U.S. Work-Related Injuries, Illnesses Cost $250 Billion Annually: The study suggests that the U.S. should place greater emphasis on reducing work-related injury and illnesses…Cost data came from the National Council on Compensation Insurance, the Healthcare Cost and Utilization Project and the National Academy of Social Insurance. Total costs were calculated by multiplying the number of cases of occupational injury or illness by the average cost per case. The study estimates that in 2007 there were: