Objectives Long-term heavy work impairs employees, and they may retire prematurely by law. We investigated the value of energy expenditure (EE) during work shifts as a means to define heavy workload. MethodsThe study comprised 79 male [mean age 32.2 (standard deviation [SD] 7.5) years] and 33 female [33.5 (SD 11.2) years] employees in different occupations classified as "heavy work" (EE of 1400 and 2000 kcal for women and men, respectively). Cycle ergometry determined exercise performance. Gas exchange measures were performed during selected phases of work, and heart rate (HR) recordings were obtained for a complete work shift. EE was calculated from gas exchange measures.Results Male and female subjects differed significantly for maximal power output (P max ) [men=206. Conclusions The legal definition of heavy workload by mean working EE per 8-hour work shift applies to all investigated occupations; however, a substantial proportion of workers may not fulfill the criterion if applied individually. Alternative definitions of heavy workload in terms of absolute oxygen consumption or EE relative to cardiorespiratory fitness lead to similar classification results of the investigated occupations.

Long-term heavy physical work often leads to early retirement and disability pension due to chronic overload, with a need to define upper limits. The aim of this study was to evaluate the value of the first lactate threshold (LTP1) as a physiological marker for heavy occupational work. A total of 188 male and 52 female workers performed an incremental cycle ergometer test to determine maximal exercise performance and the first and second lactate (LTP1; LTP2) and ventilatory thresholds (VT1; VT2). Heart rate (HR) recordings were obtained during one eight-hour shift (HR8h) and oxygen uptake was measured during 20 minutes of a representative work phase. Energy expenditure (EE) was calculated from gas-exchange measures. Maximal power output (Pmax), maximal oxygen consumption (VO2 max) and power output at LTP1 and LTP2 were significantly different between male and female workers. HR8h was not significantly different between male and female workers. A significant relationship was found between Pmax and power output at LTP1. HR8h as a percentage of maximum HR significantly declined with increasing performance (Pmax:r = −0.56; p < 0.01; PLTP1:r = −0.49; p < 0.01). Despite different cardio-respiratory fitness-levels; 95.4% of all workers performed their usual work below LTP1. It is therefore suggested that LTP1 represents the upper limit for sustained heavy occupational work; which supports its use to determine work capability and assessing the limits of heavy occupational work.

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