Introduction


Musculoskeletal disorders are a significant concern in military environments, particularly in the confined workstations aboard U.S. Navy ships. While physical discomfort is an early indicator of suboptimal ergonomic conditions, limited research has explored how it contributes to physical and mental health risks (PHR and MHR, respectively) across different ship-classes. Addressing this gap is critical for reducing injuries, healthcare costs, and improving mission readiness.


Purpose


This study had two primary objectives: 1) validate a brief assessment of workstation discomfort and 2) investigate its association with health risks among U.S. Navy sailors, while also exploring how relationships vary by ship-class. By focusing on discomfort as a precursor to injury, the study aimed to inform targeted, human-centered interventions.


Method


Survey data were analyzed from 5,957 enlisted U.S. Navy sailors serving on three ship-classes: cruisers-destroyers, amphibious ships, and littoral combat ships. A nine-item measure assessing physical discomfort from workstation design was evaluated using exploratory factor analysis (EFA). The associations between the resulting discomfort factors and health risks were then examined using generalized linear mixed models.


Results


The EFA identified three dimensions of discomfort: upper extremity, postural/lower body, and head/visual. All three dimensions were positively associated with increased PHR. In contrast, only postural/lower body and head/visual discomfort were significantly associated with MHR. Importantly, the analysis revealed that ship-class moderated the relationship between upper extremity and head/visual discomfort on PHR, indicating that the impact of this discomfort varied depending on the vessel type.


Conclusions


Our findings highlight the impact of workstation discomfort on the physical and mental health of sailors. The results strongly support the need for ergonomic interventions tailored to specific ship-classes to effectively reduce health risks. The brief scale serves as a practical tool for assessing discomfort and guiding improvements in workstation design, ultimately enhancing sailor well-being and operational effectiveness.