Maintenance workers perform some of the most physically demanding and varied tasks in any workplace. Unlike production workers who often perform standardized, repetitive jobs, maintenance personnel must regularly adapt to changing environments, equipment, and work requirements. They may be responsible for preventive maintenance programs with inspection and service intervals that span months, or even years, requiring workers to recall procedures and equipment details long after a task was last completed. At the same time, they must be prepared to respond quickly to unexpected breakdowns and corrective maintenance activities when equipment failures threaten production schedules, facility operations, or service delivery. According to Ontario WSIB Safety Check data, the average injury claim cost for maintenance and related service occupations was approximately $4,381.31 in 2025, with workers aged 50–54 years representing the leading age group affected. These findings highlight the importance of proactive ergonomic interventions, particularly as many organizations rely on experienced maintenance personnel to support operational reliability. (Workplace Safety and Insurance Board [WSIB], 2026)
The nature of maintenance work frequently exposes workers to elevated musculoskeletal injury (MSI) risks. Tasks often involve handling heavy, bulky, or awkwardly shaped components that provide poor handholds or “coupling” opportunities. Maintenance staff may find themselves replacing toilets, repairing sink basins, servicing mechanical equipment, adjusting valves in hard-to-reach locations, or transporting heavy parts through congested work areas via hand bombing. These activities are commonly performed in maintenance rooms, around boilers and process piping, on ladders, or within confined and restricted spaces where optimal body positioning is impossible. (International Organization for Standardization [ISO], 2021); (Kotowski & Gibson, 2023); (Rodgers, 1998, as cited in Eastman Kodak Company, 2004)
Common Ergonomic Challenges in Maintenance.
Several factors combine to make maintenance work particularly challenging from an ergonomic perspective:
- Non-routine and unpredictable tasks
- Emergency repair work with tight deadlines
- Awkward postures such as kneeling, squatting, crawling, or overhead reaching
- Manual handling of heavy or awkward loads
- Repetitive use of hand and power tools
- Exposure to vibration from powered equipment
- Work in confined spaces or poor-access locations
- Time pressures that can encourage workers to bypass safer work practices
Unlike planned production activities, maintenance tasks rarely occur under ideal conditions. Workers often need to adapt their body position to fit the equipment rather than bringing the equipment into an ergonomically favourable position. This combination of force, repetition, and awkward posture can significantly increase the risk of strains, sprains, and other musculoskeletal injuries. (International Organization for Standardization [ISO], 2021); (Kotowski & Gibson, 2023); (Rodgers, 1998, as cited in Eastman Kodak Company, 2004)
Practical Ergonomic Solutions for Maintenance Teams.
Fortunately, many ergonomic risks can be reduced through thoughtful planning and the use of appropriate equipment.
Material handling carts, lift-assist devices, hoists, and mobile work platforms can significantly reduce the physical demands associated with moving equipment and replacement parts. Knee pads and kneeling supports can minimize stress on joints during low-level work, while adjustable work surfaces and portable stands can help position work at more comfortable heights. Proper tool selection is equally important; lighter-weight tools, extended-handled tools, and vibration-reducing equipment can help reduce fatigue and cumulative stress on the body. (ISO, 2021)
Even small improvements to access can yield significant benefits. Relocating frequently serviced components, improving workspace clearance, or installing permanent platforms can reduce awkward reaches and excessive bending throughout the life of the equipment.
Many maintenance tasks involve sub-maximal exertions rather than all-out physical effort. Although workers are rarely lifting their maximum capacity, they may spend hours performing repetitive tasks, carrying tools, pushing carts, climbing ladders, kneeling, squatting, reaching overhead, or working in awkward postures. Over time, these lower-level but prolonged physical demands can accumulate, increasing fatigue and elevating the risk of musculoskeletal injuries. Research on ergonomics consistently identifies force, repetition, awkward posture, and vibration exposure as key contributors to work-related musculoskeletal disorders. (CCOHS, 2025.); (U.S. Department of Labor, Occupational Safety and Health Administration, 2024.); (Government of Ontario, 2021); (Rodgers, 1998, as cited in Eastman Kodak Company, 2004).
For this reason, organizations are increasingly exploring strategies commonly used in sport and athletic performance. One promising approach is the implementation of dynamic warm-ups before physically demanding work begins. Dynamic warm-ups involve controlled movements that gradually increase blood flow, elevate muscle temperature, improve joint mobility, and prepare the body for physical activity. Examples may include bodyweight squats, walking lunges, arm circles, shoulder mobility exercises, marching, and light stretching movements. A brief 5–10 minute warm-up session before the start of a shift or before particularly demanding maintenance activities may help workers mentally and physically prepare for the task ahead. These sessions can also create an opportunity to review job hazards, discuss ergonomic controls, and reinforce safe work practices. While warm-ups should never replace ergonomic improvements or hazard controls, they can serve as a complementary strategy within a broader injury prevention program.
The Value of Pre-Job Planning.
One of the most effective ergonomic controls in maintenance work occurs before the job even begins.
Pre-job planning enables workers and supervisors to identify potential hazards and determine safer ways to complete the task. Materials can be staged close to the point of use to eliminate unnecessary carrying distances. Team lifts can be organized in advance for heavier components. Tools and equipment can be gathered beforehand to minimize repeated trips and awkward handling. Scheduling physically demanding jobs when sufficient staffing and time are available also reduces the likelihood that workers will rush or place excessive strain on their bodies. (Kotowski & Gibson, 2023)
When ergonomics are considered during planning, workers spend less time improvising solutions and more time completing the job safely and efficiently.
Recognizing Early Warning Signs.
Maintenance workers should be encouraged to report discomfort and fatigue before minor symptoms develop into significant injuries. Early warning signs may include:
- Persistent soreness or stiffness
- Tingling or numbness
- Reduced grip strength
- Joint discomfort
- Fatigue that does not improve with normal recovery
Creating a workplace culture where workers feel comfortable reporting symptoms allows organizations to address underlying hazards before they result in lost-time injuries, medical restrictions, or long-term health concerns. Regular discussions about ergonomic risk factors can also improve awareness and encourage proactive problem-solving.
What Supervisors Can Improve Quickly.
Supervisors play a critical role in identifying and addressing ergonomic risks. Walk-through assessments of high-strain tasks can reveal opportunities for improvement that may otherwise go unnoticed. Reviewing recurring maintenance activities, talking with workers about their most difficult jobs, and identifying common sources of physical strain can help prioritize corrective actions.
Simple improvements such as enhancing access, providing material handling equipment, adjusting work practices, or redesigning frequently used work areas can often deliver immediate benefits. The most successful ergonomic interventions focus on eliminating or reducing the highest-risk exposures first.
Ergonomics Supports Reliability, Too.
Ergonomics is often viewed solely as a safety initiative, but its benefits extend far beyond injury prevention. When maintenance workers experience less physical strain, they can perform tasks more consistently, maintain higher work quality, and sustain productivity throughout their shifts. Reduced fatigue can also improve concentration, decrease errors, and support more reliable maintenance outcomes.
Organizations that invest in ergonomics are not only preventing injuries in their workers, they are also supporting equipment reliability, operational efficiency, and workforce sustainability. Healthy workers are better positioned to perform the skilled work required to keep facilities running effectively.
The goal is not simply to teach workers to tolerate a demanding task. It is to design work that better matches human capabilities, provides realistic recovery, and prevents predictable exposure from becoming an injury.
Conclusion.
Maintenance work will always involve unique physical challenges, but those challenges do not have to translate into unnecessary injury risk. By combining ergonomic equipment, thoughtful planning, worker training, and continuous improvement efforts, organizations can reduce physical strain while improving both safety and operational performance.
Rather than viewing ergonomics as simply a compliance requirement, maintenance leaders should embrace it as a practical planning tool, one that helps workers perform demanding jobs more safely, efficiently, and sustainably.
Explore EWI Works’ industrial ergonomic tools, learn about PoseChecker, or contact the EWI Works team to discuss your warehouse ergonomics needs.
References
Workplace Safety and Insurance Board. (2026). Injury characteristics: Provincial statistics (Schedule 1 and 2). Safety Check. https://safetycheck.onlineservices.wsib.on.ca/safetycheck/explore/provincial/SH_12/injurycharacteristics?lang=en
ISO Standard 11228-1:2021, Ergonomics – Manual Handling – Part 1: Lifting and carrying
Kotowski, S. E. and Gibson, S. L. (2023). Ergonomic Assessment Toolkit. American Industrial Hygienist Association (AIHA).
Rodgers, S. (1998). In: Eastman Kodak Company (2004). Kodak’s ergonomic design for people at work, second edition. New Jersey: John Wiley & Sons.
Canadian Centre for Occupational Health and Safety. (2025). Workrelated musculoskeletal disorders (WMSDs). https://www.ccohs.ca/oshanswers/diseases/wmsd
U.S. Department of Labor, Occupational Safety and Health Administration. (2024). Ergonomics: Solutions to control hazards. https://www.osha.gov/ergonomics/control-hazards
Government of Ontario. (2021). Manual materials handling. https://www.ontario.ca/document/manual-materials-handling?redirect_id=page%2Fmanual-materials-handling&redirect_year=2021
EWI Works offers many services that can improve your quality of life. We have developed several cost-effective remote services to help you transition to remote work. Find out more about our Online Training, Services, and Resources.
Follow us on Twitter, LinkedIn, and Facebook for more updates and offers, or sign up for our newsletter below.
