Shoulder injuries cost scaffolding firms time and money. Learn how shoulder strain and PPE failure hit site productivity, what HSE data shows, and practical steps (including Pro Armour’s padded hi-vis kit) to protect crews and reduce downtime.

How shoulder injuries are hitting the scaffolding industry — and what to do about it

Shoulder strain and shoulder-related injuries are a major but often overlooked cost for scaffolding and general construction firms in the UK. Workers who lift, carry and shoulder poles, timber and steel day after day are at high risk of musculoskeletal disorders (MSDs), lost shifts, and reduced productivity. For employers managing crews of 10, 50 or 200, that adds up — fast.

Below we explain the scale of the problem, how poor PPE can make it worse, and practical steps scaffold businesses can take to cut injuries, lower downtime and protect the workforce.

The scale of the problem (what the data says)

Work-related musculoskeletal disorders are a big drain on the UK economy and workplace productivity. According to Health & Safety Executive (HSE) statistics, hundreds of thousands of workers report non-fatal workplace injuries and millions of working days are lost annually to work-related ill health and injury. The construction sector is one of the highest-risk industries for such injuries. HSE+1

Manual handling — the kind of lifting and carrying common on scaffolding jobs — accounts for a substantial share of workplace injuries. Reducing these risks is therefore a priority for both safety and the company bottom line.

Why shoulders are vulnerable on scaffolding jobs

Scaffolders routinely handle awkward, heavy loads — long tubes, ledgers and boards — which place repeated pressure on the same shoulder areas:

• Repetitive loading: Carrying poles repeatedly creates micro-trauma in shoulder tendons and muscles over time.

• Awkward positioning: Shouldering items across one side concentrates force on the deltoid and rotator cuff.

• Poor or failing PPE: Standard hi-vis tees and hoodies can rip at the shoulder, exposing skin to abrasion and removing any padding or protection that might have helped distribute load.

The result: more mid-shift breaks, rising medical absences, greater claims risk and lost productivity.

How failing PPE worsens injuries

It’s common for standard PPE (low-cost hi-vis tees) to wear thin or rip at the shoulders — the exact spot scaffolders load against. When fabrics tear, not only does comfort fall away, but protection and weight distribution do too. That increases pain, speeds the onset of overuse injuries and forces more frequent job interruptions.

Addressing PPE quality — choosing garments designed to redistribute load and include shoulder protection — is a simple operational step that reduces risk and extends working life for both crew and clothing.

Business impact: downtime, replacement costs and hidden losses

HSE figures on lost working days and non-fatal injuries make clear the commercial value of prevention: fewer injuries means fewer lost shifts, a smaller replacement budget for PPE, and lower insurance and claims exposure. For larger outfits this can translate into real annual savings when evaluated across dozens of crews — which is why procurement managers and safety officers must treat shoulder-protection PPE as an investment, not just a cost. HSE

Practical steps scaffold businesses can take today

1. Assess tasks for manual-handling risk — map the heaviest and most frequent lifts and who does them.

2. Upgrade PPE to job-specific garments — look for reinforced shoulders, integrated shoulder pads, and high-tensile fabrics that resist tearing.

3. Train staff on safe handling and shared load techniques — even small changes in carry technique reduce strain.

4. Rotate tasks where possible — reduce repetitive strain by varying duties across a shift.

5. Measure the cost of replacements — track how often PPE is replaced; a longer-lasting shirt/hoodie can deliver clear ROI.

6. Use data to build a business case — combine time lost and replacement spend into a savings projection to pitch to owners or procurement teams.

Why job-specific PPE (like padded hi-vis shirts) helps

Garments with targeted shoulder padding and high-tensile fabrics distribute load away from vulnerable tissues and keep working crews on the job longer. Even where fabric eventually wears, modern designs keep a protective insert in place so the worker remains sheltered from abrasion and pressure while the outer fabric gets replaced — reducing immediate injury risk and extending useful life.

Fast wins for safety managers & owners

• Run a one-week trial of padded shirts on one crew and compare replacement costs and downtime against a control crew.

• Use those numbers to quantify savings — lower replacement frequency + fewer lost shift hours = quick business case for wider roll-out.

• Add a “shoulder-protection” filter to PPE procurement so teams don’t inadvertently buy low-spec shirts again.

Ready to reduce shoulder injuries on site? Try a Pro Armour padded hi-vis T-shirt or hoodie on one crew this month — we’ll help you model the expected savings 

https://www.pro-armour.co.uk/pages/business-savings