Ensuring Safe Manual Handling: Performing Hazardous Manual Tasks in the Workplace
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Safe manual handling is a fundamental aspect of many Australian workplaces, from construction and manufacturing to healthcare and aged care settings. However, when performed incorrectly, these everyday tasks can pose significant hazards to workers, leading to serious musculoskeletal disorders (MSDs) and long-term health issues. Each year, thousands of Australian workers suffer from manual handling injuries, which can impact their quality of life and result in substantial costs to both individuals and organisations.
The code of practice established by SafeWork Australia provides comprehensive guidance on how to minimise the risk of injury associated with hazardous manual tasks. This guide explores practical approaches to manage the risks of hazardous manual handling in the workplace, emphasising the importance of proper work design, ergonomic considerations, and mechanical aids. By understanding and implementing these principles, organisations can significantly reduce the risk of workplace injuries and create a safer work environment for all employees.
Approaching Hazardous Manual Handling Tasks in the Workplace
When addressing manual handling in the workplace, it’s essential to adopt a systematic approach to identify and manage hazards before they cause harm. A person conducting a business or undertaking (PCBU) must ensure that all reasonably practicable measures are taken to eliminate or minimise health and safety risks associated with hazardous manual tasks.
The work environment plays a crucial role in determining the level of risk involved in manual handling tasks. Factors such as limited space, uneven floors, poor lighting, or extreme temperatures can increase the risk of injury. Similarly, tasks involving lifting and moving heavy objects, holding or restraining a person or animal, or performing repetitive movements with awkward postures can all contribute to musculoskeletal injuries.
Risk management begins with identifying tasks that may present a hazard. This includes activities that require:
- High force to lift, lower, push, pull or otherwise move objects or people
- Repetitive movements
- Sustained or awkward postures
- Exposure to vibration
- Handling unstable or unbalanced loads
Safe Manual Handling Techniques
Proper manual handling techniques are essential for reducing the risk of injury in the workplace. While ‘how to lift’ training alone is not sufficient to prevent musculoskeletal disorders, it remains an important component of a comprehensive approach to workplace safety.
When lifting and moving objects, workers should:
- Plan the lift before attempting it
- Position themselves close to the load with feet shoulder-width apart
- Bend at the hips and knees, not the waist
- Keep the load close to the body
- Lift smoothly using the legs, not the back
- Avoid twisting the body while lifting
- Set down the load carefully, maintaining good posture
It’s important to note that even with perfect lifting techniques, some loads are simply too heavy or awkward for safe manual handling. In these cases, mechanical aids such as trolleys, hoists, or forklifts should be used. The weight of the load, the frequency of the task, and the work environment all influence the appropriate approach.
Control Measures for a Potentially Hazardous Manual Task
Implementing effective control measures is crucial for managing risks associated with hazardous manual tasks. SafeWork Australia emphasises that PCBUs must consult with workers when identifying hazards and determining appropriate risk controls.
The most effective control measures address the task at its source through work design and ergonomic principles. This might include:
- Redesigning the task to eliminate or reduce manual handling
- Modifying the workplace layout so items are stored at appropriate heights (between mid-thigh and shoulder height)
- Providing mechanical aids such as lifts, trolleys, or hoists
- Ensuring loads are packaged in manageable sizes and weights
- Implementing team lifting protocols for heavier items
- Rotating tasks among workers to reduce repetitive movements
The Role of a Manual Handling Risk Assessment
A thorough manual handling risk assessment is fundamental to identifying and managing potential hazards in the workplace. This systematic process helps organisations understand the risk factors that may contribute to musculoskeletal disorders and implement appropriate preventive measures.
When conducting a risk assessment, consider:
- The nature, size, weight, and number of objects being handled
- The actions and movements involved (lifting, pushing, pulling)
- The working posture and position
- The duration and frequency of the task
- The location of the loads and distances moved
- The availability and suitability of handling aids
- The work environment (temperature, flooring, space constraints)
- The skills, experience, and physical capabilities of workers
Risk assessments should be documented and regularly reviewed, particularly when there are changes to the workplace, equipment, or procedures. They should also be conducted in consultation with workers who perform the tasks, as they often have valuable insights into practical challenges and potential solutions.
Manual Handling Equipment
Appropriate manual handling equipment can significantly reduce the physical demands placed on workers and minimise the risk of injury. Mechanical aids should be considered whenever there is a risk that cannot be eliminated through task redesign.
Common types of manual handling equipment include:
- Trolleys and carts for moving loads horizontally
- Hoists and lifts for vertical movements
- Conveyor systems for regular transfer of materials
- Pallet jacks and forklifts for heavier loads
- Sliding sheets and transfer boards, particularly in healthcare settings
- Adjustable workstations that accommodate different worker heights
When selecting equipment, consider:
- The specific task requirements
- The work environment and available space
- The characteristics of the load (weight, size, stability)
- The frequency and duration of use
- The ergonomic design and ease of operation
- Maintenance requirements and accessibility
Manual Handling Training and Certification
Effective training and certification in manual handling techniques are vital components of a comprehensive workplace safety program. While training alone cannot eliminate all risks, it equips workers with the knowledge and skills to perform tasks more safely.
In industries with high-risk manual handling tasks, such as healthcare, construction, or warehousing, formal certification may be required. This ensures that workers have demonstrated a standard level of competence in safe manual handling practices.
Conclusion
Effective management of hazardous manual tasks is essential for preventing workplace injuries and ensuring the wellbeing of workers across all industries. By adopting a comprehensive approach that includes risk assessment, ergonomic work design, appropriate mechanical aids, and quality training, organisations can significantly reduce the risk of musculoskeletal disorders.
The hierarchy of controls provides a framework for addressing manual handling hazards, with the elimination or reduction of risks through engineering controls being the most effective approach. Administrative measures and training support these controls by ensuring workers understand and follow safe practices.
By making workplace safety a priority and addressing manual handling risks systematically, organisations can create healthier, more productive work environments while meeting their legal obligations under Australian work health and safety legislation.
Frequently Asked Questions
What if Medical Advice Conflicts With Operational Requirements?
Always prioritise compliance with health and safety regulations. Focus on practical solutions such as strategically placed first aid kits and trained personnel, while implementing necessary workspace modifications. Regular reviews help balance legal obligations with operational needs while maintaining worker safety.
Can Employees Self-Certify Their Readiness for Increased Manual Tasks?
Self-assessment is useful but insufficient. Professional evaluation is essential to verify workers can safely perform manual tasks. Proper assessment ensures compliance with WHS regulations by confirming correct lifting techniques, equipment competence and understanding of safety protocols.
How Often Should Manual Handling Risk Assessments Be Updated?
Update assessments annually and whenever workplace changes occur. Reassess after any incident or near-miss, and consult regularly with workers who often notice emerging risks. This approach helps minimise musculoskeletal disorders while maintaining regulatory compliance.
