Repetitive manual handling caused 31% of all work related musculoskeletal disorders in 2015, with the back being the site of injury 38% of the time. Despite its high resilience, studies have shown that intervertebral discs can be damaged during repetitive loading at physiological motions, causing cumulative damage and disc herniation. To understand the mechanism of disc injury resulting from repetitive lifting, it is important to measure disc deformations/strains accompanied by MRI imaging to identify disc tissue damage. Therefore, the aim of this study was to examine associations between the magnitude of 3D internal strains, tissue damage and macroscopic evidence of disc injury after simulated repetitive lifting on normal human lumbar discs.

Sixteen cadaver lumbar functional spinal units (FSUs) were subjected to pre-test MRI. Eight FSUs (control) underwent 20,000 cycles or until failure (5 mm displacement) of loading under compression (1.7 MPa – to simulate lifting a 20 kg weight) + flexion (13°) + right axial rotation (2°) using a novel Hexapod Robot. The remaining eight FSUs (experimental) had a grid of tantalum wires inserted, and stereoradiographs were taken to track internal disc displacements at increasing cyclic intervals. Maximum shear strains (MSS) were calculated from the displacements using radiostereometric analysis at cycle 1 and 20,000 cycles (or failure). Post-test MRI was conducted to determine the extent of tissue damage and associated with regions of highest MSS. A repeated measures ANOVA was performed on MSS with a within–subjects factor of cycle number (cycle 1 and failure cycle) and a between subjects-factor of disc region and failure type (p < 0 .05).

Pfirrmann grading revealed mostly normal discs [I (N=2), II (N=13), and III (N=1)]. No significant difference in MSS between control and experimental groups was found for number of cycles to failure (p=0.279). Pre and post-test MRI analysis revealed that 13 specimens were injured after repetitive lifting with either an endplate failure (N=9) or disc bulge (N=4), and two specimens did not fail. Failure strain was significantly greater than cycle 1 in all regions except posterior, left/right posterolateral (p>0.109). Largest MSS at failure was seen in the anterior (60%), and left/right posterolateral regions (64% and 70%, respectively). MSS at failure for the endplate failure group was significantly larger than the no injury group in all regions except right lateral and nucleus (p>0.707). Disc bulge group MSS was significantly larger than the no injury group in the anterior, right anterolateral, and left/right posterolateral regions (p < 0 .027).

Simulated repetitive lifting led to largest shear strains in the anterior, left and right posterolateral regions that corresponded to annular tears or annular protrusion. The no injury group shear strain was less than 50% in all regions, indicating there may be a threshold that could be associated with tissue damage linked with injuries such as disc bulge and endplate failure. There was no evidence of disc herniation in normal discs, agreeing with current clinical knowledge. These results may be indicative of the effects of repetitive manual handling on normal discs of younger patients.