Feb 5, 2025 • 8 min read

7 Most Common Workplace Injuries Across Australia

Discover the top 7 workplace injuries, their hidden costs to workers and businesses, and simple preventive measures you can readily implement.

Written by: Devanshi Sarda

Additional contributions by: Eisabess Chee

Workplace injuries can derail lives and careers in an instant, with devastating effects on both workers and their families. While workers compensation is meant to provide a safety net, the true cost of common workplace injuries often extends far beyond medical bills.

Understanding and preventing workplace accidents is crucial for both business sustainability and worker wellbeing. In this article, we examine the 7 most common workplace injuries that continue to challenge occupational safety.

#1 Musculoskeletal & Repetitive Strain Injuries (RSI)

Every time you reach for that file on the top shelf or spend hours typing at your desk, your body is silently keeping score.

Musculoskeletal injuries (MSIs) might sound complex, but they’re simple to understand – and all too common to experience. These injuries affect everything from your muscles to your ligaments, and are the quiet result of our daily workplace habits, like the way you’ve been sitting at your desk for the past five years.

According to Safe Work Australia, MSIs account for nearly one-third (32.7%) of all serious workplace claims in Australia, with 45,500 workers affected annually. These injuries often result from long hours of physical labour or repetitive motions, which can lead to chronic conditions if left untreated.

The culprits behind MSIs are often hiding in plain sight:

Your morning routine of repetitive tasks without breaks (like continuous data entry or assembly line work)
The “it’s not that heavy” approach to lifting that gradually strains your back
Those awkward positions you find yourself in throughout the day, from reaching under desks to twisting for tools
The constant pressure on specific body parts, like resting on your wrists while typing
Workstations that seem fine but slowly compromise your posture

Some industries experience MSIs more frequently than others:

Hairdressing and beauty
Construction and mining
Manufacturing (assembly lines)
Plumbing and electrical work

Prevention is about creating a workplace that works with your body, not against it. This means:

Making smart lifting choices and having the right training to back those choices
Regular workstation assessments that catch problems before they become injuries
Having the right tools and equipment to do heavy lifting (because your back shouldn’t be your only tool)
Clear safety signs that serve as constant reminders, not just workplace decorations
Properly maintained equipment with safety features that are actually used, not bypassed

#2 Falls, Trips, and Slips

We’ve all had that heart-stopping moment – a sudden slip on a wet floor or an unexpected trip over something that wasn’t there a minute ago. While these incidents might seem like simple accidents, they represent a staggering 21.8% of serious workplace claims in Australia. That’s 30,300 workers who didn’t make it home without injury.

Falls, trips, and slips might sound like minor mishaps, but in industries such as construction, the consequences can be fatal. In the workplace, be sure to watch out for:

Poor Physical Conditions

That flickering light in the corridor that makes it hard to spot the wet patch from the recently mopped floor
The “I’ll deal with it later” pile of boxes that’s gradually crept into the walkway
Those subtle floor irregularities you’ve learned to step over but new employees wouldn’t notice
The constantly busy entrance where rain meets smooth flooring, creating an unexpected skating rink
Those comfortable but smooth-soled shoes that seem fine until you encounter a spill

Physical Hazards

The “temporary” power cable solution that’s been snaking across the floor for months now
Those missing guardrails in the storage area
The printer cables that have gradually escaped their cable ties and now create a web under desks
The storage solutions that require a bit of stretching and reaching (until someone loses their balance)
The loading dock with that slope that becomes treacherous when wet

Falls, trips and slips are particularly common in certain industries, each with their own unique set of challenges:

Construction
Healthcare and social assistance
Retail trade
Transportation
Warehousing

Create an environment where safety becomes second nature by installing:

Warning signs that actually grab attention and influence behaviour
Lighting systems that illuminate every corner, because what you can’t see can hurt you
Sensible and clear storage and organisation protocols
Footwear policies that acknowledge both comfort and safety needs
Regular, preventative housekeeping routines
Maintenance schedules that catch issues before they catch someone off guard

#3 Being Hit by Moving Objects

Duck! That’s often the last thought before impact, but by then it’s usually too late.

Injuries from falling objects and moving machinery aren’t just about being in the wrong place at the wrong time; they make up 15.8% of serious workplace claims, affecting 22,000 workers annually.

Just like a game of real-life tetris, objects in motion have a way of finding unexpected paths to the ground – or to us. Here are some potential (and also very preventable) causes of these incidents:

That tool on the scaffold that’s gradually vibrating its way to the edge
The forklift load that seems balanced until it takes a sharp turn around the corner
Those stacked boxes in the storage room that are one bump away from toppling
The machine part that’s “probably fine” until it suddenly isn’t, sending dangerous debris flying
The shortcut of passing under suspended loads because “it saves time”

The chances of being hit by moving objects are statistically higher at the following workplaces:

Construction sites
Manufacturing floors
Transportation hubs
Warehouses
Logging operations

Considering this is the third most common workplace injury, it’s a tragedy preventative measures aren’t taken more seriously. Ensure the following at all times:

Wearing PPE, instead of just leaving it in the storage room
Machine guards that stay in place
Clear zones between pedestrian areas and mechanical operations
Training that strives to create true awareness of surroundings
Maintenance schedules that catch equipment issues before they catch workers off guard
Smart storage solutions that respect gravity instead of challenging it
Warning systems that people actually pay attention to

#4 Psychosocial Injuries or Mental Stress

Not all wounds are visible to the naked eye. While a broken arm garners immediate attention, psychological injuries often simmer beneath the surface, affecting 13,900 workers severely enough to file serious claims – and that’s just the ones who spoke up.

At 10% of all serious workplace claims, mental stress injuries represent a growing challenge that can’t be fixed with a bandage.

Some silent workplace stressors include:

The manager who’s “too busy” to provide guidance, leaving you second-guessing every decision
That colleague whose “jokes” aren’t really jokes, creating a cloud of tension in every meeting
The subtle exclusion from important conversations that leaves you wondering where you stand
The ever-growing to-do list that has you checking emails at 11PM just to stay on top of things
The mind-numbing repetition of tasks that makes you question your career choices
Those vague job expectations that have you doing three people’s jobs “just to be safe”

Psychosocial challenges hit some vocations especially hard:

Healthcare
Retail and hospitality
Education
Construction
Customer service and call centers

Creating a mentally healthy workplace isn’t just about having a meditation room or annual wellness talks. It requires a holistic approach:

Building support systems that catch people before they fall, not after
Developing return to work plans that consider the invisible aspects of recovery
Establishing clear boundaries between work and life, because burnout isn’t a badge of honour
Fostering a culture where mental health conversations are as normal as discussing physical safety
Ensuring mechanisms are in place to either prevent or resolve the presence of psychosocial hazards

#5 Work-related Vehicle Accidents

While vehicle accidents make up a relatively small portion of workplace claims at 4.9% (6,800 cases), their impact tends to be catastrophic. In NSW alone, road crashes are the cause of nearly 30% of all workplace fatalities.

Motor vehicle accidents are often contributed by:

Fatigue, simply from spending more than 12 hours being on the road
That mental grocery list of work tasks competing for attention with actual traffic
Inadequate training on safe driving practices, whether due to poor organisation or overconfidence
Vehicle maintenance issues that have been around for weeks, maybe even months
Failure to use proper safety gear
Driving under the influence of alcohol or drugs

Here’s what makes the difference between safe, accident-free operations and an accident waiting to happen:

What Employers Can Implement

Safety policies that actually survive contact with reality
Maintenance budgets that don’t try to squeeze another month out of worn parts
Training programs engaging enough to keep even veterans alert
Schedules that respect human limits instead of pushing them
Technology that helps rather than just monitors
Traffic plans that protect people, not just optimize flow

How Drivers Can Maximise Safety

Pre-trip checks that go beyond the bare minimum
Respect speed limits – they are there for a reason
A clear head focused on the road, not the next deadline
Regular breaks before fatigue makes the decision for you
Weather assessments that err on the side of caution
The confidence to raise red flags before they turn into accident reports

#6 Occupational Hearing Loss or Industrial Deafness

“WHAT?”

For 3.6% of serious workplace injury claims, such a response becomes a permanent reality. Industrial deafness is the workplace injury you don’t see coming, because you’re too busy hearing it happen.

Unlike a cut or fall, hearing loss doesn’t announce itself with pain or blood. It sneaks up gradually, masquerading as:

That ringing in your ears that “always goes away” after shift
The TV volume that needs to be “just a little louder” each month
Those workplace conversations that become increasingly hard to follow
The protective equipment that sits unused because “you get used to the noise”

The loudest toll rings out in industries where noise is just “part of the job”:

Construction
Lumbering/logging
Railways
Carpentry
Commercial airlines (Ground crew)

But here’s what’s fascinating about hearing protection – it’s one of the few safety measures where you can hardly be overly protected. Smart workplaces are taking note with hearing protection solutions that actually work:

Engineering controls that turn down the volume at the source
Hearing protection that workers can wear comfortably for entire shifts
Work schedules that give ears a break before damage sets in
Regular testing that catches problems while they’re still fixable
Training that helps workers understand why protecting their hearing today matters for their tomorrow

#7 Workplace Hernias

At 2.2% of serious claims, hernias might seem like a small slice of workplace injuries, but ask anyone who’s felt that sudden pop or tear. It’s an injury that changes how you move, work, and live.

The path to a hernia is paved with seemingly innocent moments:

The box you assumed was not too heavy that proves you wrong halfway up
Those rushed deliveries where proper lifting technique takes a backseat to speed
The mechanical lift that’s “too far away” to bother getting
The workstation that forces you to twist and reach just to do your job
The dusty environment that keeps you coughing, putting extra strain on your core

Hernias are most likely to occur in these trades, no thanks to the volume of physical labour that’s constantly taking place:

Construction
Retail and wholesale
Trade services
Logistics

Even the strongest workers can end up with a workplace hernia if they ignore the warning signs or don’t exercise caution by:

Having the right tools in the right place at the right time
Building core strength that supports your spine, not just your ego
Learning lifting techniques that work in real-world situations
Using support equipment that helps without hindering
Creating a culture where asking for help isn’t seen as weakness

Nip the Problem in the Bud With AusRehab

Together, the 7 common workplace injuries documented above make up over 90% of all workers compensation claims. It might sound like bad news, especially for the industries that were repeatedly listed. Construction, healthcare, retail, transportation and logging – we’re looking at you.

The good news is that these work injuries can be greatly reduced with the right preventative tools. That’s why AusRehab offers comprehensive screening services and training solutions that can be 100% tailored to your needs.

With the insights provided by our experienced allied health professionals, your reliable hires will gain work health and safety knowledge to last them a lifetime. Sounds good? Enquire with us today.

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Devanshi Sarda

Devanshi creates insightful content that highlights best practices in injury management, ergonomic solutions, and strategies to foster safer work environments. Devanshi’s writing aims to inform and support businesses and workers in implementing effective workplace safety measures and rehabilitation practices.

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