This cross-sectional study analysed the frequency and severity of work stressors and job satisfaction at workplaces in relation to work-related non-fatal injuries amongst a sample of petrochemical workers in Taiwan. The study participants consisted of 568 cases injured on the job between 1991 and 1997, and 954 injury-free controls matched to cases on frequencies of age, sex and work site. After adjusting for potential confounders, we found that cases were more likely than controls to report stressors with a higher frequency [odds ratio (OR) = 1.4, 95% confidence interval (CI) = 0.9-2.0] and a more severe reaction (OR = 1.3, 95% CI = 0.9-1.8). The dose-response analyses further indicated that the OR of injury was monotonically associated with stress reaction only (P for test for trend of ORs = 0.02). Job satisfaction, though, was unrelated to non-fatal injury. Although the cross-sectional nature of our study precludes a causal inference between stress reaction to stressors and risk of developing non-fatal injuries, our results tend to suggest that the severity of stress reaction is more associated with occupational non-fatal injury than is the frequency of stress or job dissatisfaction.