5 Most Common Manufacturing & Factory Injuries in California

Working in California's manufacturing sector puts you at the heart of America's largest state economy, but it also exposes you to significant workplace risks. With a large workforce of manufacturing workers across many facilities statewide, understanding common manufacturing and factory injuries in California is crucial for protecting your health and your rights. In fact, in 2023, California reported a higher workplace injury rate than the national average. Manufacturing workers face even higher risks, with injury rates consistently above state averages. This illustrates the dangers you endure on a daily basis. 

If you've been injured at work, knowing what to expect and how to navigate the workers' compensation system can make the difference between receiving full benefits and struggling with denied claims. Here are the five most common manufacturing injuries that affect California workers and the claim strategies that can help secure your compensation.

Top 5 Most Common Manufacturing & Factory Injuries in California 

When you are working in the manufacturing sector, you are at risk of injury every day. While there are countless manufacturing and factory injuries workers like you could sustain, there are some that are most common and stick out among the others.

Here are the top 5 most common manufacturing and factory injuries in California:

1. Crush Injuries
2. Cumulative Trauma Injuries (CTs)
3. Chemical Burns
4. Hearing Loss
5. Slip and Fall Injuries

1. Crush Injuries

What They Are: Crush injuries occur when workers become trapped between two heavy objects or caught in machinery. These devastating injuries can result in broken bones, internal organ damage, amputations, or even death.

How They Happen: According to OSHA data, approximately 25,000 crush injuries occur annually nationwide, with 800 proving fatal. In manufacturing settings, crush injuries typically result from:

• Forklift accidents and heavy machinery malfunctions
• Getting caught between moving machinery parts
• Falling objects from shelves or conveyors
• Equipment that lacks proper safety guards

Document everything immediately. Crush injuries often involve complex medical treatment and long-term disability, making thorough documentation essential. Take photos of the accident scene if possible, gather witness statements, and ensure all medical treatments are recorded. For severe crush injuries that combine with pre-existing conditions to make you unable to work, consider pursuing a Subsequent Injuries Benefit Trust Fund (SIBTF) claim for additional compensation.

2. Cumulative Trauma Injuries (CTs)

What They Are: Cumulative trauma injuries, or repetitive strain injuries, develop gradually from performing the same motions repeatedly over months or years. Common CTs include carpal tunnel syndrome, tendonitis, and back strain.

How They Happen: Manufacturing and assembly line workers are particularly vulnerable to CTs due to:

• Repetitive motions on production lines
• Prolonged awkward positioning
• Lifting, twisting, and carrying heavy materials
• Using vibrating equipment consistently

California recognizes that CTs can be just as debilitating as sudden injuries. Assembly workers frequently develop carpal tunnel syndrome from repetitive hand motions, while those in packaging roles often suffer shoulder and back injuries from repetitive lifting.

The key challenge with CTs claims is proving work-relatedness. Insurance companies often argue these are "pre-existing" conditions. Counter this by:

• Reporting symptoms early to your employer and supervisor
• Describing your specific job duties in detail to your doctor
• Getting proper medical diagnosis with imaging studies (MRI, EMG) when needed
• Documenting how your work activities specifically caused or aggravated the condition

3. Chemical Burns

What They Are: Chemical burns occur when corrosive substances contact skin, eyes, or respiratory systems. Unlike thermal burns, chemical burns can continue damaging tissue until the substance is completely removed.

How They Happen: Manufacturing workers face chemical exposure from:

• Industrial cleaning solvents and degreasers
• Battery acid and other corrosive materials
• Paint thinners and adhesives
• Improperly stored or labeled chemicals
• Lack of personal protective equipment (PPE)

Chemical burns can range from first-degree irritation to full-thickness burns requiring skin grafts. Even brief exposure to industrial chemicals can cause lasting respiratory, skin, or neurological damage.

Chemical burn claims have unique advantages under California law—you don't need to prove employer fault, only that exposure occurred at work and caused injury. Essential steps include:

• Seek immediate medical attention and document all exposure details
• Report the incident to your supervisor immediately
• Identify the specific chemical involved and obtain safety data sheets
• Keep detailed records of all medical treatments and expenses
• Document any workplace safety violations or inadequate PPE provision

Related Article: Navigating Heat-Related Work Injuries: A Guide for Injured Workers in California

4. Hearing Loss

What They Are: Noise-induced hearing loss (NIHL) develops from prolonged exposure to loud workplace noise above 85 decibels. Manufacturing environments frequently exceed safe noise levels, causing gradual, permanent hearing damage.

How They Happen: Factory environments create hearing hazards through:

• Heavy machinery and power tools operating continuously
• Metal-on-metal contact and grinding operations
• Compressed air systems and pneumatic tools
• Lack of proper hearing protection or noise controls

Under Cal/OSHA standards, employers must provide hearing protection when noise exceeds 85 dB over an 8-hour period. Many manufacturing operations routinely exceed 90 dB, requiring mandatory hearing protection.

Hearing loss claims require establishing a clear connection between workplace noise and your condition. Strengthen your case by:

• Participating in employer-required audiometric testing programs
• Documenting workplace noise levels and exposure duration
• Getting baseline hearing tests and tracking changes over time
• Reporting hearing problems promptly to your employer
• Working with medical professionals familiar with occupational hearing loss

Related Article: Understanding Noise-Inducing Hearing Loss and Workers’ Compensation in California

5. Slip and Fall Injuries

What They Are: Slip, trip, and fall accidents account for nearly 25% of all workplace injuries in California and 10% of manufacturing injuries specifically. These "same-level" falls can cause serious injuries including fractures, head trauma, and spinal injuries.

How They Happen: Manufacturing environments create numerous slip and fall hazards:

• Wet floors from industrial processes or spills
• Oil and chemical residues on walking surfaces
• Cluttered walkways and poorly maintained floors
• Inadequate lighting in work areas
• Uneven surfaces and damaged flooring

Quick action is crucial for slip and fall claims:

• Report the incident immediately to your supervisor
• Document hazardous conditions with photos if possible
• Identify any witnesses to the accident
• Seek prompt medical attention even if injuries seem minor
• Keep detailed records of all symptoms and treatment
• Note any safety violations or maintenance failures that contributed to the accident

Protecting Your Rights After a Manufacturing or Factory Injury

California's workers' compensation system provides coverage for all manufacturing and factory injuries listed above and more when they occur during employment, but navigating the system requires understanding your rights and deadlines. 

You must report workplace injuries within 30 days to maintain eligibility for benefits. The system covers medical treatment, temporary disability benefits, permanent disability compensation, and vocational rehabilitation when needed.

Manufacturing workers' comp injuries often involve complex medical treatment and significant time away from work. Insurance companies may try to minimize industrial injuries claims or argue that injuries aren't work-related. 

Having experienced legal representation ensures you receive full benefits and protects against claim denials or underpayment.

Related Article: How Long Do You Have to Report a Work Injury in California?

Get the Legal Help You Deserve

Suffered one of these injuries? Contact SoCal Workers Comp today for a free consultation. Our experienced attorneys specialize in representing injured California manufacturing workers and understand the unique challenges you face. We know how to fight insurance companies that try to minimize your claim and ensure you receive the full medical coverage, wage replacement, and disability benefits you deserve.

Don't navigate the complex workers' compensation system alone. Call 657-732-8141 or complete a web submission to schedule your free consultation with SoCal Workers Comp. We're here to protect your rights and get you industrial injuries compensation you are entitled to and need to focus on recovery.

Remember: Every worker deserves a safe workplace and full compensation when injuries occur. At SoCal Workers Comp, we fight for injured workers every day—let us fight for you.