Biggest occupational health risks by industry: what employers need to know
Occupational health risks can vary significantly between industries. In safety-critical environments, where employees may be working with heavy machinery, at height, in hazardous environments or in roles where concentration is essential, understanding and managing those risks takes on even greater importance.
The occupational health risks facing a train driver, construction worker or manufacturing operative can be very different. Even within the same industry, an employee's exposure will depend on their role, working environment and the tasks they carry out.
For employers, understanding these differences is an important part of protecting employees and meeting their health and safety responsibilities. It also helps determine what occupational health support is appropriate, from medical assessments and health surveillance to fatigue management and mental health support.
So, what are some of the most significant occupational health risks facing employees across the UK's safety-critical industries?
What are the biggest occupational health risks in the rail industry?
Rail is a safety-critical industry by its very nature. Employees work in a wide range of environments and roles, from train drivers and track workers to engineers and maintenance teams, each with their own occupational health considerations.
According to the Office of Rail and Road, 4,607 workforce injuries were recorded on the mainline network during 2024/25.
Whilst workplace injuries can arise for a range of reasons, the statistic highlights the importance of understanding factors that may affect an employee's ability to work safely.
Fatigue is one of the most significant occupational health considerations within the rail industry, with shift work, long or irregular hours, night working and safety-critical responsibilities all having the potential to affect concentration, decision-making and reaction times.
For employers, managing these risks starts with ensuring employees are medically fit to carry out their roles. Regular rail medical assessments can help identify health issues that could affect an individual's ability to work safely, while drug and alcohol testing and effective fatigue management can form part of a wider approach to maintaining a safe railway.
Occupational health can also help employers assess fitness for work following a health condition, sickness absence or other changes in an employee's circumstances.
What are the biggest occupational health risks in construction?
Construction workers can be exposed to a particularly broad range of occupational health risks, including manual handling, noise, vibration, dust and other respiratory hazards.
Work-related ill health remains a significant concern within the industry. An estimated 79,000 construction workers reported work-related ill health during 2024/25, with musculoskeletal disorders (MSDs) among the leading contributors. Repeated lifting, carrying, bending and other physically demanding activities can place considerable strain on the body over time. Occupational health can support early intervention through musculoskeletal assessments, workplace adjustments and referral for further treatment where required.
Employees may also be exposed to hazards such as hand-arm vibration, excessive noise and construction dusts, which can cause longer-term health problems if exposure is not properly managed. Health surveillance can help employers identify the early signs of work-related ill health among employees exposed to these risks. Depending on the role and exposure, this could include audiometry (hearing checks), respiratory surveillance, skin assessments or monitoring for symptoms associated with hand-arm vibration.
Safety-critical and role-specific medical assessments can also help establish whether an employee is medically fit for duties such as operating plant, working at height or entering confined spaces.
What are the biggest occupational health risks in manufacturing?
Manufacturing encompasses an enormous variety of workplaces and roles, but musculoskeletal disorders and work-related stress are two of the most significant health issues affecting the sector.
HSE figures show that an estimated 101,000 manufacturing workers suffered from work-related ill health, based on an annual average across 2022/23 to 2024/25. Of those cases, 37% related to musculoskeletal disorders, while 43% involved stress, depression or anxiety.
The physical demands of manufacturing can vary considerably. Repetitive movements, manual handling, awkward postures and prolonged standing can all contribute to musculoskeletal problems. Depending on the working environment, employees may also be exposed to noise, vibration, fumes, dust or hazardous substances.
As with construction, employers should consider appropriate health surveillance and pathways to support employees experiencing musculoskeletal issues. However, the statistics around stress, depression and anxiety also demonstrate why occupational health in manufacturing should not focus solely on physical health.
Partnering with an occupational health provider can help employers support employee wellbeing through services such as Employee Assistance Programmes (EAPs), counselling and specialist therapeutic support, whilst providing greater insight into how a health condition may be affecting an individual's ability to work.
Different industries, different risks - but the same principle applies
There is no single occupational health programme that will be right for every organisation. A construction company managing exposure to noise, vibration and dust has very different requirements from a rail operator managing fatigue in safety-critical workers. A manufacturing business may need to consider both physical exposures and growing concerns around employee mental health.
The same principle applies across other industries, whether that's transport and logistics, energy and utilities, or any organisation where employees are exposed to role-specific health risks.
What they have in common is the need to understand the risks their employees face and put appropriate measures in place to manage them.
Risk assessments are an important starting point, but occupational health provides another piece of the picture. Medical assessments can help determine whether employees are fit for particular roles, health surveillance can identify early signs of work-related ill health, and specialist support can help employees manage both physical and mental health concerns.
A proactive approach also gives employers an opportunity to identify problems earlier, review whether existing workplace controls are effective and make changes before an employee's health is significantly affected.
Express Medicals specialises in supporting organisations across safety-critical industries with occupational health services tailored to the risks faced by their workforce.
Frequently asked questions about occupational health risks
What is an occupational health risk?
An occupational health risk is something associated with a person's work that has the potential to affect their physical or mental health. This could include exposure to noise, vibration, dust or hazardous substances, physical demands such as manual handling, or factors such as fatigue and work-related stress.
Which industries have the greatest occupational health risks?
Safety-critical industries including rail, construction, manufacturing, transport and logistics, and energy and utilities can present significant occupational health risks because of the nature of the work involved. However, the type and level of risk varies considerably between industries, organisations and individual roles.
How can employers identify occupational health risks?
Workplace risk assessments are an important starting point. Employers should consider the hazards employees are exposed to, how frequently exposure occurs and whether existing control measures are adequate. Occupational health professionals can then advise on appropriate measures such as health surveillance or medical assessments where required.
What is the difference between a medical assessment and health surveillance?
A medical assessment generally considers whether an employee is medically fit to carry out a particular role or task. Health surveillance is an ongoing programme used where employees are exposed to certain workplace health risks, helping to identify early signs of work-related ill health.
When is health surveillance required?
Health surveillance may be required where employees are exposed to workplace hazards that can cause identifiable health conditions and where there are appropriate methods for detecting those conditions. Examples can include exposure to noise, vibration, respiratory sensitisers and certain substances hazardous to health.
Can occupational health help with mental health and stress?
Yes. Occupational health can help employers understand how an employee's mental health may be affecting them at work and advise on appropriate support or adjustments. Employee Assistance Programmes can also provide employees with access to confidential support.
Sources
Office of Rail and Road, rail safety statistics
HSE, work-related fatal injury statistics
HSE, Manufacturing statistics in Great Britain 2025
