Safety Bulletin – Knee Injury During Ground-Level Installation Work
A teammate sustained a torn meniscus while performing installation work on a 200A disconnect. The employee was mounting lower support bolts from a kneeling position in a tight work area; while standing up, he experienced a pinch/pop sensation in his left knee. The employee continued working through the remainder of his shift, later that evening swelling developed in the knee. The following day, the employee returned to work with continued swelling and pain; while attempting to climb a 6 ft ladder, he experienced additional pain on both the inside and outside of the knee. Medical evaluation later confirmed a torn meniscus.
The incident review determined that the injury occurred while transitioning from a kneeling position in a tight workspace that limited the employee’s ability to stand using proper body mechanics. Prolonged kneeling, awkward positioning, twisting motion, and restricted movement all contributed to increased stress on the knee joint. The review also identified that pre-task planning and hazard discussions primarily focused on electrical and installation hazards, while ergonomic risks such as strains, sprains, kneeling stress, and awkward positioning were not adequately identified or discussed.
This incident serves as an important reminder that soft tissue injuries and ergonomic strains can occur during routine tasks, especially when working at ground level, in confined areas, or while wearing tools and equipment that limit movement. These injuries are often overlooked because there is no immediate traumatic event, but the long-term impact can be significant.
Key Takeaways for the Field
- Evaluate body positioning before beginning tasks that require kneeling, crouching, or twisting motions.
- Avoid sudden twisting movements when standing from kneeling or squatting positions.
- Reposition materials, tools, or work locations whenever possible to improve body mechanics and reduce strain.
- Consider whether tool belts, pouches, or carried tools are creating additional stress or limiting mobility while kneeling.
- Use knee pads or other supportive protection during prolonged kneeling tasks.
- Rotate personnel or adjust work methods when tasks involve extended ground-level work or tight-access conditions.
- Include ergonomic hazards, strains, and sprain risks during pre-task planning and AHAs.
- Immediately report any pops, strains, discomfort, or swelling to supervision rather than attempting to work through symptoms.
Corrective Actions
- Reinforce ergonomic hazard recognition during pre-task planning activities.
- Provide and encourage the use of knee protection/support for kneeling tasks.
- Reinforce expectations to immediately report strains, pops, discomfort, or swelling.
- Evaluate tasks requiring prolonged kneeling for additional ergonomic controls or work rotation strategies.
- Encourage crews to reposition work or use alternative installation methods when working in tight or awkward spaces.
Taking time to recognize ergonomic risks and adjusting work methods before starting a task can prevent serious long-term injuries and help ensure employees go home healthy every day.