Manual Handling Policy: Hazardous Manual Handling Procedures for Health and Safety
Table of Contents
A manual handling policy provides guidelines and procedures for activities requiring a person to lift, lower, push, pull, carry, move, hold or restrain any person, animal or object. Hazardous manual handling is a significant cause of workplace injuries in Australia, with musculoskeletal disorders accounting for a large percentage of all workplace injuries. Such a policy should aim to establish procedures for identifying, assessing and controlling the risks of hazardous manual tasks in the workplace.
The Work Health and Safety Act 2011 and associated regulations require employers to eliminate manual handling risks so far as is reasonably practicable, or where elimination is not possible, to minimise these risks through appropriate control measures. Safe Work Australia provides guidance through the Hazardous Manual Tasks Code of Practice, which outlines the obligations of both employers and workers in managing manual handling in the workplace.
Identifying Hazardous Manual Tasks
A manual handling policy should help identify potentially hazardous manual handling tasks including those that involve repetitive or sustained force, high force, sudden force, awkward postures, or exposure to vibration.
Examples of Hazardous Manual Handling Tasks
A manual handling policy should address hazardous manual handling tasks in various industries which may include:
- Healthcare: Lifting, transferring, or helping to restrain patients
- Construction: Carrying building materials, operating vibrating tools
- Retail: Stocking shelves, moving heavy merchandise
- Education: Setting up classroom equipment, supporting students with mobility needs
- Manufacturing: Repetitive assembly line work, operating heavy machinery
- Hospitality: Moving furniture, carrying food trays, cleaning activities
- Office environments: Prolonged computer use, moving office equipment
Common Manual Handling Injuries
A manual handling policy should include information about common injuries associated with hazardous manual tasks including:
- Sprains and strains to muscles, ligaments and tendons
- Back injuries including damage to the muscles, discs and ligaments
- Joint injuries, particularly to the shoulder, knee and wrist
- Compressed nerves (carpal tunnel syndrome)
- Muscular and vascular disorders as a result of hand-arm vibration
- Soft tissue injuries due to sudden unexpected movements
Information on manual handling injuries should be collected and analysed to inform prevention strategies and reduce the risk of similar incidents occurring in the future.
Workplace Risk Assessment Management
A manual handling policy should establish that management of risks from manual tasks must follow a systematic process as outlined in the Health and Safety Regulations 2017. The hierarchy of controls provides a framework for determining the most effective way to control the risk of injury:
- Elimination: Remove the hazardous manual task entirely where possible
- Substitution: Replace the task with a less hazardous alternative
- Engineering controls: Modify equipment or work areas to reduce the physical demands
- Administrative controls: Implement safe work procedures, training and job rotation
- Personal protective equipment: Provide appropriate equipment as a last line of defence
Where multiple control measures are necessary, employers should implement them in combination to effectively manage manual handling hazards. Regular review of control measures is essential to ensure their ongoing effectiveness.
Safe Manual Handling Procedures
A manual handling policy should ensure that safe work procedures for specific manual tasks are developed in consultation with staff who perform these tasks. These procedures should include:
- Proper lifting techniques (bend knees, keep back straight, hold load close to body)
- Guidelines for team lifting when loads exceed recommended weight limits
- Instructions for using mechanical aids correctly and safely
- Task-specific techniques for different industries and job roles
- Procedures for handling awkward or unstable loads
Staff must take reasonable care for their own health and safety and follow established procedures when performing hazardous manual tasks. Applying proper body mechanics can significantly reduce the risk of injury during manual handling activities.
Control Measures: Equipment and Environmental Controls
A manual handling policy should emphasise that the selection of appropriate mechanical aids forms an important part of controlling hazardous manual handling risks. Equipment such as trolleys, hoists, and adjustable workstations can minimise the need for manual handling or reduce the force required to complete tasks.
Workplace design considerations should include:
- Layout of work areas to minimise carrying distances
- Storage optimisation, with frequently accessed items stored at waist height
- Adequate space for movement and use of mechanical aids
- Appropriate flooring to prevent slips and falls during manual handling
- Sufficient lighting to ensure hazards can be clearly seen
Regular maintenance schedules for handling equipment must be established to ensure safe operation, with records kept of all inspections and repairs.
Work Health and Safety Training and Competency
A manual handling policy should recognise that manual handling training is a critical component of health and safety management. Initial training should be provided to all staff undertaking manual tasks, with refresher sessions scheduled periodically. Training programs should:
- Cover relevant sections of the Work Health and Safety Regulation
- Be tailored to specific manual handling risks in the workplace
- Include practical demonstrations of safe techniques
- Address the use of specific equipment and aids
- Explain procedures for reporting hazards and injuries
Implementing Manual Handling Programs
A manual handling policy should require clear definition of roles and responsibilities for implementation:
- Managers: Ensuring resources are available and policies are implemented
- Supervisors: Monitoring compliance with safe work procedures
- Health and safety representatives: Participating in risk assessments and consultation
- Workers: Following established procedures and reporting hazards
Communication strategies should ensure all staff are aware of manual handling policies and procedures. Integration with broader WHS systems helps create a consistent approach to safety management.
Consultation with staff must occur when identifying hazards, assessing risks, and implementing control measures. This consultation should include contractors and visitors who may be exposed to manual handling risks while on site.
Incident Management and Response
A manual handling policy should outline that when incidents involving manual handling occur, prompt reporting is essential. The organisation’s incident reporting procedures should:
- Outline the process for reporting injuries or near misses
- Specify timeframes for reporting
- Identify who is responsible for investigation
- Detail documentation requirements
Investigation methodologies should identify root causes rather than just immediate factors. This approach allows for the development of effective corrective actions that address underlying issues and prevent recurrence.
Performance Monitoring and Evaluation
A manual handling policy should suggest that monitoring the effectiveness of manual handling risk controls requires the establishment of key performance indicators, such as:
- Reduction in manual handling incidents
- Decreased severity of injuries
- Increased reporting of hazards
- Compliance with safe work procedures
- Worker satisfaction with control measures
Regular audits of manual handling practices should be conducted to verify compliance with established procedures. Trend analysis helps identify emerging issues or areas requiring additional focus.
A commitment to continuous improvement ensures that manual handling programs remain effective and adapt to changing workplace conditions.
Frequently Asked Questions
Who is responsible for ensuring a workplace is safe from manual handling hazards?
According to the Work Health and Safety Act, the responsibility should be shared. Employers must provide a safe and healthy workplace, while workers must take reasonable care for their own safety and follow safety procedures.
How often should manual handling risk assessments be conducted?
Risk assessments should be conducted when new tasks are introduced, when work environments change, after incidents occur, and periodically (typically annually) to ensure controls remain effective.
What should I do if I identify a potentially hazardous manual handling task?
Report it to your supervisor or health and safety representative immediately. The task should be assessed and control measures implemented to eliminate or reduce the risk so far as is reasonably practicable.
