The aim of this study was to determine biomechanical loads and subjective stresses on lumber graders and associated morbidity in a high risk and repetitive sawmill occupation. The exposures of all 29 male sawmill worker volunteers were recorded. Motion and posture were studied with electrogoniometers, muscle loads were recorded with surface electromyography, and psychophysical stresses were assessed with subjective responses. Fifty-nine percent of the participants reported greater than moderate discomfort in their task-dominant upper extremity. Job performance required an average range of motion of 44°, 21°, and 52° in flexion/extension, radial/ulnar deviations, and pronation/supination respectively. It also required an average of 9% maximum voluntary contraction force and was repeated an average of 34 times/min. This repetitive exertion over an 8-h shift was deemed to be a significant risk factor associated with prevalent upper extremity morbidity.