A pre-employment physical assessment evaluates whether a candidate can safely perform the physical demands documented in the IROJ for a specific role. It is not a general fitness test — every component is calibrated to the documented demand thresholds of that role, and the fitness determination references those thresholds, not population averages.
Physical demand categories — the IROJ foundation
The starting point for any pre-employment physical assessment is the IROJ demand category for the role. Australian occupational health practice uses five physical demand categories derived from the US Department of Labor Physical Demand Classification and adapted in Australian OHS tools including the Physical Demands and Bending/Carrying/Lifting Rating (PDBF) tool. The demand category sets the framework for the assessment protocol.
Sedentary
Occasional lifting up to 5 kg. Primarily seated work. Minimal ambulation and no sustained postural challenge.Assessment protocol
Targeted upper-limb and cervical spine screen where IROJ documents computer or keyboard work. FCE not typically required.
Light
Lifting up to 10 kg occasionally, frequently carrying lighter loads up to 5 kg. Mostly sedentary or light standing work.Assessment protocol
Musculoskeletal screen calibrated to IROJ. Upper and lower limb and lumbar assessment. FCE for roles at the upper end of light demand.
Medium
Lifting up to 20 kg occasionally, frequently lifting up to 10 kg. Moderate standing and walking.Assessment protocol
Full musculoskeletal screen. Functional lifting test calibrated to IROJ demand thresholds. Postural tolerance assessment where IROJ documents sustained postures.
Heavy
Lifting up to 45 kg occasionally, frequently lifting up to 25 kg. Substantial standing, walking, pushing, pulling.Assessment protocol
Full functional capacity evaluation — floor-to-bench and floor-to-shoulder lifting, carry test, push/pull assessment. Postural tolerance. Repetitive task endurance. Full spine and limb musculoskeletal screen.
Very Heavy
Lifting above 45 kg occasionally. All postures required. Maximum physical demand.Assessment protocol
Full FCE at very heavy thresholds. All components of the heavy category plus cardiovascular fitness assessment. Clinical review by occupational physician for high-risk exposures.
What is physically tested — component by component
The following describes the clinical components that may be included in a pre-employment physical assessment, calibrated to the IROJ demand profile.
Musculoskeletal screen
Joint range of motion and soft tissue assessment of the spine (cervical, thoracic, lumbar), upper limb (shoulder, elbow, wrist), and lower limb (hip, knee, ankle). Calibrated to the regions relevant to the IROJ demand profile — a role with overhead work requires a different screen emphasis than a role requiring sustained floor-level work. Pre-existing conditions are assessed for their functional impact on documented IROJ demands, not recorded as automatic exclusions.
Lifting capacity test
Systematic testing of floor-to-bench and floor-to-shoulder lifting at the weight thresholds documented in the IROJ. The test uses a validated progressive approach — starting below the demand threshold and progressing to the documented requirement. Heart rate, observed movement quality, and reported discomfort are recorded throughout. The result is interpreted against the specific IROJ lifting demand, not against population lifting norms.
Carry test
Carrying at the documented IROJ weight over the documented carry distance. Tests grip endurance, arm strength, and whole-body dynamic stability under load. Relevant to materials handling, construction, healthcare (patient-handling equipment), and logistics roles. Carry test thresholds are taken directly from the IROJ manual task inventory.
Push/pull assessment
Measured push and pull force generation — initial force (to start load movement) and sustained force (to maintain movement). Calibrated to documented IROJ push/pull demands — trolleys, carts, wheelchairs, warehouse equipment. Uses a dynamometer or calibrated resistance where available. The IROJ should document the type of equipment, the load, and the surface conditions to allow accurate threshold calibration.
Postural tolerance
Assessment of ability to sustain the postures documented in the IROJ — kneeling, squatting, crouching, sustained standing, sustained sitting, overhead reach. Time-tolerance tested at clinically relevant durations. Relevant for trade, service, and healthcare roles with sustained postural demands. Identified limitations are interpreted against whether the posture is a genuine inherent requirement or whether an alternative approach is practicable.
Repetitive task endurance
For roles with documented high-frequency upper-limb or whole-body repetitive tasks, the assessment may include a timed repetitive task test — paced to the documented IROJ cycle frequency. Assesses fatigue resistance relevant to the specific repetitive demands. Particularly important for production line, data entry, and clinical treatment roles.
Handling musculoskeletal findings — the clinical approach
Musculoskeletal findings are among the most common findings in pre-employment physical assessments, and the most commonly mishandled. A pre-existing lumbar disc history, a previous ACL reconstruction, a controlled shoulder impingement — these are extremely common in any adult working population. They are not automatic exclusion criteria.
The relevant clinical question is always functional: given this finding, can this candidate safely meet the physical demands documented in the IROJ? A candidate with a lumbar disc history who demonstrates full lifting capacity at the IROJ threshold, with normal movement quality and no pain provocation, is functionally capable of meeting the role demand. The history is noted; the functional capacity is assessed; the fitness determination is based on function.
Where a musculoskeletal finding does create a functional limitation, the assessing clinician should specify the nature of the restriction (what movement, what threshold, what timeframe), assess whether the restriction can be accommodated within the role, and — where the restriction is likely to be temporary — recommend a review date. An open-ended unfit determination for a time-limited condition is poor clinical and legal practice.
Frequently asked questions
What is a pre-employment physical assessment?
A pre-employment physical assessment is a functional evaluation of a candidate's physical capacity to meet the documented physical demands of a specific role. It is calibrated to the Inherent Requirements of the Job (IROJ) demand profile — assessing lifting, carrying, posture, endurance, and movement patterns at the thresholds the role actually requires, not against generic population norms. It is conducted after a conditional offer of employment and is the primary clinical basis for fitness determination in physically demanding roles.
What physical tasks are tested in a pre-employment physical assessment?
The tasks tested are determined by the IROJ demand profile of the specific role. For a heavy-demand role (e.g., construction, mining, materials handling), this typically includes: floor-to-bench and floor-to-shoulder lifting at the documented weight and frequency; carry distances and weights; push and pull force generation; sustained posture tolerance (kneeling, squatting, overhead reach); and repetitive upper-limb tasks. For medium-demand roles, lighter thresholds apply. Sedentary roles may require only a targeted musculoskeletal screen rather than a functional capacity evaluation.
How long does a pre-employment physical assessment take?
For medium-demand roles, a pre-employment physical assessment typically takes 45–60 minutes. For heavy or very heavy demand roles with full functional capacity evaluation, allow 60–90 minutes. Where additional health surveillance components (audiometry, spirometry) are included, 90–120 minutes is typical. The assessment should be scheduled at a time when the candidate is rested — not immediately after a shift or long journey — to avoid fatigue artefacts in the functional testing.
Can a pre-employment physical assessment be used to exclude older candidates?
No. A pre-employment physical assessment measures functional capacity against documented role demands — it cannot be used as a proxy for age. If a candidate of any age demonstrates they can safely meet the IROJ demands of the role, they must be assessed as fit. Using a physical assessment to screen out older candidates — even without explicit intent — is age discrimination and disability discrimination where age-related conditions are involved. The IROJ protects against this by ensuring the assessment criteria are specific to role demands rather than general fitness or demographic characteristics.
What is the difference between a pre-employment physical assessment and a functional capacity evaluation?
A functional capacity evaluation (FCE) is a specific type of pre-employment physical assessment — the most structured and clinically rigorous form. An FCE uses validated protocols (such as WorkHab or Isernhagen) to systematically assess lifting, carrying, push/pull capacity, and postural tolerance against standardised demand categories. A pre-employment physical assessment may include a full FCE or a targeted physical screen depending on the IROJ demand profile and the role being filled. For heavy and very heavy demand roles, a full FCE is typically required. For medium demand roles, a targeted screen calibrated to the IROJ is often sufficient.
Pre-Employment Screening — Complete Framework
IROJ-based screening, legal conditions, and documentation standards.
Pre-Employment Functional Assessment
Detailed FCE methodology and IROJ calibration.
Pre-Employment Medical Test
All tests included in a pre-employment medical and when they apply.
Pre-Employment Screening Service
OccuSpan's IROJ-calibrated PES platform.
OccuSpan PES Module
Physical assessment calibrated to your IROJ demand profile
OccuSpan generates physical assessment protocols from the IROJ demand profile for each role. Lifting thresholds, carry distances, push/pull requirements — all pre-filled from the documented demands, not manually assembled by your OHS team.
See the PES module