Purpose Psychosocial factors have been identified as risks for delayed recovery after work injuries but results from interventions for high-risk cases have been mixed. An earlier Australian study that matched care to assessed psychosocial risk factors with injured workers showed better return to work outcomes over 2 years than the usual care control, but as the study was not randomized it needed replication in another population. The present study, using the same protocol as the earlier study, but with injured workers from a different industry and different providers, attempted to replicate the earlier findings.  Methods A 2-group prospective design was used, with participants being allocated to Intervention or Control groups based on their home state of Australia. High-risk cases were identified within 5-10 days of injury. Those in the Intervention states were offered a coordinated, multidisciplinary intervention that targeted both identified psychological and social/workplace risk factors. Participants from both groups received usual care as required, including surgery, from their healthcare providers.  Results After 1-year, time to return to pre-injury work hours, total costs, and medical costs were significantly less in the Intervention group, relative to the Controls. Having surgery was associated with more lost time from work, but surgical cases in the Intervention group had significantly less lost time than the surgical cases in the Controls.  Conclusions These results replicate those of the earlier study and indicate that long-term disability from work injuries can be prevented by matching psychosocial interventions to identified psychosocial risk factors. Having surgery was associated with higher costs and delayed recovery, but did not alter the psychosocial findings.  Trial Registration. The study was registered prospectively with the Australian and New Zealand Clinical Trials Registry (ACTRN12620000041954).