Work-related musculoskeletal disorders in the warehouse: how can they be prevented?

Physical overexertion at work is the leading cause of sick leave in Spain, according to data collected by the National Institute for Safety and Health at Work. More specifically, the INSST states that musculoskeletal disorders account for 78% of occupational diseases in the country.

Professionals in construction, manufacturing, logistics and warehousing have a particularly high incidence of these disorders due to manual handling of loads and repetitive movements. In order to reduce the risks associated with these jobs, the INSST has updated its Technical Guide on Manual Handling of Loads, highlighting different technical criteria and recommendations that help prevent accidents and injuries that put the physical health and job satisfaction of warehouse workers at risk. 

What are the main musculoskeletal disorders caused by warehouse work? 

Warehouse jobs often involve repeated physical exertion and awkward postures maintained for long periods. These demands can lead to various musculoskeletal disorders, mainly affecting muscles, tendons, joints and nerves. 

1. Lower back pain 

It is caused by overloading the lower back when lifting or carrying weight incorrectly or maintaining awkward postures for a long time. The disorder can become chronic.

2. Tendinitis 

For warehouse workers, it usually occurs in the shoulder area and is associated with overhead movements or frequent handling of heavy objects at mid-height. It is especially common in order-picking jobs, where the professional performs dozens of lifts every day.

3. Knee and meniscus injuries 

Squatting postures, moving across uneven surfaces and load-handling efforts involving leg flexion can cause joint injuries. They particularly affect people who carry out loading and unloading tasks or work in confined spaces.

4. Neck pain 

Activities that require repeatedly looking upwards, carrying weight on the shoulders or maintaining poor cervical alignment can cause chronic neck pain. In addition, the pain can radiate to the shoulders or arms.

5. Carpal tunnel syndrome 

This injury is caused by compression of the median nerve in the wrist and is caused by repetitive flexion and extension movements. In warehouse work, it arises from the constant use of hand tools, intensive handling of small packages or continuous product scanning. 

Measures to prevent work-related musculoskeletal disorders

As we have seen, the tasks performed by warehouse operatives entail a high risk of causing musculoskeletal disorders if they are not properly managed. To protect workers' health and create a safe working environment, companies must implement preventive measures with a comprehensive approach. The National Institute for Safety and Health at Work (INSST) offers extensive information on risk factors and the most appropriate strategies to prevent MSDs. Here are some of the most effective measures. 

1. Adapting workspaces to each person 

Redesigning workstations should begin with an initial risk assessment and involve the operators themselves in order to adapt them to their needs. It may include aspects such as adjusting the height of tables, trays or conveyor belts and ensuring that machine controls are within reach without unnecessary stretching.

2. Active breaks and task rotation

Short breaks involving stretches or gentle exercises during the working day improve circulation and release accumulated tension, especially in the shoulders, back and wrists. In addition, rotating duties helps reduce muscle fatigue. 

3. Proper warehouse layout and signage 

It is important to organise aisles, loading areas and travel routes in a way that avoids unnecessary movements and sudden twists. Signage should indicate walkways, load limits, rest areas and mechanical-assistance points.

4. Use of professional footwear 

In environments where the worker stands for many hours or moves around constantly, comfortable footwear with a slip-resistant sole, cushioned insole, good shock absorption and reinforced toe cap reduces the risk of accidents and helps prevent potential knee, foot and back problems. 

5. Training in load-handling techniques 

In many cases, musculoskeletal disorders in the warehouse occur because the goods being handled are managed incorrectly. Therefore, it is essential to provide regular practical training that teaches workers to keep their backs straight, bend their knees and avoid sudden twisting of the torso.

6. Mechanical aids 

Tools such as trolleys, pallet trucks and roller systems facilitate the transport and handling of heavy or bulky goods, minimising repetitive exertion and awkward postures.

7. Ongoing monitoring 

Working conditions and tools in a warehouse are constantly changing. Therefore, it is important to carry out regular assessments and postural-hygiene surveys among workers and adopt preventive measures according to needs. 

The postural health of warehouse workers is key to maintaining their motivation and productivity. At Shoes For Crews, we offer a wide catalogue of professional footwear specifically designed to meet the demands of the working environment. Contact us and we will help you choose the models that best suit your team's needs.