Safe Manual Handling Techniques for Every Workplace
Table of Contents
Workplace health and safety is paramount in any organisation, with proper manual handling techniques being essential to prevent one of the leading causes of injuries in the workplace. Poor manual handling techniques can lead to serious musculoskeletal disorders and injuries that affect both workers and businesses. In Australia, each state and territory has specific work health and safety (WHS) legislation that requires a person conducting a business or undertaking to manage the risks associated with hazardous manual tasks.
This guide outlines proper manual handling techniques that can help reduce the risk of injury when performing manual tasks. By implementing safe work procedures and following the code of practice for manual handling, organisations can create a safer work environment for all workers. It is reasonably practicable to prevent most manual handling injuries through proper training, risk assessment and the use of appropriate mechanical aids.
Safe Manual Handling Techniques
Manual handling refers to any activity requiring a person to lift, lower, push, pull, carry, move, hold or restrain any person, animal or object. To perform manual tasks safely and reduce the risks associated with hazardous manual tasks, workers should:
- Assess the manual handling risk before commencing the task
- Use mechanical aids where practicable (trolleys, hoists, forklifts)
- Consult with workers about the safest way to lift or move objects
- Design the work area to minimise manual handling requirements
- Wear appropriate clothing that is not too constricting
- Consider the weight of the load and whether assistance is needed
- Follow proper lifting techniques to reduce strain on the body
- Get a good grip before attempting to move any load
- Avoid unexpected movements that could cause injury
Examples of Hazardous Manual Tasks
Hazardous manual handling tasks that may pose risks to health and safety include:
- Lifting heavy objects from floor level or above shoulder height
- Handling a load that is awkward to lift due to size, shape or weight
- Repetitive movements that can lead to repetitive strain injuries
- Tasks that require pushing and pulling heavy trolleys or equipment
- Manual labour involving sustained awkward postures
- Moving patients or animals that may resist being held or restrained
- Working in a confined work environment with limited space to manoeuvre
- Tasks involving vibration or extreme temperatures
- Handling unstable or unbalanced loads
- Activities requiring high force or speed
Common manual handling hazards in different industries include healthcare workers transferring patients, construction workers handling building materials, retail staff stocking shelves, and office workers using improper posture at workstations. By identifying these hazards, employers across different states and territories can implement effective control measures.
Safe Lifting Techniques
Maintain a straight back and bend at the hips and knees when lifting, keeping the load close to your centre of gravity to minimise strain. Engage your core muscles for additional lumbar support and avoid twisting or leaning sideways that can compromise healing tissues. The correct technique for safely lifting involves positioning your feet shoulder-width apart to create a stable base before attempting to lift the load.
| Lifting Phase | Standard Technique | Post-Injury Adaptation |
|---|---|---|
| Preparation | Feet shoulder-width | Wider stance for stability |
| Execution | Steady lift with core engaged | Slower, controlled movement with deliberate breathing |
| Completion | Step to turn | Avoid twisting; use mechanical aids when practicable |
When planning to perform manual handling tasks, consider whether you can reduce manual handling by using mechanical aids or getting assistance from colleagues. Always assess if the object is too heavy or awkward to lift alone, and remember that proper manual handling techniques are essential for injury prevention. If training and instruction have been provided but the load still presents risks, consult with your supervisor about alternative approaches.
Load Positioning
Proper load positioning during manual transfers is essential. Maintain loads close to your body to reduce strain on healing shoulder structures while ensuring even load distribution across muscle groups. This is a key aspect of workplace safety that helps prevent manual handling injuries.
| Positioning Principle | Rehabilitation Benefit |
|---|---|
| Keep loads at waist height | Minimises overhead strain on rotator cuff |
| Maintain proximity to body | Reduces moment arm and muscular demand |
| Use handling aids when possible | Decreases compensation patterns |
| Distribute weight asymmetrically | Offloads affected shoulder during recovery |
| Maintain stable base of support | Prevents sudden compensatory movements |
When transferring loads, prioritise postural alignment and avoid stretching movements that could compromise shoulder joint integrity. The way to lift and carry items should always keep the load close to your centre of gravity. For heavier items, it’s important to use the correct technique and appropriate mechanical aids rather than risking injury by handling loads that exceed your physical capabilities.
Workplace Injury Control Measures
To manage the risks associated with hazardous manual tasks, employers should implement comprehensive control measures:
Eliminate the hazard – Redesign the workplace or task to remove the need for manual handling where practicable.
Substitute the risk – Replace heavy items with lighter alternatives or break down loads into smaller, more manageable portions.
Engineering controls – Modify equipment or provide mechanical aids such as trolleys, hoists, and conveyor systems to reduce manual handling.
Administrative controls – Develop safe work procedures, provide training and supervision, rotate workers between different tasks, and schedule regular breaks.
Personal protective equipment – Provide gloves for better grip or back supports when other control measures are not reasonably practicable.
Equipment Options
Using mechanical aids is one of the most effective ways to reduce manual handling risks. Some common equipment options include:
- Trolleys and carts: Ideal for moving heavy or bulky items across level surfaces
- Pallet jacks and forklifts: For moving palletised goods in warehouses
- Hoists and cranes: Essential for lifting very heavy loads in construction and manufacturing
- Patient lifting devices: Specifically designed for healthcare settings
- Adjustable workstations: Allow workers to position tasks at optimal heights
- Conveyor systems: Eliminate the need for carrying items between workstations
- Vacuum lifting devices: For handling awkward materials like glass or panels
- Sliding sheets: Reduce friction when moving patients or heavy objects
- Hand trucks: For moving boxes, appliances or stacked items
When selecting handling aids, consider the specific tasks, environment and the workers who will use them. Proper training on equipment use is essential, as improper use of mechanical aids can itself become a hazard. Regular maintenance of equipment ensures it remains in good working condition and continues to effectively reduce manual handling risk.
Team-Based Lifting and Moving Objects
When a load is too heavy or awkward for one person to lift, team-based lifting may be necessary. However, this approach brings its own risks and should be carefully planned:
- Appoint a team leader to coordinate the lift and give clear instructions
- Ensure all team members understand the plan before attempting the lift
- Select team members of similar height and capability where possible
- Use standard verbal cues (e.g., “Ready, set, lift”) to ensure synchronised movements
- Move at the pace of the slowest person to avoid unexpected movements
- Ensure clear communication throughout the task
- Consider using handling aids even for team lifts when practicable
Frequently Asked Questions
How do I know if a manual handling task is hazardous?
A task is hazardous when it involves risk factors like repetitive force, high force, awkward postures, or handling unstable loads. Signs include discomfort while performing the task or colleagues developing related health conditions. WHS regulations require employers to identify and assess these risks across all states and territories.
How can I reduce manual handling risks when mechanical aids aren't available?
Break loads into smaller parts, adjust your work environment to minimise awkward postures, and use correct technique by bending at hips and knees. Keep loads close to your centre of gravity and avoid twisting. Consider team lifting for heavy items with proper coordination, and take regular breaks during repetitive tasks. Combining these control measures helps prevent handling injuries even without mechanical aids.
What are the most common manual handling injuries and how can they be identified early?
Common injuries include back strains, shoulder injuries, herniated discs and repetitive strain injuries. Watch for warning signs: persistent pain, numbness, reduced movement range, and discomfort that worsens with certain motions. Report symptoms immediately for first aid and treatment. Poor manual handling techniques cause gradual damage, so address even minor discomfort promptly. Employers should implement health monitoring for high-risk manual handling tasks.
