It’s a number that can keep any manager awake at night: $167 billion.
That was the total cost of workplace injuries in the U.S. in 2022, according to the National Safety Council (NSC).This staggering figure isn’t just about medical bills and lost wages; it represents lost productivity, potential legal fees, and damage to a company’s hard-earned reputation. Workplace injury prevention is about keeping people safe, while saving companies money.
While no two job sites are identical, the risks often are. In fast-paced environments like warehouses, construction sites, and waste management facilities, the same preventable incidents occur time and again.
In this guide, we’ll break down the five most common types of workplace accidents and show how simple changes in process, culture, and technology can make a world of difference in keeping your team safe.
1. Slips, Trips, and Falls
From a minor scrape to a life-altering injury, the consequences of a simple fall are dangerously unpredictable. The culprit is often something simple: a wet surface, a cluttered walkway, poor lighting, or even a moment of distraction.
How Can You Prevent Slips and Falls?
• Clean and Well-Lit Walkways: Make it a daily routine to ensure all surfaces are free of spills, debris, and obstructions. Good lighting in all work zones and traffic areas is non-negotiable.
• Clear and Visible Signage: A simple “Wet Floor” sign is a powerful tool. Use signs to alert workers to uneven ground or other hazards before they enter an unsafe area.
• Slip-Prevention Measures: Install anti-slip mats in high-risk zones, apply non-slip coatings to floors, and mandate appropriate, slip-resistant footwear.
• Promote Situational Awareness: A “heads-up” culture is crucial. Encourage workers to store their phones while walking and to always check the ground before exiting a vehicle or machine.
2. Struck-By Incidents
Being struck by a moving vehicle or heavy equipment is one of the leading causes of workplace fatalities, especially in construction. According to OSHA, these “struck-by” incidents often happen when personnel are working in close proximity to active machinery, a risk that multiplies in fast-paced or low-visibility conditions.
According to U.S. Bureau of Labor Statistics data, 67 workers lost their lives in 2023 in incidents involving forklifts, order pickers, or platform trucks. Fatal injuries were most common among workers aged 45–54, while younger workers were more frequently involved in nonfatal incidents during 2021–2022.
How Can You Prevent Struck-By Incidents?
• Leverage Smart Safety Technology: This is where modern tech becomes a game-changer. Equipping vehicles with 360° cameras, blind spot detection, and pedestrian alerts gives operators the visibility they need to prevent collisions.
• Establish Clear Zones and Pathways: Designate and clearly mark safe walking lanes for pedestrians. Use barriers and high-visibility signage to separate people from moving equipment.
• Conduct Targeted Safety Training: Regularly train both operators and ground personnel on site-specific protocols, hazard recognition, and emergency procedures.
• Reinforce a Culture of Accountability: Safety isn’t a one-time meeting. Reinforce expectations in daily briefings and with visible reminders to keep safety top-of-mind for everyone.
3. Falling Objects and Material Handling
When work happens on shelving or at height, even a small, dropped tool can cause a serious injury. These incidents are common in warehouses and on construction sites, often caused by improperly stacked materials, unsecured loads, or rushed handling.
How Can You Prevent Falling Object Injuries?
• Secure All Tools and Loads: Use tool lanyards when working at height. Always use tie-downs, netting, and proper restraints when transporting or storing materials.
• Wear the Right Personal Protective Equipment: This is the last line of defense. Hard hats, steel-toe boots, and high-visibility clothing can significantly reduce the severity of an injury.
• Train for Safe Lifting and Loading: Educate all workers on proper techniques for stacking boxes, and securing items to prevent loads from shifting or tipping.
• Schedule High-Risk Work Strategically: When possible, schedule tasks like crane work or elevated repairs during times of lower foot traffic to minimize risk to others on site.
4. Overexertion and Repetitive Strain
Often called “wear-and-tear” injuries, overexertion from heavy lifting, pulling, or repetitive motions can have devastating long-term effects. These musculoskeletal disorders lead to chronic pain, reduced mobility, and can even shorten a skilled worker’s career.
How Can You Reduce Overexertion Injuries?
• Provide Ergonomic Training: Teach workers proper lifting techniques, body mechanics, and the importance of posture to reduce physical strain.
• Rotate Job Tasks:Design workflows that allow employees to alternate between physically demanding and lighter tasks. This prevents fatigue and overuse of any single muscle group.
• Encourage Early Reporting: Foster a culture where workers feel safe reporting pain or discomfort before it becomes a chronic injury.
5. Operator Fatigue and Human Error
Ultimately, many workplace accidents boil down to human error—often driven by fatigue. An alert, focused worker is the most valuable safety asset you have. When fatigue sets in, situational awareness drops, reaction times slow, and the risk of an incident skyrockets.
How Can You Combat Fatigue and Human Error?
• Prioritize Rest: Enforce scheduled breaks and educate your team on the importance of adequate rest. A tired worker is a risk to everyone.
• Utilize Real-Time Monitoring Tools: Technology can serve as a vital co-pilot. An Advanced Driver Safety Systems (DSS), can detect signs of driver drowsiness, distraction (like mobile phone use), and smoking, providing real-time alerts to prevent an incident before it happens.
• Conduct Regular Safety Refreshers: Keep safety protocols fresh in everyone’s mind with ongoing training sessions, not just during onboarding.
• Foster a “Safety-First” Culture: Empower every team member to speak up about hazards, to slow down when necessary, and to hold each other accountable for staying safe and alert.
Workplace injury prevention should be a top priority for safety managers, and companies. While training and safety culture are the foundation, technology can push the limits that brings safety into the modern era. The VIA Tech Mobile360 Safety Solution combines AI-powered detection, camera and radar sensing, blind spot detection, and real-time operator alerts to eliminate guesswork in the workplace. From detecting pedestrians and vehicles to monitoring operator fatigue, it delivers the visibility and awareness needed to stop accidents before they happen.
Learn more about how we can help prevent workplace injuries for you by booking a consultation with us.