Hazardous manual handling

Everything about hazardous manual handling in one place.

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Manufacturing - hazardous manual handling

Manual handling

These are the most common injuries related to manual handling, as shown by injury claims.

Safety solutions

WorkSafe expects employers to have safety solutions in place to protect workers from the most common sources of injury.

Hazards and solutions

Hazard 1
Manual handling in all workplaces
Provide appropriate mechanical aids and equipment to control the risk of manual handling.

Ensure mechanical aids and equipment are used and maintained in accordance with manufacturer specifications.

Store objects at waist height to reduce the need to lift objects.

Reduce the size and weight of objects to be lifted (ensure this does not increase the frequency of lifting).

Ensure floors and ground surfaces in work areas, car parks and entrances are level, clean, well lit, clear of obstacles and in good condition.

7 per cent of the injuries were to a persons knee.

20 per cent of the injuries were to a persons shoulder.

7 per cent of the injuries were to a persons arm.

35 per cent of the injuries were to a persons back.

6 per cent of the injuries were to a persons abdomen / pelvis.

5 per cent of the injuries were to a persons hand / fingers.

7 per cent of the injuries were to a persons forearm / wrist.
Hazard 2
Manual handling in construction
Provide appropriate mechanical aids and equipment (eg cranes, material hoists, forklifts, hand trucks) to control the risk of manual handling.

Ensure mechanical aids and equipment are used and maintained in accordance with manufacturer specifications.

Arrange for bulky materials to be delivered to the final work location.

Provide lifting points or handles for heavy or awkward loads.

Order materials in smaller sizes (eg 20kg bags instead of 40kg bags).

Ensure employees are not exposed to repetitive tasks for long periods or tasks that require a significant amount of high force.

Train employees on safe handling methods (eg that the best working zone is when work is between shoulder and mid-thigh height and where the elbows are close to the body) and how to safely use any mechanical equipment and aids.

Supervise employees, particularly young workers, while using mechanical aids and equipment

When lifting objects use appropriate personal protective equipment (eg gloves, long trousers, boots, knee protection pads) and cover any sharp edges.

7 per cent of the injuries were to a persons knee.

20 per cent of the injuries were to a persons shoulder.

7 per cent of the injuries were to a persons arm.

35 per cent of the injuries were to a persons back.

6 per cent of the injuries were to a persons abdomen / pelvis.

5 per cent of the injuries were to a persons hand / fingers.

7 per cent of the injuries were to a persons forearm / wrist.
Hazard 3
Manual handling in health care and social services
Provide appropriate mechanical aids and equipment (eg overhead tracking, hoists, mobile hoists, electric tugs, wheeled equipment, inflatable mats, slide sheets) to eliminate manual transfer of patients, where reasonably practicable.

Ensure mechanical aids and equipment are used and maintained in accordance with manufacturer specifications.

Provide trollies or lifting aids for moving heavy equipment (eg orthopaedic sets).

Provide appropriate mechanical aids (eg self-height adjusting bin inserts in laundry trolleys) to eliminate manual lifting.

Ensure floor surfaces are appropriate (eg for trolleys and wheelchairs) and pathways are clear of obstructions.

Train employees on safe handling methods (eg that the best working zone is when work is between shoulder and mid-thigh height and where the elbows are close to the body) and how to safely use and mechanical aids and equipment.

Supervise employees, particularly young workers, while using mechanical aids and equipment.

7 per cent of the injuries were to a persons knee.

20 per cent of the injuries were to a persons shoulder.

7 per cent of the injuries were to a persons arm.

35 per cent of the injuries were to a persons back.

6 per cent of the injuries were to a persons abdomen / pelvis.

5 per cent of the injuries were to a persons hand / fingers.

7 per cent of the injuries were to a persons forearm / wrist.
Hazard 4
Manual handling in manufacturing and retail
Provide appropriate mechanical aids and equipment (eg forklifts, height adjustable trolleys, cranes) to control the risk of manual handling.

Ensure mechanical aids and equipment are used and maintained in accordance with manufacturer specifications.

Provide suction systems for bulk supply of product and move them via forklift or other mechanical aids.

Use height-adjustable workstations and raise, lower or move either the work or the worker.

Provide height access equipment (eg mobile steps with handrails and work platforms) to reach objects or undertake work above shoulder height.

Ensure floor surfaces are appropriate (eg for trolleys) and pathways are clear of obstructions.

Position shelving and racking in storage areas at accessible heights.

Train employees on safe handling methods (eg that the best working zone is when work is between shoulder and mid-thigh height and where the elbows are close to the body) and how to safely use any mechanical equipment and aids.

Supervise employees, particularly young workers, while using mechanical aids and equipment.

7 per cent of the injuries were to a persons knee.

20 per cent of the injuries were to a persons shoulder.

7 per cent of the injuries were to a persons arm.

35 per cent of the injuries were to a persons back.

6 per cent of the injuries were to a persons abdomen / pelvis.

5 per cent of the injuries were to a persons hand / fingers.

7 per cent of the injuries were to a persons forearm / wrist.
Hazard 5
Manual handling in transport and warehousing
Provide appropriate mechanical aids and equipment (eg height adjustable order picking trolleys, automatic in-feeds, four-wheel trolleys and lifters) to control the risk of manual handling.

Ensure mechanical aids and equipment are used and maintained in accordance with manufacturer specifications.

Eliminate manual lifting of hardwood pallets.

Provide appropriate wrapping and stillages to prevent objects falling from containment.

Stack heaviest items at the base of the load.

Use plate freezers or trolley systems. If this isn't reasonably practicable, use aids such as height adjustable racking and trolleys, pallet lift tables and vacuum lifters.

Ensure employees are not exposed to repetitive tasks for long periods or tasks that require a significant amount of high force.

Train employees on safe handling methods (eg that the best working zone is when work is between shoulder and mid-thigh height and where the elbows are close to the body) and how to safely use any mechanical equipment and aids.

Supervise employees, particularly young workers, while using mechanical aids and equipment.

7 per cent of the injuries were to a persons knee.

20 per cent of the injuries were to a persons shoulder.

7 per cent of the injuries were to a persons arm.

35 per cent of the injuries were to a persons back.

6 per cent of the injuries were to a persons abdomen / pelvis.

5 per cent of the injuries were to a persons hand / fingers.

7 per cent of the injuries were to a persons forearm / wrist.

Featured case study

A hazardous manual handling incident causes a worker on a construction site to become unconscious and hospitalized. How did this happen and what was the solution to avoid this from happening?

Read full case study View all case studies

Hazardous manual handling

Is the work safe? Do I feel safe?

Manual handling

Safety solutions

Hazards and solutions

Manual handling in all workplaces

Manual handling in construction

Manual handling in health care and social services

Manual handling in manufacturing and retail

Manual handling in transport and warehousing

Featured case study

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