Pat Testing Fees: What’s Behind This Investment

TL;DR: New hires who are physically capable are essential—especially for labor-intensive roles. Physical Abilities Testing (PAT) helps prevent injuries and improve hiring outcomes. Here's what the costs cover and why it's a smart move

Main points:

• Customized tests tailored to job demands
• Professional oversight from licensed experts
• Use of specialized facilities and equipment
• Legally compliant documentation
• Functional Capacity Evaluations (FCEs) for return-to-work cases
• Fewer workplace injuries and lower compensation costs
• Improved employee fit and retention
• Legal protection through objective, ability-based screening
• Investing in PAT testing pays off in safety, savings, and smarter hiring.

Hiring the right person is important. But ensuring they’re physically ready for the job is just as critical—especially in roles that involve lifting, carrying, or repetitive motion. Physical Abilities Testing (PAT) can help with that. It screens new hires for their ability to perform the physical demands of the job and helps prevent injuries before they happen.

Still, when employers see PAT testing fees, they sometimes pause. What exactly are they paying for? Is it worth the cost? Let’s break it down.

What’s Included in PAT Testing Fees?

PAT test pricing isn’t just about the time it takes to run a test. The cost includes planning, scheduling, professional oversight, and the tools needed to do the job right. Here’s what you’re paying for:

• Customized assessments that match real job duties
• Time from licensed professionals, like physical therapists
• Use of online testing software, testing facilities and equipment
• Secure documentation of test results and protected medical information
• Legal, regulatory, and safety compliance

These tests aren’t one-size-fits-all. If you’re hiring for physically demanding roles, you want a screening process that closely reflects that. A well-designed PAT screening ensures candidates can safely do what the job requires. PAT testing fees may vary, based on test length, test quality, legal defensibility, and volume of testing.

The greatest cost differences often arise between local clinics and national testing organizations. While local clinics may offer lower pricing, this can sometimes come with trade-offs in consistency and quality.

In many cases, local clinics do not perform a detailed job analysis prior to developing a test. Instead, they may rely on a general checklist of tasks without standardized procedures or scoring criteria. This can lead to variability in how tests are administered and interpreted, which may affect the reliability and validity of the results. Additionally, results are often not stored in a centralized database, and ongoing outcome analysis may be limited. In the event of a legal or regulatory challenge, these limitations could make it more difficult to support the test's defensibility.

Functional Capacity Evaluation Costs

For some situations, especially after a workplace injury, a more thorough test is needed. You may need someone to conduct a complete functional capacity evaluation (FCE). It looks at strength, endurance, flexibility, and more.

It helps employers and doctors understand whether someone can return to work safely—or if they might need accommodations. Keep that in mind when considering functional capacity evaluation costs.

The average cost of functional capacity evaluation ranges from $871 to $916, based on data from MDsave. Unlike a basic PAT screening, an FCE involves several hours of testing. FCE is ideal for high-risk roles or for making decisions after time off because of an injury.

FCEs are especially useful in cases involving musculoskeletal disorders (MSDs), which are some of the most common workplace injuries. Better understanding of a worker’s limits can reduce re-injury risk and support better recovery outcomes. In some cases, you may even help prevent issues like sciatica, which can start small but lead to chronic pain and lost work time.

Are Investing in PAT Testing Fees Worth It?

When you consider the bigger picture, PAT testing fees actually save businesses money.

First, there are fewer injuries. By screening for physical readiness, you reduce the chances of a new hire getting hurt. Fewer injuries mean fewer claims—and a lot less disruption and lost productivity.

Second, your workers’ compensation costs go down. Injuries are expensive. From medical bills to lost productivity, they snowball fast. The total cost (both direct and indirect costs) of a lost time musculoskeletal injury on average is $60K. Preventing just one serious injury can cover the cost of over 300 tests.

Third, you get better hires. Screening helps match people to the physical demands of the job. That means fewer resignations, fewer performance issues, and more satisfied employees.

And finally, there’s the legal side. Professionally designed post-offer employment testing can help protect you from claims of discrimination. It shows that hiring decisions were based on ability—not assumptions.

Choosing the Right Testing Partner

Not every provider is the same. When looking for someone to handle your PAT screening, make sure they:

• Clearly explain their PAT testing fees
• Describe the research behind their tests
• Offer tests that match your actual job requirements
• Use credentialed staff for testing
• Provide thorough documentation
• Understand employment laws and compliance
• Have references from other clients

It’s also smart to ask if they offer services like ergonomic analysis, especially to reduce injury risks even further in your workplace. A good provider should be your partner in workplace health, not just a test administrator.

Making a Smart Call

If your jobs involve lifting, pushing, climbing, or long hours on your feet, PAT is worth considering. PATs are a preventive step that can improve workplace safety and hiring quality.

To make the best decision, ask yourself:

• Are strains and sprains affecting my bottom line?
• Do I have a plan for selecting the best applicants for our physically demanding roles?
• Am I confident in my return-to-work process?

If you’re unsure, testing might be a helpful next step.

And don’t forget about long-term benefits. The cost of PAT test pricing initially may seem steep —but when you factor in reduced injury claims, stronger hires, and better compliance, the math works out fast.

Request a custom quote from ErgoScience to implement a compliant, defensible Physical Abilities Testing (PAT) program tailored to your job roles.