— unspecified | 8 |
| 7 | Radiculopathy and disc disorders | 7 |
| 8 | Soft tissue injuries— n.e.c. | 4 |
Employers are required to maintain safe work environments under the OSHA General Duty Clause, Section 5(a)(1). When tasks require repetitive reaching or lifting, employers must implement ergonomic controls to prevent musculoskeletal disorders, as failing to provide adequate training or mechanical assistance may constitute a safety violation.
Where these injuries occur most frequently
Manufacturing accounts for 22.4 percent of all severe bodily motion injuries, largely due to the high volume of manual handling tasks required on production lines. Health care and transportation follow, where workers frequently navigate tight spaces while managing heavy equipment or patient transfers.
In high-risk industries, employers must adhere to 29 CFR 1910.132 regarding personal protective equipment and general ergonomic guidelines to mitigate strain. Compliance involves conducting thorough job hazard analyses to identify movements that lead to fractures and hernias, ensuring that workers are not forced into unsafe positions to complete their duties.
From actual OSHA investigation files
Reports from the field consistently show that simple, everyday actions like reaching for a pallet or bending to pick up clothing can result in severe outcomes like hip dislocations, umbilical hernias, and herniated discs. These incidents often occur during routine tasks, highlighting how quickly a standard movement can lead to a hospitalization when the work environment lacks proper ergonomic support.
"An employee strained his back after reaching for product on a pallet. The employee was hospitalized."
"An employee was reaching to hook her harness into a lanyard and began to experience abdominal pain. The employee sustained an umbilical hernia."
"An employee was entering an area while carrying a tray containing 20 pounds of product. A plastic curtain came into contact with the employee's shoulder; the employee suffered a herniated disc while dislodging the curtain."
"An employee was bending down when he suffered an abdominal strain and was hospitalized."
"An employee dropped a piece of clothing on the sales floor. She bent over to pick it up and her hip dislocated. The employee was hospitalized and required surgery."
"An employee was standing on the shop floor tightening a bolt on a bulldozer. The employee twisted her left leg and sustained fractures to her tibia and fibula. The employee was hospitalized."
"On May 1, 2025, at approximately 11:00 AM, an employee was jump-starting the battery of a forklift and his back went out while he was bending down. The employee was hospitalized with a slipped disc and required surgery."
"An employee was troubleshooting connectors for computer controls and was kneeling down on the ground to disconnect a pin cable connection. He reached forward and felt his lower back pop/lock and could not move to a standing position. The employee was hospitalized for a lower back sprain/strain. "
"An employee developed shooting pain up and down both legs and the back while bending over to remove restraints from a patient. The employee was hospitalized, suffering from a herniated disk with cauda equina syndrome."
"An employee was using a small cup to move glass bead media from a container on the floor to the blasting equipment when their back locked up. The employee sustained a herniated disc and was hospitalized."
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.