Musculoskeletal risk profiling
Musculoskeletal risk profiling (MRPro) is the first national research study into the scope, prevalence and severity of musculoskeletal (MSK) risks faced by workers across the Strategic Road Network.
The project was developed collaboratively with National Highways as part of the wider Healthier Highways programme and aimed to create an evidence-based profile of MSK risks affecting the highways sector. The research covered on-road supply chain activities across construction, maintenance, renewals, operations and specialist disciplines, using focus groups, surveys and task analysis to identify the most significant risks and opportunities for improvement.
Focus area / business challenge
Musculoskeletal disorders (MSDs) are the leading cause of work-related ill health within the construction industry, accounting for more than half of all occupational health cases. As National Highways increasingly focuses on maintaining and renewing existing infrastructure, workers are exposed to activities involving manual handling, repetitive movements, awkward postures and restricted-access environments.
The highways sector lacked a comprehensive evidence base identifying which tasks presented the greatest MSK risks and where interventions would have the biggest impact. The MRPro project was established to address this gap and support targeted improvements across the sector.
Key business challenges included:
- high rates of work-related MSK ill health.
- long-term impacts on worker health and wellbeing.
- workforce retention and sustainability challenges.
- productivity losses and sickness absence associated with MSDs.
- maintenance activities creating increased ergonomic and manual handling risks.
- historic infrastructure designs presenting ongoing health risks during maintenance.
- limited sector-wide understanding of the highest-risk tasks.
- need for evidence-based prioritisation of interventions and innovation.
Objectives
Develop a comprehensive MSK risk profile for the highways sector.
Identify the highest-risk and most frequently performed tasks across the SRN.
Gather evidence to support prioritisation of risk reduction interventions.
Improve understanding of worker health risks.
Promote 'Health by Design' principles.
Identify and share examples of good practice.
Encourage innovation and investment in safer working methods.
Support National Highways' Healthier Highways programme.
Success criteria
Engagement from across the highways supply chain.
Completion of sector-wide research and analysis.
Identification of key high-risk tasks.
Production of an evidence-based risk profile.
Development of practical recommendations for National Highways, designers, contractors and industry.
Increased awareness of MSK risks and controls.
Identification of opportunities for innovation and mechanisation.
How the project supports National Highways KPIs
Supports workforce health, wellbeing and occupational health objectives.
Reduces potential for lost-time injuries and sickness absence.
Improves safety and health performance across the supply chain.
Supports efficient delivery through reduced workforce harm and improved productivity.
Encourages innovation and continuous improvement.
Supports sustainability by helping retain experienced workers for longer.
Aligns with Healthier Highways culture transformation initiatives.
The approach
The project followed a structured, evidence-based research methodology to understand the scale and nature of MSK risks across the highways sector, identify the tasks posing the greatest risk to workers, and develop targeted recommendations to support long-term improvements in workforce health and wellbeing. This was delivered through the following activities:
- Stakeholder analysis and engagement
- Establishment of more than 80 MRPro champions
- 23 cross-discipline focus groups involving 135 industry participants
- Surveys completed by 285 participants
- Identification of approximately 100 high-risk tasks
- Narrowing to 45 priority tasks through analysis
- Task assessments using HSE MAC, ART and RAPP tools
- Population exposure and frequency analysis
- Development of final prioritised risk ranking and recommendations
Project obstacles
Undertaking the first sector-wide assessment of MSK risk across the Strategic Road Network presented several challenges. The project required engagement with a diverse range of organisations, disciplines and job roles, each undertaking different activities in varying environments. In addition, there was limited existing data available on MSK risks within the highways sector, making it necessary to gather and analyse new evidence from across the supply chain.
The project also sought to challenge long-established ways of working and identify opportunities for innovation in areas where risk had often been accepted as unavoidable.
Key obstacles included:
- lack of previous sector-wide data on MSK risk
- wide variation in work types, activities and environments
- existing infrastructure designed without maintenance health considerations
- difficulty accessing representative task data
- limited availability of detailed task footage for assessment
- differences in standards and practices across the supply chain
- cultural acceptance of MSK pain as "part of the job"
- cost and practical barriers to mechanisation and innovation
These obstacles were addressed by:
- establishing a broad industry engagement network
- using focus groups to capture frontline experience
- collecting survey responses from a wide range of organisations
- applying recognised HSE assessment methodologies
- capturing examples of best practice and innovation
- working collaboratively across National Highways and supply chain stakeholders
- using evidence-based prioritisation to focus on highest-risk activities
Outcomes and impact
The project produced the first comprehensive MSK risk profile for highways work, creating an evidence base for future intervention, innovation and investment decisions. It identified widespread exposure to MSK risk, highlighted high-risk activities, and demonstrated opportunities to significantly improve worker health through better design, mechanisation and working practices.
Key outcomes include:
- engagement from over 100 highways companies
- 23 focus groups completed
- 135 industry delegates participated in focus groups
- 285 survey responses collected
- approximately 100 high-risk tasks identified
- 45 priority tasks analysed in detail
- 41 ergonomic assessments completed using MAC, ART and RAPP tools
- clear recommendations produced for industry, contractors, designers and National Highways
- identification of successful innovations such as cone laying machines, robotic hydro-demolition and mechanised lifting solutions
User and stakeholder outcomes
For National Highways
- Improved understanding of workforce health risks
- Evidence to support future policy, standards and investment decisions
- Stronger basis for Health by Design initiatives
For contractors
- Clear identification of priority risks
- Practical recommendations for risk reduction
- Greater awareness of good practice and mechanisation opportunities
For workers
- Increased focus on long-term health and wellbeing
- Reduced exposure to preventable MSK hazards
- Improved opportunities for safer, more sustainable careers
For designers
- Increased awareness of how design decisions impact worker health
- Stronger focus on maintainability and accessibility
Key insights and learning
The project demonstrated that MSK risk is widespread throughout highways work but is often accepted as unavoidable. However, the research also showed that many solutions already exist and that meaningful risk reduction is achievable through collaboration, innovation and early consideration of health impacts. Successful outcomes require intervention across the project lifecycle, from design and procurement through to delivery and maintenance.
Key learnings:
- Many risks originate from historic asset designs
- Early contractor involvement improves opportunities to reduce risk
- Mechanisation significantly reduces exposure
- Good practice exists but is not consistently applied
- Cultural attitudes can act as barriers to safer working
- Design decisions have a major influence on long-term workforce health
- Industry-wide collaboration is required to solve common high-risk tasks
- Worker engagement is critical when developing solutions
Future value and next steps
- Embed Health by Design into National Highways processes
- Strengthen early contractor involvement
- Encourage greater use of mechanisation and automation
- Review DMRB processes to support innovation
- Establish industry-wide collaboration forums for high-risk tasks
- Improve consistency of standards across the supply chain
- Continue development of innovative solutions for persistent high-risk activities
- Support a healthier, more diverse and sustainable future workforce
Visuals and supporting evidence
Visuals and supporting evidence are not yet available at this stage, as these will be developed as part of the ongoing Phase 1 work.
