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May 27, 2025 • 6 min read

What is a Functional Capacity Assessment?

Learn what a functional capacity assessment is, when to book one, and how this evaluation supports workers comp and return-to-work planning in NSW.

Written by: Ginny Cai

Not sure when your injured worker can return to their job? A functional capacity assessment can give you a clear answer through a simple process.

Read this article to learn all the facts you wonder about functional capacity assessments (FCA), a crucial tool in workers compensation and return-to-work planning. We’ll break it down for you – what it is, why it matters, and what to expect.

Functional Capacity Assessment 101: What Is It and What’s It For?

Also called Functional Capacity Evaluations (FCE), a functional capacity assessment is a professional and comprehensive evaluation of a worker’s health conditions and physical functionality. It takes into consideration the worker’s musculoskeletal concerns to:

Check what the worker can physically do based on their job tasks
Spot any issues slowing down recovery, like pain, weakness, or mental health factors
Decide if the worker can return to their usual role or needs modified duties
Guide employers and health providers on the next steps for treatment and return to work

When Do I Need to Book a Functional Capacity Assessment?

A functional capacity assessment provides a structured report with evidence of current capacity and physical restrictions — essential for any workers comp strategy. If you’re experiencing one of the following:

The injured worker’s recovery has plateaued, not seeing improvements on their health conditions
You’re unsure whether or when they can perform their pre-injury duties
Difficulty obtaining a medical update from the injured worker’s treating provider(s)
Additional clarity is needed for claim progression, suitable duties or medical review

It’s a sign that a functional capacity evaluation can come in to help.

Why Does a Functional Capacity Assessment Matter?

Functional capacity assessment serves as an important part of workplace rehabilitation. By performing functional assessments, you’ll receive a detailed report identifying the worker’s current capacity, suitable duties and recommendations, ensuring treatment plan is tailored to the injury. In general, it has a couple of benefits for both employers and employees:

For employers:

Reduce return-to-work risks
Make informed decisions on suitable duties
Provide reassurance for safe re-engagement in activities
Support claims with evidence-based reports

For workers:

Identify physical limitations caused by their injury or other health issues
Receive education on minimising re-injury risk
Support a safe, structured return to work

What Should I Expect During a Functional Capacity Assessment?

Conducted by a qualified allied health professional (usually an exercise physiologist, physiotherapist, or occupational therapist), the entire process of functional assessments can take up to 3 hours – it’s designed to be a comprehensive evaluation to provide a complete picture.

Here’s what happens during a functional capacity assessment:

First, the professional will discuss with the worker about their general health, including injury history, current health status, medical concerns, and medication use.
Next, we’ll go over how the injury affects the worker’s daily activities — like their pain levels during chores / self-care and what tasks they find particularly difficult.
Then comes the core of the assessment: evaluating functional abilities. This includes testing the worker’s range of motion, lifting and carrying capacity, manual handling technique, and positional tolerances – all tailored to the worker’s injuries and specific job demands.

We can perform the functional capacity evaluation at one of our offices with a fully equipped gym, or we can come to your place anywhere in the Sydney Metro Area.

After the Functional Capacity Assessment

Once the functional assessment is completed, an in-depth report will follow within 10 business days. The report will specify:

Past and current medical conditions of the worker, as well as their injury circumstances;
Objective & subjective measurements of the worker’s range of motion, functional abilities and independence to complete their activities of daily living;
Factors affecting their performance;
Recommendations on suitable duties and treatment.

Book Functional Capacity Assessment with AusRehab

As specialists in workplace rehabilitation and CTP claims, AusRehab is committed to delivering professional, personalised support. Backed by both passion and expertise, we don’t just offer a service — we guide you through every step of the process.

Still unsure if you need a functional capacity assessment? It never hurts to reach out. Let us help you understand which services best suit your situation — and how AusRehab can support your recovery or return-to-work goals. Talk to us today to know more about functional capacity assessment and all other workers comp services.

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Ginny Cai

Ginny Cai is a dedicated writer with extensive experience in digital marketing and content creation. She is passionate about transforming data insights into compelling narratives and strategic content across multiple platforms.

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