Workplace Injuries Incur Increased Costs and Extended Recovery Periods: Travelers

A slew of factors have been contributing to workplace injury costs and long recovery times for employees since the pandemic, according to Travelers' 2025 Injury Impact Report.
By: | June 4, 2025

While workplace injuries continue to decline, their associated costs are rising significantly, driven by an aging workforce, high employee turnover, and longer recovery times that pose growing challenges for businesses across all sectors, according to recent findings from Travelers’ 2025 Injury Impact Report.

The U.S. workforce is experiencing demographic shifts that directly impact workplace injury trends. By 2033, approximately 24% of employees will be 55 or older – a substantial increase from 15% of the workforce in 2003. This aging trend is already evident in injury data, with workers aged 50+ comprising 41% of injured employees over the past five years, up from 39% in the pre-pandemic period, the report noted.

“Over the past decade, we’ve seen three trends intensify: increasing retirement ages, ongoing employee turnover and longer injury recovery times,” said Rich Ives, senior vice president of Business Insurance Claim at Travelers. “Our aim with this report is to provide employers with insights on these dynamics that are contributing to growing claim severity.”

Travelers’ analysis of more than 2.6 million claims also highlights the vulnerability of new employees. Workers in their first year on the job accounted for approximately 36% of injuries during the last five years, an increase from 34% in the previous five-year period. Their share of overall claim costs rose correspondingly to 34% from 32%, resulting in more than 5 million missed workdays, Travelers noted.

The impact of employee turnover varies by industry. Restaurants face the highest proportion of first-year employee injuries at 51% of claims, followed by construction (44%) and retail (40%), the report showed. Even manufacturing, with the lowest percentage among analyzed sectors, still sees 30% of injuries occurring among first-year workers.

Extended Recovery Periods Amplify Business Disruption

What’s concerning for employers is the trend toward lengthier recovery times, according to Travelers. The average employee now misses 80 workdays per injury – an increase of more than seven days compared to the pre-pandemic period, according to the report. This extended absence creates significant operational challenges and increases costs for businesses already struggling with labor shortages.

The recovery timeline varies by industry and age group. Construction workers face the longest average recovery at 115 days, followed by transportation at 92 days. Employees aged 60 and above face particularly lengthy recoveries, averaging nearly 97 days away from work – almost 17 days longer than the overall average and 14 days more than before the pandemic.

Injury types also play a crucial role in recovery duration, the analysis found. Shoulder injuries emerged as the most common across most industries, with the wholesale sector being a notable exception where lower back injuries predominate. Workers over 60 experience a higher proportion of fractures and dislocations, including complete ligament tears, disc herniations with nerve pain, and complete rotator cuff tears – all injuries that typically require extended recovery periods, Travelers found.

High-Cost Claims Highlight Critical Safety Priorities

While most workplace injuries result in manageable claims, the report identifies key causes of high-impact claims exceeding $250,000. These severe injuries not only devastate affected employees but also create financial and operational challenges for businesses.

Slips, trips and falls top the list of causes for these high-cost claims, particularly falls from different elevations such as ladders or scaffolding. Overexertion injuries from lifting, pushing, pulling or twisting represent another major category, along with being struck by objects, whether falling, flying, or being handled improperly.

Motor vehicle accidents continue to generate significant claims, including collisions with other vehicles, being struck by vehicles, vehicle upsets, and impacts with fixed objects. Rounding out the major causes are caught-in or caught-between hazards, which occur when workers are trapped in machinery, between objects, or under collapsing materials.

Access the full report here. &

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

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