Manual Handling Techniques: A Comprehensive Guide to Safety and Efficiency

Manual Handling Techniques: A Comprehensive Guide to Safety and Efficiency

Manual handling, the act of moving objects by hand, remains common across construction, healthcare, retail, and manufacturing industries. While these tasks benefit workers and employers alike, poor technique can quickly become a source of serious injury. Statistics on work-related injuries show that lifting, pushing, pulling, or bending was the most common cause of injury or illness, accounting for 24% of all cases in the 2021-22 financial year. Moreover, statistics on manual handling injuries in Australia reveal that claims related to body stress injuries accounted for the highest percentage, standing at 37%.

Below, we explore the importance of correct manual handling, associated risks, and offer practical guidance so teams can learn effective techniques for executing manual tasks safely and efficiently.

Understanding Manual Handling

What is Manual Handling?

Manual handling, or what industry professionals call manual tasks, includes any activity where a person uses their body to lift, lower, push, pull, carry, move, hold, or restrain anyone, anything, or even animals. This work appears in many workplaces, including construction sites, hospitals, and retail stores. However, certain manual handling tasks can be hazardous and may cause injuries or illnesses. Examples of hazardous manual handling tasks include lifting heavy and large objects, using a jackhammer, working on a conveyor line, and entering data into a computer.

Here are further examples of hazardous manual handling tasks:

• Moving and carrying large sacks of grain
• Using a jackhammer
• Sitting at a cramped desk and typing for long periods at a time
• Using tin snips with widely spaced grips
• Steering a heavily loaded trolley through a busy warehouse
• Stacking shelves
• Pruning plants
• Helping a person into a bath
• Using a chainsaw
• Operating a lawn mower

Manual Handling Hazards

Manual handling hazards refer to potential risks and injuries that can occur due to lifting, carrying, lowering, or moving heavy objects. These tasks can lead to musculoskeletal disorders (MSDs), which affect muscles, nerves, blood vessels, ligaments, and tendons. Below are common manual handling hazards:

• Heavy Loads: Lifting or carrying loads too heavy for one person can cause strain injuries. This also applies when a load is too large to see over, potentially leading to accidents.
• Repetitive Tasks: Performing the same manual handling task repeatedly can lead to repetitive strain injuries (RSI). Such repetition is common in jobs requiring constant lifting or carrying.
• Awkward Postures: Bending, twisting, or reaching while handling loads can put pressure on the back and other parts of the body, leading to injuries.
• Poor Environment: Slippery floors, cluttered workspaces, or insufficient lighting can increase accident risk during manual handling tasks.
• Duration of Activity: Prolonged periods of manual handling without sufficient breaks can result in fatigue, increasing injury risk.
• Vibration: Regular exposure to vibration, such as when using certain machinery, can lead to health issues like Hand-Arm Vibration Syndrome (HAVS).
• Temperature: Working in extreme temperatures can affect a worker's ability to safely perform manual handling tasks. Cold conditions can reduce muscular strength, while heat can cause fatigue.

Musculoskeletal Disorders (MSDs)

Musculoskeletal disorders remain a significant health issue in Australia, affecting millions of people. Known collectively as MSD, these injuries or diseases affect the body's movement or musculoskeletal system. An MSD isn't a result of injury caused by crushing, entrapment, or cutting resulting from mechanical operation of plant machinery. Instead, it arises either suddenly or over time due to various factors impacting the musculoskeletal system.

MSDs are responsible for a significant burden of disease in Australia, ahead of both mental health conditions and unintentional injuries. Low back pain (LBP) was the most prevalent musculoskeletal condition and remained the leading driver of disability burden nationally. The recognised leading cause of MSDs stems directly from manual handling.

Types of MSDs

MSDs can manifest in several ways, such as:

• Sprains and strains: Injuries to muscles, ligaments, and tendons, often caused by a sudden wrench or twist.
• Back injuries: Damage to muscles, tendons, ligaments, spinal discs, nerves, joints, and bones in the back.
• Joint and bone injuries or degeneration: This includes injuries to the shoulder, elbow, wrist, hip, knee, ankle, hands, and feet.
• Nerve injuries or compression: Conditions like carpal tunnel syndrome fall under this category.
• Muscular and vascular disorders: These can occur as a result of hand-arm vibration.
• Soft tissue injuries: This includes conditions like hernias.
• Chronic pain: Persistent discomfort extending beyond a duration of 12 weeks.

Why is Proper Manual Handling Important?

Given risks associated with manual handling, understanding correct technique matters greatly. Human bodies deserve more protection than any piece of machinery, and proper manual handling helps ensure this protection and preservation. Below are benefits of proper manual handling, explained further in our guide on mastering manual handling techniques.

Prevention of Musculoskeletal Disorders (MSDs)

Incorrect manual handling can lead to a wide range of injuries and health problems, especially MSDs. Such outcomes can seriously impact an individual's health and well-being. Proper manual handling helps prevent MSDs, along with other injuries that may arise due to incorrect techniques.

Efficiency & Productivity

Good manual handling techniques prove essential for workplace efficiency. Correct posture and body mechanics reduce strain and fatigue during manual tasks, allowing workers to complete duties quickly and safely. This approach increases productivity while reducing accident or injury risk.

Improved Workplace Safety

Proper lifting and carrying techniques protect workers from back injuries and other harm. Keeping loads close to the body, then lifting with thigh muscles rather than the back, exemplifies safe manual handling practice.

Promotion of a Safer and Healthier Workplace

Proper training in manual handling fosters an environment that stays not only safer and healthier but also more positive. By prioritising employee safety and well-being, employers demonstrate genuine value for their workforce.

Compliance with Procedures and Equipment Usage

Manual handling training supports pre-existing procedures, such as rules on using certain equipment safely. Knowing how to operate tools and equipment correctly helps workers stay safe and avoid accidents, particularly when handling heavy or bulky objects like furniture or machinery.

Understanding Australia's WHS Framework for Manual Handling

While the Work Health and Safety (WHS) Act serves as primary health and safety legislation in many Australian states and territories, variations exist. Victoria, for instance, operates under the Occupational Health and Safety (OHS) Act. Staying aware of these nuances matters, so always consult the respective state's regulatory body for detailed information, or review our complete overview of occupational health and safety for further context.

1. Work Health and Safety Act (WHS Act)

Primary legislation provides a framework to secure worker health and safety. This framework outlines responsibilities of a person conducting a business or undertaking (PCBU) to ensure health and safety, particularly in managing risks associated with manual tasks.

2. Work Health and Safety Regulations (WHS Regulations)

These specific provisions reinforce the WHS Act. In the context of manual handling, such regulations may involve identifying hazardous manual tasks, assessing related risks, and implementing control measures to manage those risks.

3. Code of Practice for Hazardous Manual Tasks

This code offers practical advice for PCBUs navigating risks tied to hazardous manual tasks. Coverage ranges from tasks involving repetitive motions and prolonged postures to those requiring significant force. The code delves deep into risk management processes, providing insights on control measures and guidelines for designing tasks, workstations, layouts, and environments.

4. Roles and Responsibilities

PCBU (Person Conducting a Business or Undertaking): PCBUs must ensure health and safety risks stemming from hazardous manual tasks are either eliminated or minimised where elimination isn't feasible. They also bear responsibility for furnishing workers with relevant information, training, and supervision concerning safe manual handling practices.

Workers: Every worker holds an obligation to prioritise personal health and safety and act in a manner that doesn't jeopardise others' well-being. This includes adhering to prescribed procedures and utilising equipment that supports safe manual handling.

WHS Duties

Regarding hazardous manual tasks, health and safety duties are held by:

• Person Conducting a Business or Undertaking (PCBU): Must eliminate or minimise risks from hazardous tasks whenever practicable, plus consult workers on health and safety matters.
• Designers, manufacturers, importers, installers, and suppliers: These stakeholders play a significant role in reducing MSD risks often associated with poorly designed work areas or equipment. They need to ensure products remain safe and provide necessary information about them.
• Officers: Company directors, for example, carry a duty to ensure the PCBU complies with health and safety regulations, including ensuring appropriate resources minimise risks from hazardous tasks.
• Workers: Must take reasonable care of personal health and safety and avoid adversely affecting others. Compliance with instructions and use of provided Personal Protective Equipment (PPE) remain mandatory.
• Other persons at the workplace: Visitors, for example, must also take care of their own health and safety and follow PCBU instructions to comply with the Work Health and Safety (WHS) Act.

Principles of Safe Manual Handling

Risk Assessment

Determining the safest and best technique for a task requires considering the environment, the handler's ability to perform the work, and the nature of the load, whether animate or inanimate. Risks can be identified and assessed in workplaces by following these steps:

• Walk through the Workplace: Inspect the workplace and look for potential hazards. Doing so includes identifying manual handling tasks that involve lifting, pushing, pulling, holding, restraining, throwing, and carrying.
• Talk to Workers: Consult workers to identify any manual handling risks they've noticed or experienced firsthand.
• Assess the Risks: Once hazardous manual handling tasks have been identified, assess the risk of injuries such handling might cause. Consider factors that contribute to injury risk, including load weight and size, task frequency and duration, plus the work environment.
• Implement Control Measures: Apply control measures to eliminate or reduce injury risk associated with manual handling tasks. Options include using machines to remove or reduce manual handling, or redesigning work processes to eliminate the need for it entirely.
• Provide Training and Instruction: Offer training and instruction to workers on safe manual handling techniques.

Plan

Before lifting or moving an object, always remember to follow the TILE approach to assess the surrounding area carefully. TILE stands for Task, Individual, Load, Environment:

• Task: The manual handling activity and employee needs.
• Individual: Employee's capabilities including age, health, training, and strength.
• Load: Factors of the object being moved like weight, size, shape, and surfaces.
• Environment: Area of activity, checking for potential hazards.

Proper Technique

Use correct lifting techniques. This usually involves keeping the load close to the body, using legs to lift rather than the back, and avoiding twisting or jerking movements.

• Position the Feet: The handler should position feet shoulder-width apart with one foot slightly in front of the other to maintain balance. The vertebral column should stay in correct alignment following normal spinal curvature.
• Get a Secure Grip: The handler should get a secure grip on the load, using both hands if possible, holding it close to the body.
• Keep the Load Close to the Body: Keeping loads near the body reduces injury risk, achieved by bending the knees while keeping the back straight.
• Maintain Good Posture: The handler should maintain good posture throughout the task, keeping head up and neck straight, while bracing abdominal muscles to support the back.

Use of Equipment

Where possible, use mechanical aids or equipment like trolleys, forklifts, or hoists to move heavy items. This equipment reduces injury risk to handlers and helps improve efficiency during material handling operations. Protective clothing can also help protect employees from potential hazards such as cuts, scrapes, or burns. Wear comfortable clothing that allows free movement, plus shoes featuring flat heels, covered toes, and good foot support. Remove articles of jewellery that could become entangled during tasks.

Training and Education

Workers should receive adequate training on safe manual handling techniques and proper use of relevant equipment. Employers should ensure provided training remains adequate and effective, while employees take steps to stay informed about the latest safety regulations. Manual handling training typically includes:

• Understanding of Manual Handling: Introduction to what manual handling involves and why it matters for safety.
• Manual Handling Regulations: Explanation of relevant laws and regulations that apply to manual handling.
• Risk Assessment: Training on how to assess risks associated with manual handling tasks.
• Safe Lifting Techniques: Instructions on how to lift, carry, push, and pull objects safely to prevent injuries.
• Practical Exercises: Hands-on training to practise safe manual handling techniques.
• Health Implications: Information on potential health risks and injuries associated with incorrect manual handling.

Communication

Employers should ensure effective communication exists between all parties involved in manual handling activities. Coverage should include supervisors, workers, and other persons who may be affected by tasks being performed. Communication should address:

• Availability of equipment
• Warning signs of potential hazards
• Any changes to work processes or procedures
• Emergency plans
• Safe work practices

Regular toolbox talks help ensure everyone stays aware of safety regulations and best practices for manual handling tasks.

Ergonomics and Workplace Design

Good ergonomics and workplace design remain essential in manual handling tasks. Ergonomics serves as a key factor in ensuring safe manual handling at work, tailoring workplaces, systems, and tasks to suit worker abilities and limitations, which can boost productivity while reducing injury risk.

• Choosing Equipment: Equipment used should suit the materials being handled, workspace layout, and tasks performed. For instance, adjustable workstations can cater to different body sizes and postures, reducing strain and discomfort.
• Designing the Workstation: Workstations should be designed to prevent excessive bending, twisting, and stretching. Tool supports can be utilised for prolonged tool use, helping lessen fatigue and prevent MSDs.
• Involving Employees: Workers should have an active role in the ergonomic process by expressing concerns and suggestions. Their firsthand experience provides valuable insight for identifying and mitigating ergonomic hazards.
• Workplace Safety: Altering workplace design can effectively prevent manual handling injuries. Options include reorganising workspaces to minimise heavy lifting, adjusting storage areas to reduce excessive reaching, or implementing mechanical aids to assist with material handling and storage.
• Ergonomic Standards: Adherence to ergonomic standards like the ISO 11228 series, which sets out recommendations for various dynamic manual handling tasks, can further enhance workplace safety.

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With SafetyDocs, get started using a variety of easy-to-use tools and templates, including Manual Handling Risk Assessments, Safe Work Method Statements (SWMS), Job Safety Analysis (JSA) forms, and Toolbox Talks. Explore our range of manual handling safety documents below:

• Manual Handling Management Plan
• Manual Handling Safe Work Method Statement
• Manual Handling Task Register
• Manual Handling Safe Operating Procedure

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Our team of experts remains dedicated to providing accurate and informative content. Craig Cruickshank, our senior HSEQ advisor at SafetyDocs by SafetyCulture, has reviewed this blog post to ensure the highest level of quality. Learn more about Craig's work on LinkedIn for further industry insights.

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Please note that the above information is provided as a comment only and should not be relied on as professional, legal or financial advice.