Physical strain in the workplace costs companies significantly more than just sick days. The hidden costs include replacement costs, lost productivity, higher insurance premiums, legal risks, and long-term absences of experienced employees. For industries involving intensive manual labor, such as logistics, manufacturing, and warehousing, these costs can quickly add up to tens of thousands of euros per incident. This article answers the most frequently asked questions about physical strain and how you, as an employer, can address it systematically.
What are the financial consequences of work-related musculoskeletal disorders?
Work-related musculoskeletal disorders (MSDs) are one of the most costly health issues for companies. The direct costs—such as continued pay during sick leave and medical care—are obvious. But the indirect costs are at least as significant: loss of production capacity, additional overtime for coworkers, hiring temporary staff, and loss of knowledge due to long-term absences.
Back pain, shoulder injuries, and repetitive strain injuries are the most common forms of MSDs. They not only lead to short-term absenteeism but also to chronic conditions that result in employees being permanently sidelined or reassigned to lighter duties. The costs of reassignment and retraining are rarely factored in, but they constitute a substantial portion of the total cost of claims. Employers who invest in prevention through ergonomic measures will see a clear reduction in their absenteeism rates and associated costs over time.
Which tasks in the workplace cause the most physical strain?
The tasks most likely to cause physical strain are heavy lifting, working for long periods in a bent or twisted position, performing repetitive movements, and working in environments with vibrations. Combinations of these factors exponentially increase the risk of MSA.
In practice, these are the procedures that carry the highest risk:
- Manually lifting and moving heavy loads, such as boxes, bags, or pallets, without the use of assistive devices
- Repetitive bending and twisting, such as when loading and unloading vehicles
- Working in static positions that are physically straining, such as crouching for long periods or with arms raised
- Working with barrels or rolls that are difficult to grip and cause an asymmetrical load
- Pushing and pulling heavy carts on uneven surfaces
Sectors such as pallet handling and box handling are particularly vulnerable, because employees repeat these movements dozens to hundreds of times a day. The cumulative effect on the body is significant, even though each individual movement may not seem dangerous on its own.
How does physical overexertion affect long-term productivity?
Physical strain affects long-term productivity in three ways: increased absenteeism due to illness, reduced work capacity among employees who continue to work despite pain, and chronic staff turnover. Even when employees are present, chronic pain leads to reduced concentration, slower work performance, and more errors.
The phenomenon of presenteeism—where an employee is present but performs below their normal capacity due to physical ailments—is often underestimated. Research in manufacturing environments shows that presenteeism sometimes has a greater impact on output than absenteeism, precisely because it remains invisible. Furthermore, employees who perform physically demanding work for years without adequate support are at a higher risk of early retirement. This loss of experienced workers has a direct impact on the quality and continuity of business processes.
What are employers' legal obligations regarding ergonomics?
Belgian employers are legally required to assess working conditions and take measures to prevent MSDs. This stems from the Code on Workplace Well-Being, which requires employers to identify, evaluate, and manage risks, with particular attention to the manual handling of goods.
In practical terms, this means that employers:
- A risk assessment must be conducted for all tasks that involve physical strain
- Technical and organizational measures must be taken to mitigate those risks
- Employees must be informed and trained on safe work practices
- Periodically evaluate the effectiveness of the measures taken
The prevention advisor and the occupational physician play a central role in this regard. If an employer can be shown to have been negligent in taking preventive measures, this may result in liability for workplace accidents and occupational diseases. The law establishes not only a duty of care but also an obligation to achieve specific results in the area of risk management.
How can ergonomic aids prevent physical strain?
Ergonomic aids prevent physical strain by reducing or completely eliminating the load on the human body. They enable employees to move, lift, or rotate loads without straining the spine, shoulders, or joints. This reduces the risk of musculoskeletal disorders (MSDs) in a structural and sustainable way.
Choosing the right tool depends on the specific task and the type of load. Examples of effective ergonomic solutions include:
- Vacuum lifters and hoists for lifting sheets, boxes, or drums without manual effort
- Electric pallet trucks that eliminate the need to push and pull heavy pallets
- Mobile lifts for positioning loads at the correct working height
- Pallet turners that eliminate the need to turn pallets manually
A good ergonomic aid not only solves the immediate lifting problem but also contributes to more efficient work processes. Employees can be deployed more flexibly, including those whose physical capacity is limited due to a previous injury. View the full product lineup for an overview of available solutions by application.
When is a job analysis useful for your company?
A job analysis is useful whenever employees regularly report physical complaints, absenteeism is on the rise, or when tasks involve manual lifting, carrying, pushing, or pulling. A job analysis is also highly recommended when introducing new products, processes, or workstations.
In practice, many companies wait too long to conduct a workstation analysis—often only after an incident has occurred. A proactive approach, however, is much more cost-effective. An analysis not only identifies risks but also provides concrete recommendations for improvements that can be implemented immediately. This prevents minor ergonomic issues from escalating into chronic health problems. Check out our completed projects for inspiration on how other companies have addressed ergonomic challenges.
How Logitrans Handling Helps Prevent Physical Strain in the Workplace
At Logitrans Handling, we offer a comprehensive approach for companies that want to systematically address physical strain. Our approach is practical and tailored to each client’s needs:
- Free workstation analysis: Our specialists will identify the ergonomic risks in your workplace and propose specific improvements
- Customized advice: We select the most suitable ergonomic lifting solution for your specific situation, whether it involves boxes, bags, sheets, pallets, drums, or rolls
- Try it out in the demo room: In our demo room in Drongen, you can test solutions using your own materials, so you can be sure you’re making the right choice
- Implementation and training: We oversee the installation and, if desired, provide training for the users
- Maintenance Contracts: Through our service and maintenance programs, we ensure that your equipment continues to perform and that safety remains guaranteed
Ergonomic work practices are an investment that pays for itself: less absenteeism due to illness, higher productivity, and a more flexible workforce. Would you like to know what we can do for your company? Feel free to contact us with no obligation and discover how a simple workstation analysis can be the starting point for a healthier and more efficient workplace.
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