LifeCare FCA will assess according to 3 role intensities (medium role, heavy role and very heavy role [with/without safety risk]). Presence of safety risk involves roles involved in working at heights or on water. The role intensity is identified by the business. Should further information be required to make a decision, the ACC Work Type Detail Sheets can be used for some useful extra information (www.acc.co.nz).
Functional Capacity Assessments
Functional Capacity Assessments (FCAs) provide an objective snapshot of a person’s ability to safely meet the physical demands of a job. Our assessments measure functional capacity directly, including structured testing of upper and lower limb strength, back and postural tolerances, overall fitness, and a sequence of lifting and carrying tasks that reflect common workplace demands.
Each component is measured against consistent, standardised criteria, allowing us to identify an individual’s strengths, limitations, and tolerances. Our reports translate these functional outcomes into clear task relevance, showing how a person’s results may affect their ability to perform specific job requirements.
By focusing on measurable physical function rather than simulated tasks, FCAs enable employers to make informed decisions about job placement, suitable duties, or any necessary adjustments. This ensures workers are placed in roles that align with their capabilities, supporting both workplace safety and long-term workforce sustainability.
Why would FCAs be needed?
Musculoskeletal injuries have a significant economic and social impact in the workplace and are high-impact on the cost of Lost Time Injuries (LTIR’s). Conducting a FCA prior to/during employment can reduce the risk of injury during employment and improve productivity by ensuring employees are physically suited for their roles.
Who should have FCA done?
Pre-employment Health Assessments
Provides employers with the necessary information to ensure a good match between the candidate’s abilities and the job requirements. The goal is to ensure that new hires can perform the essential tasks of the role safely and efficiently, reducing the likelihood of workplace injuries, minimising absenteeism and improving overall productivity.
Employees with Work-Related Injuries
Assesses the extent of their recovery and determines if they can return to their previous role, modify their duties, or transition to a different position within the company.
Employees in High-Demanding /Physically Strenuous Roles
Evaluates whether physical limitations or injuries could affect their ability to safely perform their job duties, and to recommend possible accommodations or role adjustments.
Employees Seeking Career Transitions
It assesses their abilities to potential new roles that might be better suited to their functional capacity.
The Benefits of FCAs
In the Pre-Employment Stage
1. Ensures Job Fit
FCAs verify that a candidate can safely meet the physical requirements of a role before starting work.
- Prevents placement in unsuitable roles.
- Reduces the risk of early injuries and time-off claims.
- Helps match the right person to the right task, improving productivity from day one.
2. Reduces Workplace Injuries and ACC Claims
By identifying limitations or potential risk factors early, employers can reduce the likelihood of musculoskeletal injuries — one of the top causes of work-related claims in NZ.
- ACC data shows over half of all workplace injuries are soft-tissue related (sprains, strains, and back injuries).
- Early identification lowers both direct (treatment) and indirect (downtime, retraining) costs.
3. Supports Compliance with HSWA
Under the HSWA, employers must ensure workers are fit to perform their tasks safely. FCAs provide documented evidence that this obligation has been met, strengthening your compliance posture during audits or investigations.
4. Informs Workplace Adjustments
Results from FCAs can guide reasonable accommodations — such as modified duties, ergonomics, or assistive equipment — helping employers support diversity and inclusion without compromising safety.
5. Improves Recruitment Decisions
When combined with medical and drug testing, FCAs offer a holistic view of a candidate’s readiness to work, helping HR and hiring managers make evidence-based, defensible hiring decisions.
In Annual or Periodic Health Monitoring
1. Tracks Functional Decline or Improvement
Regular FCAs provide measurable data over time — allowing you to identify patterns of deterioration or recovery in physical capability. This supports early intervention before an injury or health event occurs.
2. Supports Return-to-Work and Rehabilitation
FCAs are invaluable after injuries or extended leave, ensuring employees are genuinely fit to return to their role.
- Helps plan gradual return-to-work programmes.
- Confirms capacity to resume specific tasks safely.
3. Drives Preventive Health Culture
Including FCAs in annual health checks promotes a culture of safety and proactive wellbeing. Workers become more aware of their physical health and are empowered to manage risks in daily tasks.
4. Reduces Long-Term Costs
Early identification of potential musculoskeletal issues means fewer lost-time injuries, lower insurance premiums, and reduced ACC levies over time.
5. Supports Data-Driven Health & Safety Management
Aggregated FCA data allows businesses to identify workplace trends — for instance, which departments or tasks create the most strain — helping to design safer workflows and justify equipment investments.
How FCAs Work at LifeCare NZ
| Job role & assessment | Medium Role | Heavy Role (with/without safety risk) | Very Heavy Role (with/without safety risk) |
|---|---|---|---|
| Physical demands of work | 10-20kg handled occasionally 3-9kg handled frequently 0-4.5kg handled constantly Includes: walking, standing, stairs, steps, use of tools<10kg, operation of machinery, lifting and carry of loads less than 20kg occasionally. |
>20kg handled occasionally 10-20kg handled frequently 0-9kg handled constantly Includes: walking, standing, stairs, steps, use of tools <10kg, operation of machinery |
over 45 kg handled occasionally 20-45 kg handled frequently over 9kg constantly Includes: walking, standing, stairs, steps, use of tools <10kg, operation of machinery. |
| Examples of job roles | Foreman, operations support, truck drivers, manufacturing and production, insurance assessors, field representatives, retail and sales, supermarket | Lighter construction workers, warehouse workers, farm workers, road workers, miners |
Heavy construction work, farm workers, forestry workers, miners, scaffolders, stevedores, fisherman, riggers |
| 3 min step test | Y | Y | Y |
| Range of motion | Y | Y | Y |
| Upper limb functional | Y | Y | Y |
| Lower limb functional | Y | Y | Y |
| Trunk functional | Functional reach and sit and reach only | Y | Y |
| Balance | Static only | Static and dynamic if safety risk role | Static and dynamic if safety risk role |
| Weight | Lifting to 15 kg | Lifting to 20kg | Lifting to 25kg |
| Time | 25 mins | 30 mins | 35 mins |
Functional Capacity in the Health Monitoring space at LifeCare
When your employees are scheduled for a Functional Capacity Assessment (FCA) as part of their Annual Health Monitoring (AHM), here is what you need to know to ensure the process runs smoothly.
Book a Consultation1. Pre-Assessment Questionnaire
- All employees must complete the pre-assessment safety questionnaire before the FCA.
- The booking contact will receive a link to share with all employees prior to our on-site visit. This will be a Microsoft form. Each employee will fill it out individully and submit the form for our clinical team to review.
2. GP Clearance Requirement
Employees who indicate certain health conditions on the questionnaire will need a GP clearance certificate confirming they are safe to complete the FCA.
Conditions requiring GP clearance may include:
- Recent surgery or joint replacements
- Heart conditions
- Ongoing treatment for high blood pressure
Employees must bring their GP clearance certificate on the day of the FCA.
3. On the Day of Assessment
- If employees have not completed the questionnaire or do not have the required GP clearance, our Health Consultant will complete the questionnaire on the day.
- If they do not meet the criteria to continue with the FCA, a minimum charge per person will apply.
4. Notifications and Booking Adjustments
- Our Health Services Team will notify the booking contact and the Safety Critical (SC) contact if any employee requires GP clearance.
- If you need to adjust the number of employees scheduled, please notify your account manager as soon as possible to avoid extra fees.
- The standard 10-day cancellation policy applies.
Key Responsibilities
- Booking Contact: Distribute the questionnaire link, track GP clearance requirements, and notify the account manager of any changes to employee attendance.
- LifeCare Health Consultant: Perform the FCA for employees with no health issues or with valid GP clearance.
Service delivery:
We can deliver FCAs across most of NZ (except outlying areas e.g. Whangarei, Dunedin and Invercargill).
Reporting
Reports are available within 48 hours. FCA results are summarised using a traffic light system regarding the individual’s suitability for a specific role. Health Services team will review results and documentation prior to generating the final report and it being sent to company.
The client report includes recommendations, further support and guidance on findings for the client. Recommendations and task specific comments are provided around task relevance and functional impact for any orange or red rating assessment scores so a business knows which specific task may be impacted.
Green
No issues have been identified or declared to indicate a risk in employing this person in the role specified. Successfully able to complete all assessments with no restrictions. Meets or exceeds the norms and was successful at meeting all components of the assessment with good technique applied. May indicate a low risk of injury within the role.
Orange
Issues have been identified or declared, which may have an impact on their ability to carry out the work in the role specified. Meets some of the norms or was successful at meeting most components of the assessment, however they scored below what would be expected of them to safely conduct some physicality’s of the role. May indicate a moderate risk of injury within the role. Further information on the specific implications and weaknesses outlined below.
Red
Issues have been identified or declared, which may have an impact on their ability to carry out the work in the role specified. Meets some norms or was successful at meeting some components of the assessment but may have a high risk of a new injury or aggravation of pre-existing condition based on poor manual handling techniques or identified weakness in functional assessment components. Further information on the specific implications and weaknesses outlined below.
Unable to conduct functional capacity assessment.
Current medical certificate prohibiting physical activity provided, or absolute contraindications of testing criteria met.
Partner with LifeCare, New Zealand’s trusted occupational health provider, to ensure your workforce is fit, safe, and supported. Our nationwide team of qualified clinicians delivers Functional Capacity Assessments tailored to your industry and job demands, providing clear, actionable results that help you make smarter hiring decisions, reduce injury risks, and stay compliant with HSWA.
Book a ConsultationGet in touch with LifeCare today to discuss how FCAs can strengthen your pre-employments and health monitoring programme and protect both your people and your business.
