Workplace Risk Assessments: Protecting Employees From Manual Handling Hazards Through Safety Risk Controls
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Workplace risk assessments are important as manual handling activities are among the most common causes of workplace injuries across Australia. Every day, workers are exposed to a hazard when lifting, carrying, pushing or pulling objects as part of their regular work activities. These tasks present significant work health and safety risks that can cause harm to employees and create costly disruptions for organisations.
A thorough risk assessment is the first step of the risk management process to identify, assess risks and implement effective control measures. By taking a proactive approach to manage risk, organisations can create a safe and healthy work environment while meeting their legal obligations under Australian WHS laws.
This guide provides practical information on how to conduct a risk assessment specifically for manual handling hazards within your workplace, helping you to eliminate or minimise risks and protect your most valuable asset – your workforce.
What are Workplace Risk Assessments?
Workplace risk assessments are a systematic approach to evaluate hazards in your workplace that could potentially cause harm to workers during their daily work activities. This structured process helps person conducting a business or undertaking (PCBU) identify the hazards, analyse and evaluate the level of risk, and determine appropriate ways to control or eliminate these risks.
For manual handling specifically, a risk assessment examines tasks that require physical exertion and movement that might lead to musculoskeletal injuries or other health problems. The risk assessment process typically involves:
- Identifying workplace hazards related to manual handling tasks
- Determining who might be harmed and how
- Evaluating the risks and deciding on control measures
- Recording your findings and implementing controls
- Reviewing and updating your assessment regularly
Legal Requirements for Manual Handling Risk Assessments
When operating businesses in Australia, you must comply with the Work Health and Safety Act 2011 and relevant state regulations, which establish clear legal obligations for employers regarding workplace risk assessments. These regulations operate alongside Safe Work Australia’s Code of Practice, creating a thorough framework for protecting your workforce. Your legal obligations include conducting detailed risk assessments for all workplace activities.
You’re required to provide adequate equipment, facilities, and access to trained personnel. Failing to meet these requirements can result in significant penalties under WHS legislation, including substantial fines and possible prosecution.
Identifying Hazards in the Workplace
Preparedness forms the foundation of any successful workplace safety program. When establishing workplace risk assessments for your workplace, you’ll need to systematically assess several categories of potential emergencies. Start by recognising common workplace injuries like cuts, burns, fractures and cardiac events that require immediate response. Assemble a diverse team from various departments to enhance your hazard identification and planning process. Utilise structured resources such as the Safe Work Australia Code of Practice and customised workplace assessment checklists to guarantee thorough emergency preparedness.
The first step in the risk management process is to identify the hazards within the workplace. For manual handling, this means examining all work activities that involve physical tasks such as lifting, pushing, pulling, holding, or carrying.
To effectively identify hazards in your workplace:
- Observe work practices: Watch how employees perform manual tasks and note any awkward postures, repetitive movements, or excessive force being used.
- Consult workers: Speak directly with employees and health and safety representatives who perform these tasks daily. They can provide valuable insights into risks in the workplace that might not be immediately obvious.
- Review incident reports: Analyse past incidents or near misses to identify patterns or recurring issues that need addressing.
- Conduct workplace inspections: Regularly inspect your workplace environment to identify potential manual handling hazards like awkward spaces, slippery floors, or inadequate equipment.
- Consider the full range of tasks: Assess both routine and non-routine work activities that might expose workers to a hazard.
Assess the Risk: The TILE Framework
Beyond basic preparedness, workplaces must address manual handling operations through systematic workplace risk assessments methods. The TILE framework provides a structured approach that complements your strategy, helping to prevent injuries before emergency response becomes necessary. When implementing the TILE framework as part of your comprehensive planning, you should evaluate:
Task – Analyse movement types, repetition, and rest periods to identify hazardous actions like twisting or sudden movements that could lead to injuries requiring response.
Individual – Consider physical capabilities, health conditions, and training level of employees performing manual handling tasks.
Load – Assess weight, size, stability, and potential hazards of items being handled that could cause injuries requiring intervention.
Environment – Examine workplace conditions including flooring, lighting, temperature, and access to equipment and emergency exits.
Control Measures to Minimise Risk: Risk Management and Reduction Strategies
Elimination and Substitution
The most effective way to control risks is to eliminate the hazard completely from your workplace. This approach sits at the top of the hierarchy of control measures and should always be your first consideration when managing work health and safety risks.
For manual handling tasks, elimination might involve:
- Redesigning the work process to remove the need for manual handling altogether
- Automating tasks that previously required physical handling
- Changing materials or components to lighter alternatives
When it is not reasonably practicable to eliminate the risk, substituting the hazard with something less dangerous is the next best option. This might include:
- Replacing heavy materials with lighter alternatives
- Substituting bulky packages with smaller, more manageable units
- Using mechanical aids instead of manual force
Engineering Controls
When you cannot eliminate or minimise the risk through substitution, engineering controls provide the next level of protection in the hierarchy of control. These measures involve physically changing the workplace environment or equipment to separate the hazard from workers.
Effective engineering controls for manual handling include:
- Installing lifting equipment like hoists, cranes, or forklifts
- Providing height-adjustable workstations that reduce bending and reaching
- Implementing conveyor systems to move materials
- Using trolleys, wheelbarrows, or other transport devices
- Redesigning storage systems to keep frequently used items at accessible heights
Administrative Controls
Administrative controls focus on changing how people work to reduce their exposure to manual handling risks. While less effective than elimination or engineering controls, they play an important role in your overall strategy to manage risk.
Practical administrative controls include:
- Developing safe work method statements for high risk construction work
- Creating clear procedures that outline safe manual handling techniques
- Implementing job rotation to limit exposure to repetitive tasks
- Scheduling regular breaks during physically demanding activities
- Providing comprehensive training on proper lifting techniques
- Ensuring adequate staffing for team lifting when required
- Using visual reminders and signage about safe handling practices
Personal Protective Equipment (PPE)
Personal protective equipment represents the final layer in your approach to control risks. While PPE should never be your only strategy to minimise the risk, it can provide additional protection when used alongside other control methods.
For manual handling tasks, relevant PPE might include:
- Back supports for specific high-risk activities
- Non-slip gloves to improve grip
- Protective footwear with good traction
- Knee pads for tasks requiring kneeling
When implementing PPE, ensure that:
- Equipment is suitable for the specific task and hazard
- Items fit correctly and are comfortable to wear
- Workers are trained in the proper use and maintenance
- PPE is regularly inspected and replaced when worn or damaged
Compliance, Documentation, and Recordkeeping
Implementing workplace risk assessments documentation approach ensures informed decision-making through clear understanding of potential impacts. Your organisation’s management plan and incident register should clearly outline procedures for injury assessment and treatment protocols using standardised formats and clear language.
Essential documentation for manual handling risk management includes:
- Risk assessment reports detailing identified hazards and risk analysis
- Records of control measures implemented and their effectiveness
- Training registers showing when workers received manual handling instruction
- Maintenance logs for equipment used to control manual handling risks
- Incident reports and investigation outcomes
- Minutes from health and safety committee meetings discussing manual handling issues
- Records of consultation with workers and health and safety representatives
Your documentation system should facilitate easy review of the effectiveness of control measures over time. This enables you to track whether your strategies to eliminate or minimise risks are working and make adjustments as needed.
Conclusion
Effective management of manual handling risks through workplace risk assessments is essential for creating a healthy work environment while meeting regulatory obligations under Australian workplace health and safety legislation. By following a structured risk assessment process, you can systematically identify hazards within the workplace, assess their potential impact, and implement appropriate control measures using the hierarchy of control.
Consulting with workers and their health and safety representatives throughout this process not only fulfils your legal obligations but also enhances the quality of your risk management approach. Those performing manual handling tasks daily often have valuable insights into practical ways to eliminate or minimise risks.
By prioritising thorough risk assessments and implementing effective control strategies, you create a workplace where manual handling hazards are properly managed, workers are protected from preventable injuries, and your organisation benefits from improved productivity and reduced costs associated with workplace incidents.
Frequently Asked Questions
What types of manual handling tasks require a formal risk assessment in the workplace?
Any manual handling task that involves lifting, lowering, pushing, pulling, carrying, or moving loads—especially if the task is repetitive, involves awkward postures, or heavy loads—requires a formal risk assessment. This includes tasks such as unloading deliveries, moving equipment, or handling clients in healthcare.
How Often Should Manual Handling Risk Assessments Be Updated?
Manual handling risk assessments should be updated annually at minimum, after workplace incidents, when tasks or equipment change, or when regulations evolve. Regular reviews ensure your assessment procedures remain effective and compliant with Australian WHS standards.
How Can Small Businesses Implement the Hierarchy of Control Measures?
By taking a strategic, prioritised approach that begins with identifying the highest-risk manual handling tasks and questioning whether each is necessary or could be redesigned. For essential tasks, explore cost-effective controls before implementing administrative controls while taking advantage of free resources from SafeWork Australia.
