Manual Handling: Your questions answered

Injuries due to poor manual handling practices are known as ‘musculoskeletal disorders’ and include injuries and conditions that cause pain to the back, joints, or limbs.Here are five common injuries due to poor manual handling; 

• Back pain 
• Strains  
• Hernia 
• Slipped disc  
• Crushing of extremities 

1. Conduct a Manual Handling risk assessment  

Remember the acronym TILE 

Task: Before starting any manual handling, consider the task ahead, specifically the weight and distance you’ll be carrying the load. It’s important to remember that depending on the load, significant effort may be required to start and stop it. The risk also increases over longer distances and with the speed at which the load is moved.  

Individual: Consider the individual(s) involved in the task, as each person will have varying physical abilities. If the task requires specific capabilities, the individual may not be the best fit for the task. 

Load: Consider the weight and size of the load when planning, as well as its ability to navigate any rises, corners, or rough surfaces. 

Environment: Several factors can impact the effort required to push or pull the load. The surface, temperature, lighting, and even wind can all increase the effort needed. A clean, dry surface can significantly reduce the effort required. Limited room to manoeuvre can result in awkward postures or the risk of becoming trapped or crushed. 

Correct Training: 

• Provide your employees with the right manual handling training. This training should match the specific work they do and their individual needs, always keeping their health and safety as a top priority. SafeWorkforce recommends offering health and safety training once a year to update workers on new practices and refresh their knowledge. 

• The type of manual handling training needed can vary by role. As an employer, consider the frequency and requirements of each role to determine the right level of training. For example, an office employee might need to carry boxes of paper. Although this seems minor, they still need proper training to stay safe. SafeWorkforce suggests giving manual handling training when new employees start and providing yearly training for those who often do manual handling tasks. 

2. Use mechanical lifting aids 

Where Identified in Risk Assessment:some examples of lifting aids include trolleys, carts, pallet jacks, winches, forklifts, lifting buckets, and vacuum lifts. These are typically used when it is deemed unsafe or impractical to push or pull manually. 

Remember that some of this equipment legally requires proper training to use safely. Always refer to the risk assessments and internal guidance for the appropriate course of action. 

3. Plan the task/lift before you start 

You can do so by following these steps;  

• Assess what the task required is. 
• Clear the pathway ensuring there is no obstruction. 
• Find any other hazards that may cause an issue when carrying out the task, this can be anything from electrical to aerial hazards. 
• Evaluate the weight of the load in question. 
• Pick the elements of the load that can be lifted safely. 
• From the remaining load, find ways to reduce the risk, this can be through the use of mechanical lifting aids. 

4. Wear the right clothing

• When performing manual handling, wearing the right clothing is crucial for safety. For example, a loose-fitting shirt can get caught in the load. Similarly, wearing trainers while carrying a load or using a lifting aid is dangerous, as your feet could easily be crushed. 

Clothing to wear during a manual handling task; 

• Wear gloves when carrying a load to protect your hands from potential lacerations or fingers being crushed. 
• Wear shirts that feel comfortable but aren’t loose to prevent being caught up in the load. 
• Wear steel toe cap boots when either carrying a load or operating a lifting aid to prevent feet being crushed.  
• Use a hard hat if there is a risk of head injury from impact or from falling objects when operating a mechanical lifting aid.

This list is non-exhaustive. We recommend researching beforehand or speaking to your competent health and safety person for advice on the correct clothing and PPE for your business. Alternatively, if you do not have one, contact our experts who are available to advise. 

• The HSE advises that the maximum load for men is 25kg and 16kg for women. However, this recommendation applies only if the load is between elbow height and knuckle height and close to the chest of the worker. 

• Know your limits. Encourage this within your business by talking to your employees and letting them know they can speak out if carrying out the task makes them uncomfortable, without fear of repercussion. This will help foster a safety-first culture.

Some key points to remember when carrying a load. 

• Push don’t pull. Pushing the load is safer than pulling the load 
• Bend the knees! Not your back 
• When lifting and manoeuvring, always keep your head up 
• Hug the load. Avoid twisting or leaning with the item 

Planning in Advance: 

When putting a plan in place during the design phase of the process, ensure that you factor in manual handling. This way, you can eliminate unnecessary moving and handling. 

Automate/Mechanise Where Possible: 

By using machinery to lift equipment, you are less likely to cause injuries. 

Encourage Communication Around Issues: 

When talking to your employees, try to encourage them to report any problems with existing manual handling procedures. 

• Factor in each person’s individual capability 

Each person will require a different way of working when carrying out manual handling. Whether this is regular breaks or extra carries to be able to carry out the task. Carry out an assessment of each of your workers so you can plan around their capability. 

• Ensure you have the correct equipment  

You’ll need to make sure your workers have the necessary equipment to carry out the manual handling activity. If the equipment is not available, try and source a new piece of equipment or if its being used wait until its available. Its not worth risking it. 

Unfortunately, even if you follow every procedure exactly, there may still be circumstances where an accident occurs. While this is very unfortunate, it’s not uncommon, so it is crucial that you have an effective accident reporting procedure included in your health and safety policy. 

Record and Report All Details: 

No matter how trivial it might seem, the injury needs to be reported to the injured person’s employer, manager, or supervisor. This is a legal requirement, so ensure that all workers are aware of their responsibilities and your reporting procedure. 

Investigate the Accident: 

The level of investigation should be proportional to the seriousness of the incident. Investigating the accident will provide employers with the opportunity to understand the cause and how to mitigate risks in the future. We recommend reviewing and amending your manual handling risk assessment each time an accident or incident occurs. 

Report the Incident to HSE: 

Certain types of accidents, cases of occupational diseases connected with specific work activities, and some dangerous occurrences must be reported to the Health and Safety Executive under RIDDOR. 

Dangerous Occurrences: 

Dangerous occurrences are near-miss events relevant to all workplaces. Not all need to be reported, but there are 27 categories, including one related to manual handling, such as “The collapse, overturning, or failure of load-bearing parts of lifts and lifting equipment. 

According to the Health and Safety Executive’s 2023 annual statistics, the highest rate of musculoskeletal disorders is in the ‘administrative and support service activities’ industry. The statistics also indicate that smaller businesses have a greater chance of musculoskeletal disorders occurring. 

In an office environment, manual handling involves more than just lifting boxes—it includes a range of tasks that, if not approached with care, can lead to strain and discomfort. The same HSE statistics highlight that the main causes of self-reports were manual handling, working in awkward or tiring positions, and repetitive actions including keyboard work. 

Here’s what employers can do to limit the risk for their employees: 

• Provide information on setting up workstations/desks to alleviate strain on the back, neck, and wrists. 
• Encourage proper lifting techniques and offer assistance for heavier items. 
• Educate staff on the correct use of equipment like trolleys and organising cables to prevent tripping hazards. 
• Promote regular breaks to combat prolonged sitting and support a culture of reporting discomfort. 

By incorporating these practices into your workplace and encouraging an active approach to manual handling within the office, businesses can adopt a healthier, more comfortable, and injury-free workplace for their employees.