10 Most Common Workplace Injuries (And How to Avoid Them)

The 10 Most Common Workplace Injuries

Based on data from California's Division of Workers' Compensation and Bureau of Labor Statistics, these are the injuries that send the most workers to doctors, emergency rooms, and disability:

1. Overexertion and Repetitive Motion Injuries

The most common workplace injury in California. Overexertion includes lifting, pushing, pulling, carrying, or throwing that strains muscles, tendons, and joints. Repetitive motion injuries develop from performing the same movements thousands of times.

Common Examples

• Back strains and herniated discs: From lifting heavy objects
• Carpal tunnel syndrome: From repetitive typing, scanning, or hand tool use
• Rotator cuff tears: From overhead reaching and lifting
• Tendonitis: In shoulders, elbows, and wrists from repetitive motions

High-Risk Industries

Healthcare (patient handling), warehousing, manufacturing, construction, retail, office work

Prevention Strategies

• Use proper lifting techniques: bend at knees, keep loads close, don't twist
• Request assistance for heavy or awkward items
• Use mechanical aids: dollies, forklifts, patient lifts
• Take micro-breaks to vary motions and rest muscles
• Set up ergonomic workstations with proper keyboard and monitor height
• Rotate job tasks to avoid repetitive strain

Workers' Comp Settlement Range

$15,000 - $120,000 depending on severity, surgery requirements, and permanent restrictions

2. Slips, Trips, and Falls on the Same Level

Falls on wet floors, uneven surfaces, cluttered walkways, and poorly maintained areas cause fractures, head injuries, and soft tissue damage.

Common Causes

• Wet or slippery floors (spills, cleaning, weather)
• Uneven flooring or torn carpeting
• Cluttered walkways and electrical cords
• Poor lighting in hallways or stairwells
• Inadequate footwear for work conditions

Common Injuries

• Fractured wrists, arms, ankles (from catching falls)
• Hip fractures (especially in older workers)
• Knee injuries and torn ligaments
• Head injuries and concussions
• Spinal injuries

Prevention Strategies

• Clean up spills immediately and post wet floor signs
• Keep walkways clear of obstacles and cords
• Report uneven flooring or torn carpeting for repair
• Ensure adequate lighting throughout the workplace
• Wear slip-resistant footwear appropriate for your work environment
• Slow down when walking, especially around corners

Workers' Comp Settlement Range

$15,000 - $150,000 depending on fractures, head injuries, or spinal damage

3. Falls from Heights

Falls from ladders, scaffolding, roofs, and elevated platforms cause some of the most catastrophic workplace injuries. Construction workers face the highest risk, but warehouse, maintenance, and retail workers also fall from heights.

Common Scenarios

• Ladder falls (improper setup, overreaching, defective equipment)
• Scaffold collapses or falls through weak planking
• Roof work without proper fall protection
• Falling through skylights or roof openings
• Falls from loading docks or truck beds

Common Injuries

• Spinal cord injuries and paralysis
• Traumatic brain injuries
• Multiple fractures
• Internal organ damage
• Fatalities

Prevention Strategies

• Use proper fall protection equipment: harnesses, guardrails, safety nets
• Inspect ladders before use and follow 3-point contact rule
• Ensure scaffolding is properly erected by qualified workers
• Never work on roofs without fall protection
• Cover or guard floor openings and skylights
• Refuse to work at heights without proper safety equipment

Workers' Comp Settlement Range

$50,000 - $500,000+ for serious injuries; catastrophic cases can exceed $1 million with third-party claims

4. Being Struck By or Against Objects

Workers are hit by falling objects, moving equipment, or collide with stationary objects. This category includes everything from a box falling from a shelf to being struck by a forklift.

Common Scenarios

• Objects falling from shelves, overhead storage, or trucks
• Being struck by moving vehicles or equipment
• Swinging doors or gates
• Walking into low-hanging obstacles
• Tools or materials dropped from heights

Common Injuries

• Head injuries and concussions
• Fractures and broken bones
• Crush injuries
• Soft tissue injuries
• Eye injuries

Prevention Strategies

• Secure overhead storage and don't overload shelves
• Use spotters when operating forklifts and heavy equipment
• Wear hard hats in areas with overhead hazards
• Mark low-clearance areas with bright warnings
• Keep work areas organized to prevent tripping over objects
• Establish designated walkways separate from vehicle traffic

Workers' Comp Settlement Range

$20,000 - $200,000 depending on injury severity; traumatic brain injuries settle at the high end

5. Vehicle Accidents

Workers who drive for their jobs—truck drivers, delivery drivers, salespeople, couriers—face significant accident risk. Vehicle accidents cause some of the most severe workplace injuries.

High-Risk Workers

• Commercial truck drivers
• Delivery drivers (UPS, FedEx, Amazon)
• Sales representatives
• Taxi and rideshare drivers
• Couriers and messengers
• Mobile service technicians

Common Injuries

• Whiplash and neck injuries
• Back and spinal injuries
• Traumatic brain injuries
• Broken bones and fractures
• Internal injuries
• Fatalities

Prevention Strategies

• Avoid distracted driving (phones, eating, GPS)
• Follow hours-of-service regulations to prevent fatigue
• Perform pre-trip vehicle inspections
• Drive defensively and anticipate other drivers' actions
• Adjust speed for weather conditions
• Always wear seatbelts

Workers' Comp Settlement Range

$30,000 - $500,000+; often combined with third-party personal injury claims against at-fault drivers

6. Machinery and Equipment Injuries

Workers caught in, struck by, or crushed by machinery suffer catastrophic injuries. Manufacturing, construction, and warehouse industries have the highest rates of machinery accidents.

Common Scenarios

• Hands or clothing caught in moving machinery
• Crush injuries from presses or heavy equipment
• Amputations from saws, grinders, or conveyor belts
• Entanglement in rotating equipment
• Machinery malfunctions due to poor maintenance

Common Injuries

• Amputations (fingers, hands, arms)
• Crush injuries
• Fractures
• Lacerations and tissue damage
• Fatalities

Prevention Strategies

• Never bypass or disable machine safety guards
• Use lockout/tagout procedures before servicing equipment
• Keep hands, clothing, and jewelry away from moving parts
• Report malfunctioning equipment immediately
• Receive proper training before operating machinery
• Wear appropriate protective equipment

Workers' Comp Settlement Range

$100,000 - $750,000+ for amputations and severe crush injuries; often include third-party product liability claims

7. Cuts, Lacerations, and Puncture Wounds

Sharp objects, tools, glass, and metal cause cuts ranging from minor to life-threatening. Kitchen workers, manufacturing employees, and construction workers face the highest risk.

Common Causes

• Knives and cutting tools (restaurants, food processing)
• Broken glass
• Sharp metal edges
• Power saws and cutting equipment
• Needles (healthcare workers)

Common Injuries

• Lacerations requiring stitches
• Tendon and nerve damage
• Puncture wounds and infections
• Bloodborne pathogen exposure (needlesticks)
• Amputations from severe cuts

Prevention Strategies

• Use cut-resistant gloves when handling sharp objects
• Keep cutting tools sharp (dull tools require more force and slip easier)
• Cut away from your body, never toward yourself
• Clean up broken glass immediately using proper tools
• Use safety guards on power cutting equipment
• Dispose of needles in proper sharps containers immediately

Workers' Comp Settlement Range

$5,000 - $80,000 for lacerations; $15,000 - $300,000 for needlestick injuries depending on disease transmission

8. Workplace Violence and Assaults

Physical attacks by coworkers, customers, patients, or third parties cause serious physical and psychological injuries. Healthcare workers, retail employees, and social workers face the highest risk.

High-Risk Industries

• Healthcare (psychiatric facilities, emergency departments)
• Retail and convenience stores
• Social services
• Law enforcement and security
• Education
• Transportation (taxi, rideshare)

Common Injuries

• Concussions and traumatic brain injuries
• Facial fractures and dental damage
• Neck and back injuries
• PTSD, anxiety, and depression
• Bite wounds and scratches

Prevention Strategies

• Implement workplace violence prevention programs
• Install security cameras and panic buttons
• Train workers to recognize warning signs of escalation
• Provide adequate security staffing
• Design workspaces with clear escape routes
• Report threats and concerning behavior immediately

Workers' Comp Settlement Range

$25,000 - $150,000 for physical injuries; PTSD can add $20,000 - $100,000

9. Exposure to Harmful Substances

Chemical exposure, toxic fumes, asbestos, lead, and other hazardous substances cause respiratory illness, skin conditions, and long-term diseases including cancer.

Common Exposures

• Chemical burns from acids, solvents, or cleaning products
• Respiratory illness from inhaling fumes or dust
• Asbestos exposure (construction, demolition)
• Lead poisoning
• Pesticide exposure (agriculture)
• Infectious disease exposure (healthcare)

Common Injuries

• Chemical burns
• Occupational asthma
• Chronic obstructive pulmonary disease (COPD)
• Mesothelioma and other cancers
• Neurological damage
• Dermatitis and skin conditions

Prevention Strategies

• Use proper personal protective equipment (respirators, gloves, protective clothing)
• Ensure adequate ventilation in areas with fumes or dust
• Follow Material Safety Data Sheet (MSDS) procedures
• Shower and change clothes after exposure to hazardous materials
• Report exposure incidents immediately
• Participate in required medical monitoring programs

Workers' Comp Settlement Range

$25,000 - $400,000+ depending on disease severity; asbestos cases often exceed $500,000

10. Burns (Thermal, Electrical, Chemical)

Burns from hot surfaces, steam, flames, electricity, and chemicals cause excruciating pain and permanent scarring. Restaurant workers, electricians, and manufacturing employees face the highest risk.

Common Causes

• Contact with hot surfaces, liquids, or steam (kitchens, manufacturing)
• Electrical burns from faulty wiring or equipment
• Chemical burns from acids or caustic substances
• Flash fires and explosions
• Arc flash incidents (electrical work)

Common Injuries

• First-degree burns (minor, surface level)
• Second-degree burns (blistering, deeper tissue damage)
• Third-degree burns (full-thickness, requiring skin grafts)
• Permanent scarring and disfigurement
• Nerve damage
• Psychological trauma

Prevention Strategies

• Use insulated gloves when handling hot items
• Follow lockout/tagout procedures for electrical work
• Wear flame-resistant clothing in high-risk areas
• Store and handle chemicals according to MSDS guidelines
• Ensure electrical equipment is properly grounded and maintained
• Keep fire extinguishers accessible and know how to use them

Workers' Comp Settlement Range

$20,000 - $350,000+ depending on burn severity and scarring; third-party product liability claims may apply

Your Rights When Injured at Work

Regardless of which injury you suffer, you have workers' compensation rights in California:

Immediate Benefits

• Medical treatment: All injury-related care at no cost
• Emergency care: Immediate treatment for serious injuries
• Temporary disability: Two-thirds of your wages while unable to work

Long-Term Benefits

• Permanent disability: Cash settlement for lasting impairment
• Future medical care: Ongoing treatment coverage
• Vocational rehabilitation: $6,000 retraining voucher plus $5,000 return-to-work supplement if you can't return to your job

Important: You're Covered Even If

• The accident was your fault
• You were working overtime or off the clock
• You're a temporary, part-time, or seasonal worker
• You're undocumented (immigration status doesn't affect workers' comp rights)
• Your employer claims you're an independent contractor (often misclassification)

Steps to Take After Any Workplace Injury

1. Report Immediately

Tell your supervisor the same day. Don't wait, even for "minor" injuries. Delayed reporting gives insurers ammunition to deny your claim.

2. Seek Medical Attention

For emergencies, call 911. For non-emergencies, see a doctor within 24-48 hours. Document everything.

3. Demand a DWC-1 Claim Form

Your employer must provide a workers' compensation claim form within one business day of your report.

4. Document the Scene

• Take photos of hazards that caused your injury
• Get witness names and contact information
• Write down exactly what happened while details are fresh
• Keep copies of all medical records and bills

5. Don't Give Recorded Statements

Insurance adjusters will request statements. Politely decline and consult an attorney first.

6. Hire a Workers' Comp Attorney

Insurance companies minimize payouts. An experienced attorney ensures you receive fair compensation. We work on contingency—you pay nothing unless you win.

Industry-Specific Injury Prevention

Construction

Primary risks: Falls, struck-by, electrocution, caught-in machinery. Use fall protection, guard machines, lockout electrical sources, conduct daily toolbox talks.

Healthcare

Primary risks: Patient handling, needlesticks, violence. Use mechanical lifts, never recap needles, implement violence prevention protocols.

Warehousing

Primary risks: Overexertion, forklift accidents, falls. Use proper lifting technique, establish pedestrian walkways, maintain equipment.

Retail

Primary risks: Slips/falls, overexertion, violence. Keep floors dry, assist customers with heavy items, train workers in de-escalation.

Office Work

Primary risks: Repetitive strain, slips/falls. Set up ergonomic workstations, take micro-breaks, clear walkways of cords.

When to Consult a Workers' Comp Attorney

Hire an attorney immediately if:

• Your claim is denied (full or partial)
• The insurance company delays or refuses treatment authorization
• You're offered a settlement (before accepting anything)
• Your injury is serious (surgery required, permanent disability, lost wages)
• You're being pressured to return to work before medically cleared
• Your employer retaliates against you for filing a claim

Early legal representation prevents mistakes that cost you tens of thousands of dollars.

Frequently Asked Questions

The Bottom Line: Prevention and Protection

Workplace injuries are largely preventable. Employers who prioritize safety, provide proper equipment, train workers thoroughly, and maintain safe conditions dramatically reduce injury rates.

But when prevention fails and you're injured, California workers' compensation provides critical protection. Don't let employers or insurance companies minimize your injury or deny you benefits you've earned.