Two Injury Types Drive 40% of America’s $58.78B Workplace Safety Bill

Liberty Mutual's 25-year analysis reveals overexertion and same-level falls dominate workplace injury costs, while repetitive motion injuries plummet.
By: | July 18, 2025
Topics: News | Safety | Workers' Comp

Workplace injuries cost American businesses $58.78 billion annually, with just two causes—overexertion involving outside sources and falls on the same level—accounting for nearly 40% of total losses, according to Liberty Mutual’s 2025 Workplace Safety Index.

The insurance company’s quarter-century analysis of top causes of injury shows a complex workplace safety landscape where injury rates have fallen, but total costs continue to rise. Overexertion involving outside sources leads all categories at $13.7 billion in annual costs, followed by falls on the same level at $10.5 billion. These two injury types have consistently dominated the rankings for 25 years, according to Liberty Mutual.

However, significant shifts are occurring within the occupational injury landscape. Falls on the same level have experienced an 84% cost increase, with total financial impact rising by $4.6 billion while accounting for 4.8% more of the total cost proportion.

In contrast, repetitive motion injuries from microtasks have plummeted by 44%, even dropping out of the top 10 causes of injury entirely in 2022 and 2023 before returning to ninth place in 2025 at $1.8 billion, Liberty Mutual found.

The remaining top 10 categories of injury in the 2025 report include struck by object or equipment and falls to lower level (tied at $5.8 billion each), other exertions or bodily reactions ($3.9 billion), roadway incidents involving motorized land vehicles ($2.8 billion), slip or trip without fall ($2.6 billion), caught in or compressed ($2.2 billion), and struck against object or equipment ($1.7 billion).

Cost Concentration Creates Strategic Opportunities

The data reveals significant concentration that presents both challenges and opportunities for risk management professionals. Just 10 injury types account for over 86% of all workplace injury costs, with seven causes consistently appearing in the top 10 rankings throughout the 25-year period analyzed. These persistent categories represent $44.7 billion in annual losses across the insurance industry.

Musculoskeletal injuries show another critical concentration point, with more than half (56%) of workplace injuries affecting the back, shoulder, knee, or multiple body parts. This category alone generates nearly $32.6 billion in costs and represents a major driver of both financial loss and lost productivity for employers, the report noted.

The dramatic reduction in repetitive motion injury costs demonstrates that targeted safety efforts can achieve measurable results, Liberty Mutual said. This category’s 44% cost decline proves that focused prevention strategies can effectively address previously expensive injury types.

“The Index provides employers a trusted roadmap for improving workplace safety,” said Dorothy Doyle, senior vice president and general manager, risk control for Liberty Mutual. “We’re proud to provide this important report, which offers valuable data and insights to help employers prevent injuries and manage risks more effectively, underscoring our commitment to protecting workers and supporting safer, more resilient businesses.”

Access Liberty Mutual’s full findings here. &

The R&I Editorial Team can be reached at [email protected].

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