Work-related Injuries and Illnesses on the Rise: What Safe Work Australia’s latest data means for workplaces

Safe Work Australia’s Key Work Health and Safety Statistics Australia 2025 report is out, and it provides a snapshot of workplace risks across Australia. While it’s reassuring to see a decline in fatalities, the number and cost of serious injuries and illnesses continue to rise.

For teams in warehousing, logistics, manufacturing, and other high-risk industries, these figures aren’t just statistics – they highlight the ongoing challenges workplaces face in keeping people safe and healthy, and the importance of continuously refining prevention and early intervention strategies.

Serious claims trending upwards

The latest findings show that in 2023–24, Australian workplaces recorded 146,700 serious workers’ compensation claims, up from 139,000 the year before – a 5.5% increase.

• Incidence rate: 10.9 claims per 1,000 jobs, up from 10.7

• Frequency rate: 6.8 claims per million hours worked, up from 6.6

• Median time lost per claim: 7.4 weeks, up from 7.2

• Median compensation paid: $16,300, up from $14,400

These increases suggest not only that more injuries and illnesses are occurring but also that each claim is costing more in time, disruption, and dollars. Looking at trends over the past 3–5 years reinforces that this is a persistent challenge, not a one-off spike, reinforcing the need for proactive prevention and early intervention strategies.

Mental health claims on the rise

Mental health conditions now account for 12% of all serious claims, up from 11% the previous year. While the proportion may seem modest, the business impact is significant:

• Median time lost: 35.7 weeks – roughly five times longer than physical injuries

• Business impact: extended absence, complex return-to-work processes, and higher risk of recurring claims

These statistics highlight why managing psychosocial hazards is critical. Compliance with new psychological health regulations is important, but workplaces that take a proactive approach – embedding onsite mental health support into their culture

Four Mechanisms Dominate Serious Claims

Approximately 84% of serious claims come from just four mechanisms:

1. Body stressing (manual handling, repetitive movement)

2. Falls, slips, and trips

3. Being hit by moving objects

4. Mental stress

Older workers (aged 55+) continue to have the highest claim rates, highlighting the need for tailored prevention strategies that consider physical capacity, fatigue, and recovery time.

These patterns haven’t shifted significantly over years — meaning that workplaces often know the risks but still struggle to act early enough to prevent them.

Why These Stats Matter for Your Business

Rising injury and illness rates affect more than insurance premiums. They have direct operational and financial consequences:

• Lost productivity and downtime

• Increased claims and rehabilitation costs

• Strain on teams and managers

• Impact on employee engagement and retention

A holistic view – addressing both physical and mental health risks – is essential to mitigate these impacts and maintain workforce performance.

Actionable Steps for Employers

The 2025 statistics provide a roadmap for where to focus. Here’s how businesses can respond:

1. Be proactive, not reactive

   • Invest in onsite physiotherapy, ergonomics, manual handling training, and functional movement screening.

   • Identify risk before it triggers a claim for maximum return.

2. Early intervention saves time and money

   • Quick reporting systems for pain, discomfort, or near-misses reduce severity and downtime.

   • Triage services and immediate access to onsite physiotherapy support faster recovery.

3. Treat mental health as a core business issue

   • Integrate psychosocial risk management into workplace culture.

   • Provide hazard training, mental health services, and structured return-to-work pathways.

4. Tailor injury prevention programs to your workforce

   • Consider workforce age, physical demands, and role-specific risks.

   • Fatigue management, job design, and ergonomic adjustments reduce claim likelihood.

5. Use data to drive focus

   • Review your own claim and incident data to identify dominant risks.

   • Deploy targeted interventions, track outcomes, and adjust strategies continuously.

Bottom Line

The 2025 WHS report is a wake-up call: while fatalities are slightly declining, serious injuries and illnesses are rising — and the costs, both human and financial, continue to grow.

With 84% of serious claims coming from just four mechanisms, businesses have a clear focus for action. By investing in proactive injury prevention, early intervention, and integrated mental-health support, organisations can reduce claims, protect employees, and maintain a healthy, productive workforce.

Need support?

At Bodycare, we help businesses build integrated health, wellbeing, and injury prevention programs that protect your people, reduce incidents, and create safer, more productive workplaces. If you’re ready to take a proactive approach, we can design tailored programs that meet the unique needs of your workforce.

• Call: 1300 222 639

• Email: inquiries@bodycare.com.au

To read the full report click here