Ergonomics in the Workplace: Manufacturing and Construction

The manufacturing and construction sectors are inherently physical: heavy lifting, repetitive tasks, awkward postures, and variable environments are daily realities. These conditions put workers at high risk for Work‐Related Musculoskeletal Disorders — back strains, shoulder sprains, carpal tunnel syndrome, etc. Effective ergonomic interventions can drastically reduce these injuries, save employers money, improve employee morale and retention, and boost productivity and product quality. We’ll discuss how physical therapists are uniquely positioned to lead these efforts — both in prevention and recovery.

Studies have consistently shown that ergonomic interventions can significantly reduce injuries. In fact, data from numerous sources have found that implementation of ergonomic programs resulted in reductions in musculoskeletal disorders, incidence rates, and in lost workdays.^1,2,4 As you might imagine, this had significant impact on reducing workers’ compensation costs. Additionally, workplaces that implemented ergonomic redesigns can see increases in productivity and drops in employee turnover and absenteeism.^1,2,4 This also benefits employers bottom line.⁴

Yet the return on investment from ergonomic interventions is not solely measured in dollars. In manufacturing and construction environments, ergonomics often translates directly into improved worker morale. Employees who feel physically supported are more likely to stay with their employer, work more effectively, and report greater satisfaction.¹

So, what exactly do effective ergonomic strategies look like in these demanding industries? In manufacturing settings, they may involve the use of lift-assist devices, tilting worktables, conveyors, and other equipment designed to reduce physical strain. Adjustable workstations and anti-fatigue mats can minimize stress on joints and muscles. Meanwhile, in construction, common interventions include adjustable scaffolding, vibration-dampening hand tools, safe lifting protocols, and work rotation to prevent overuse injuries.

Crucially, ergonomic success doesn’t hinge solely on equipment upgrades. Worker education and participatory ergonomics programs, where employees are involved in identifying risks and developing solutions, can play a key role. Companies that engage workers in this way not only improve the practical implementation of ergonomic solutions but also enhance buy-in and long-term sustainability.

This is where physical therapists come in. PTs are uniquely equipped to serve as both post-injury resources and pre-injury collaborators. Their expertise in human biomechanics, injury recovery, and movement optimization position them as valuable allies for employers aiming to reduce workplace injuries and create healthier work environments.

Post-injury, physical therapists help employees recover and return to work safely. They analyze job demands, identify task modifications, and recommend equipment or workflow changes that accommodate the injured worker while preventing further harm. Studies have shown that incorporating workplace assessments and ergonomic adjustments into rehabilitation programs can reduce time away from work.³ The financial benefits are equally compelling. One study estimated that workplace-focused therapy programs yielded cost savings with a return on investment of 9 to 1.⁴

Equally important, physical therapists can play a preventive role long before injuries occur. Employers can collaborate with PTs to conduct on-site ergonomic assessments, customize workplace setups, and deliver hands-on training in safe lifting techniques and posture management. Physical therapists can also create job-specific stretching routines and fatigue-reducing exercise programs tailored to the demands of each industry. These strategies help strengthen muscles prone to strain, promote proper movement patterns, and reduce the risk of cumulative trauma disorders.

Involving physical therapists in participatory ergonomics programs further enhances workplace safety culture. PTs bring evidence-based insight into how tasks impact the human body and can help design changes that workers will use and appreciate. When employers include PTs as part of their ergonomics committees, they benefit not only from clinical expertise but also from a deeper connection between worker needs and operational goals.

For employers, the message is clear. Ergonomics is not a luxury — it’s a smart, data-backed investment. With reductions in injuries, compensation claims, and lost time, and improvements in productivity, quality, and retention, the return is more than financial — it’s cultural. And physical therapists are essential partners in this transformation.

In fast-moving, physically demanding sectors like manufacturing and construction, creating safe, ergonomic work environments is not only the right thing to do for workers — it’s also one of the most effective ways to build a sustainable and high-performing business. By integrating the knowledge and skills of physical therapists into ergonomic planning, employers can ensure they are not just reacting to injuries, but preventing them before they happen.

To learn more about how Upstream Rehabilitation and our family of brands can assist with Workers’ Compensation and how physical therapy plays an effective role in helping injured workers return to work, contact our Workers’ Compensation team today!

1. Goggins RW, Spielholz P, Nothstein GL. Estimating the effectiveness of ergonomics interventions through case studies: implications for predictive cost-benefit analysis. J Safety Res. 2008;39(3):339-44. doi: 10.1016/j.jsr.2007.12.006. Epub 2008 Apr 28. PMID: 18571576.
2. Larson N, Wick H. 30 years of ergonomics at 3M: a case study. Work. 2012;41 Suppl 1:5091-8. doi: 10.3233/WOR-2012-1043-5091. PMID: 22317510.
3. Neubert N, Bruder R, Toledo B. The charge of ergonomics–a model according to the influence of ergonomic workplace design for economical and efficient indicators of the automotive industry. Work. 2012;41 Suppl 1:4389-95. doi: 10.3233/WOR-2012-0735-4389. PMID: 22317394.
4. 1. Aarås A. The impact of ergonomic intervention on individual health and corporate prosperity in a telecommunications environment. Ergonomics. 1994 Oct;37(10):1679-96. doi: 10.1080/00140139408964945. PMID: 7957020.