Top 10 causes of accidents in the workplace and their costs

Workplace injuries can be extremely costly for small businesses and their employees. Serious, non-fatal workplace injuries now account for $48.15 billion in U.S. workers’ compensation costs, according to the 2023 Liberty Mutual Workplace Safety Index that reflects 2020 data.

Liberty Mutual found that overexertion continued to be the leading cause of workplace injuries, followed by injuries related to falling.

Two new categories joined the top 10 index for the first time in 2020: exposure to harmful substances, which includes communicable diseases such as COVID-19, and pedestrian vehicular incidents, which are likely related to the impacts of the pandemic on certain industries.

Knowing the most common workplace injuries and how to prevent them can have a significant impact on the safety of your employees and the longevity of your business.

Top 10 causes of workplace accidents and their costs

1. Overexertion

Overexertion can happen with lifting, pushing, pulling, holding, carrying, or throwing objects. To prevent injuries related to overexertion, be sure to provide your employees with ergonomic equipment and properly train them about safety involving physical tasks.

• Cost: $12.84 billion
• Percent: 21.9%

2. Falls on same level

Same-level falls can occur anywhere and happen to anyone at a workplace, which is why they’re so common. Loose wires, wet floors, or even a file cabinet drawer left open can cause people to trip or slip.

• Cost: $8.98 billion
• Percent: 15.3%

3. Falls to lower level

Falling from a height, such as a ladder or a roof, to a lower surface can cause major injuries and even death. These injuries are less common than falls on the same level. Protect your employees from these accidents by providing them with the right kind of equipment and fall protection gear.

• Cost: $6.09 billion
• Percent: 10.4%

4. Struck by object or equipment

Being struck by a falling object or a piece of equipment or machinery is one of the leading causes of death in the construction industry, according to the Occupational Safety and Health Administration, and other industries aren’t immune from such accidents.

• Cost: $5.14 billion
• Percent: 8.8%

5. Other exertions or bodily reactions

Bodily reactions and exertions rank fifth on the Workplace Safety Index and are caused when a person is engaged in a strenuous effort or excessive physical motion. Repetitive actions are often the cause, so they can happen with just about any kind of job.

• Cost: $3.67 billion
• Percent: 6.3%

6. Exposure to other harmful substances

Exposure to other harmful substances includes COVID-19 illnesses and joined the index for the first time in 2023, coming in as the sixth most costly cause of injury.

• Cost: $3.3 billion
• Percent: 5.7%

7. Roadway incidents involving motorized land vehicles

Motorized land vehicles can include everything from trucks to motorcycles, and an incident can involve the driver, a passenger, or even a pedestrian.

• Cost: $2.58 billion
• Percent: 4.4%

8. Caught in or compressed by equipment or objects

These accidents typically involve an employee having a body part crushed or caught by a workplace object or piece of equipment. Examples include workers caught by moving machinery or crushed between two heavy objects.

• Cost: $1.98 billion
• Percent: 3.4%

9. Slip or trip without fall

Slip and trips happen when there’s a lack of traction between a person’s shoe and the walking surface. They can also occur when there’s an uneven surface or an unexpected change in flooring or steps.

Proper housekeeping is key to avoiding employee injuries. Ensure floors are clean and that slippery surfaces are well-marked. Maintain well-lit and uncluttered areas, and make sure your employees are wearing proper shoes at all times.

• Cost: $1.92 billion
• Percent: 3.3%

10. Pedestrian vehicular incidents

These incidents joined the index for the first time. The increase in these incidents likely resulted from COVID-19 pressures on supply chain, industrial hygiene, security, and delivery operations. These incidents were evident in material movers, sales and truck drivers, distribution managers, retail salespersons, building cleaning and maintenance, protective service, and food service.

• Cost: $1.61 billion
• Percent: 2.7%