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Introduction: The average life expectancy continues to increase around the world. In parallel, many countries have decided to raise retirement age as a mean to e.g., account for shortage in workforce. However, keeping workers in in physically demanding occupations can also have negative consequences due the age-related decline in physical capacities. Thus, understanding the age-related changes in physical capacities in demanding jobs can help the design of future interventions for healthy sustainable employment.

Methods: Physical capacities were assessed in a cross-sectional design using a broad test batterie among manual workers in their last two decades of working life. The test batterie was composed of handgrip strength measurements, heart rate monitoring, body composition assessment, spirometry, static and dynamic posturography as well as 3D movement analysis. In total, 97 manual workers completed all tests. The tests were then, analysed as a function of age and musculoskeletal complaints.

Results: Based on a published protocol, the conducted tests showed that age and musculoskeletal pain status (acute vs. chronic) differentially affects the structure of handgrip force variability in manual workers. Similarly, an age-dependency on the effects of musculoskeletal pain on lower extremity function and dynamic balance was found. We also found that response times were markedly slower for older manual workers compared with younger controls during a hammering task. Contrary to what was expected, there were no differences in hammering accuracy. Our cohort was characterized by greater strength and body size, but poorer cardiorespiratory fitness and pulmonary function compared with general populations.

Discussion: The present findings and body of literature indicate that manual workers do not improve their physical capacities by being in jobs keeping them physically active. Especially cardiorespiratory fitness, pulmonary function, as well as motor control are negatively affected, whereas handgrip muscle strength can be maintained among manual workers. Still, engaging high-intensity leisure-time physical activity is associated with greater physical-work ability among manual workers while workers with high physical-work demands have risks of having an occupational accident.

Conclusion: Pushing retirement age further is not without consequences as manual workers have decrease physical capacities making them more prone to musculoskeletal disorders and accidents. Future intervention studies should aim at increasing cardiorespiratory fitness and balance but also at reducing fat mass among older manual workers.