As America’s workforce ages, employers are facing a shift in the cost and complexity of workplace injuries. While older employees bring experience, reliability and institutional knowledge, they also tend to file more expensive and longer-lasting workers’ compensation claims.
New data reveals that employees aged 60 and older saw the highest increase in new workers’ compensation claims between 2020 and 2024. These claims are 35% more costly than those filed by younger workers, and recovery periods are on average nine days longer, according to data from Sedgwick Claims Management.
More Americans are working past traditional retirement age. According to the U.S. Bureau of Labor Statistics, the number of workers aged 65 to 74 is expected to increase by 22.4% between 2023 and 2033. Even more dramatically, the number of workers over age 75 is projected to grow by 79%.
These trends make it likely that injuries among older workers and the associated claims costs will become an even bigger issue for employers and insurers in the years ahead.
Longer recoveries, higher costs
The higher costs stem from several factors. Older workers often have comorbidities — such as diabetes, heart disease or arthritis — that may complicate recovery. These conditions increase the likelihood of extended disability durations and more intensive medical treatment.
In fact, one industry expert noted during a session at the Risk and Insurance Management Society Inc.’s 2025 annual conference that having a single comorbidity can double the cost of a workers’ compensation claim. Two or more comorbidities can increase the claim cost fivefold. That’s especially concerning as comorbid conditions become more common with age.
Also, while older employees are typically more cautious and experience fewer injuries overall, when injuries do occur, they tend to be more severe and slower to heal. These longer recovery times translate into higher wage replacement costs and more complex medical needs.
Common injuries among older workers
The types of injuries that affect older employees tend to reflect the aging process. Common claims include:
- Sprains and strains from overexertion or slips and falls.
- Fractures resulting from decreased bone density.
- Musculoskeletal injuries like back and shoulder strain from repetitive motion.
- Joint problems such as knee or hip damage aggravated by years of wear and tear.
Even minor injuries in older workers can become more complicated due to slower healing times and the presence of underlying health issues.
Preparing for an aging workforce
As more older employees remain in or return to the workforce, employers can take steps to reduce injury risk and manage claims more effectively:
- Invest in ergonomic equipment and job redesign to minimize physical strain.
- Offer wellness programs that address chronic conditions like obesity, diabetes and cardiovascular disease.
- Provide regular safety training with emphasis on fall prevention and proper lifting techniques.
- Work with the insurer to implement early intervention protocols for injured workers to catch complications early.
By proactively adjusting to demographic shifts, employers can reduce the financial burden of claims while supporting the health and productivity of their aging workforce.
The takeaway
People are living longer and staying healthier as they age, and many older workers are highly productive and know how to do their jobs safely and efficiently. Some even return to work in lower-intensity roles because they enjoy it and the feeling of belonging to a team. Thanks to their institutional knowledge, they can be an integral part of your workforce.
Still, employers that have older workers should understand their risks and invest in proactive, age-conscious safety strategies.
