Repetitive movements in industrial work: definition, common injuries and prevention

The report Occupational safety and health in Europe, published by the EU in mid-2023, notes that ergonomic risks are among the main health concerns for workers. One of the most common is repetitive movements, which 65% of the professionals surveyed in the study reported performing. The conditions and needs of the industrial sector make these actions particularly frequent in its activities. 

Numerous documents have been developed with the aim of preventing injuries linked to these movements. Examples include the Ministry of Health report Repetitive movements of the upper limb and the Technical Guide for the assessment and prevention of risks related to manual load handling. Following the recommendations made by specialists in these and other publications is the best way to reduce injuries and workplace accidents related to these situations.     

What are they and what are the most common repetitive movements in industry? 

Repetitive movements include all continuous activities that require rapid, recurring manoeuvres or efforts and involve the same muscle group. The affected area is most commonly the upper limbs, and they are especially harmful when accompanied by awkward postures and prolonged over time.

More specifically, the international standard ISO 11228-3:2007 considers repetitive movements to be tasks involving a work cycle or a sequence of movements repeated more than twice per minute and which can be considered repetitive for more than 50% of their duration. Based on this information, here are the most common repetitive movements to which industrial professionals are exposed. 

• Loading and unloading products. On production lines, it is common to repeatedly lift, place and move parts. Likewise, the continuous manual lifting and transport of materials is a health risk in the industrial sector. 
• Manual packaging. Repeatedly packing or wrapping boxes and items creates a risk of injury. 
• Welding work. Specialists are required to repeat movements when welding parts, in addition to the risk of maintaining uncomfortable, static postures. 
• Machine operation. Operating heavy machinery or using precision instruments requires repeated actions over prolonged periods. 
• Movements using hand tools. Cutting with hand tools or screwing and unscrewing causes strain on the upper limbs. 

What are the most common injuries caused by repetitive movements?

Repeated exertion is not always identified as a risk by professionals, leading to overload and prolonged poor postures that cause musculoskeletal disorders. These are the most common injuries linked to repeated exertion. 

Tendinitis 

Overload resulting from frequent movements triggers inflammation of muscle tendons, causing particularly acute pain when the injured limb or joint is moved. It is common in the shoulders, elbows, wrists and knees. 

Epicondylitis 

Also known as “tennis elbow”, repetitive movements cause intense pain and inflammation in the forearm or the entire arm. In industry, it is usually linked to activities requiring considerable force from the arm or forearm, as well as repetitive wrist twisting or gripping movements. Although rest and painkillers may be sufficient for recovery, surgery is sometimes necessary. 

Lower back pain 

Actions performed suddenly that also involve lifting weights or forced movements of the torso can cause this pain in the lower back, one of the most prevalent conditions in our country. Lower back pain can become a chronic condition and be disabling for the worker, worsening their quality of life.  

Rotator cuff injury

The rotator cuff is the structure that enables shoulder mobility and stability. Its constant activity when the joint is used makes it prone to injury when repetitive movements are performed above the head. This injury causes acute pain, especially at night. 

How to prevent repetitive movements at work

Avoiding potential injuries caused by repetitive movements requires preventive measures with a comprehensive approach. It is essential to consider a range of factors, such as working conditions, the particular needs of each professional and appropriate rest time depending on the task being performed. 

1. Establish appropriate rest periods 

The incidence of injuries increases considerably when movements are performed for prolonged periods. Depending on the type of activity and the overload it places on muscles and joints, workers need to be given time to recover through regular breaks. 

2. Individual adaptation of workstations

Customising the layout of workstations, equipment and tools for each professional prevents awkward postures which, combined with frequent movements, can cause injuries. 

3. Task alternation 

Rotating activities that involve different muscle groups helps distribute exertion and contributes to preventing injuries linked to the overload caused by repetitive movements. 

4. Use of personal protective equipment

In addition to protecting against impacts, falls and cuts, PPE reduces the risks associated with recurring movements in industrial environments. Ergonomic gloves, for example, reduce the effort required to handle tools, helping maintain a neutral position and avoid forced, repeated movements. 

Likewise, professional shoes with slip-resistant soles and good support help workers control their movements better and avoid repeatedly making compensatory movements to maintain balance. 

5. Worker training and awareness 

Professionals should receive personalised training based on the activity they perform, informing them of the risks of repeating movements in their work and showing them alternatives. 

Taking appropriate measures to reduce repetitive movements among industrial workers lowers the risk of injuries that affect your team's productivity and job satisfaction. Professional Shoes For Crews footwear meets the needs of your workforce, improving professionals' ergonomics and increasing their wellbeing. If you are looking for personalised advice, contact us and we will help answer all your questions.