Most manual handling injuries are preventable, and they usually trace back to a short list of failures: no risk assessment, no training, poor planning, missing handling aids and worker fatigue. Manual handling injuries are the main work activity to cause back disorders and are one of the three most frequent causes of workplace injury. It is the responsibility of the employer or manager to ensure that all staff are protected against manual handling injuries. The 1992 MHOR (Manual Handling Operations Regulations) explain clearly the definition of manual handling:
“… any transporting or supporting of a load (including the lifting, putting down, pushing, pulling, carrying or moving thereof) by hand or bodily force“.
Under the MHOR an employer has responsibility to:
- “Avoid hazardous manual handling operations so far as is reasonably practicable.”
- “Assess any hazardous manual handling operations that cannot be avoided.”
- “Reduce the risk of injury so far as is reasonable practicable.”
In order to meet these regulations, it is important to first understand the causes of manual handling injuries so we’ve listed the top 10 below:
TL;DR
- Manual handling injury is a major, preventable problem, causing 33% of work related injuries and being one of the three most frequent causes of workplace injury.
- The law sets the framework: under the 1992 MHOR employers must avoid hazardous manual handling where practicable, assess what cannot be avoided, and reduce the risk of injury.
- Risk assessment and training are the foundations, and their absence is repeatedly cited in injury and compensation cases.
- Practical failures cause injuries: poor systems planning, unavailable mechanical aids, unbroken heavy loads, awkward loads and worker fatigue all raise the risk.
- Off-site and static work are easy to miss: deliveries at client sites and jobs with no chance for dynamic movement need specific planning.
- Regular training is the best mitigation, and AFTT is an AITT-accredited training provider offering manual handling and forklift safety training at instructor, manager and workforce level.
Why is a lack of risk assessment a manual handling risk?
A lack of risk assessment is a risk because you cannot control hazards you have never identified. Regular risk assessment has to be the bedrock of any safety planning for manual handling tasks. Infrequent or inadequate risk assessment can lead to incorrect provision of mechanical aids, lack of understanding and ultimately preventable injuries.
How does a lack of manual handling training cause injuries?
Untrained staff are more likely to be injured because they do not understand the risks or the correct lifting techniques. The lack of manual handling training is often cited in injury compensation cases. Even within a system of excellent risk assessment and careful planning, if the employees concerned do not have the understanding of risk and the expertise to use lifting techniques and aids, injuries are more likely to occur.
Why does poor systems planning lead to manual handling injuries?
Poor systems planning leads to injuries because badly organised loading, access and housekeeping create hazards even for careful workers. The careful planning of systems for the loading and unloading of stock can go a long way towards mitigating the manual handling risks involved. Insufficient access and poor housekeeping, that is the maintenance and cleanliness of workspaces, can contribute to injuries.
What happens when mechanical handling aids are unavailable?
When the right aids are unavailable, workers are tempted to lift by hand or use the wrong equipment, and that is when injuries happen. Injuries when manual handling can occur if the correct mechanical handling aids, for example a counterbalance or forklift truck, sack truck or hand pallet truck, are unavailable for an important job. It is understandably tempting in these situations for employees to carry out the task without aids or with the wrong ones, but this should be actively discouraged.
How does an existing injury increase manual handling risk?
An existing injury increases risk because a worker who is already hurt is more likely to be injured again by related strain. Manual handling injuries are more likely to occur in employees who have an existing injury of a related nature. Whilst employees have a responsibility to report existing health problems, it is also recommended that supervisors be trained to spot these issues before they cause further injury.
Why should heavy loads be broken down into components?
Breaking a load down reduces the weight handled at once, which is one of the easiest ways to prevent injury. The first question that should be asked when faced with a heavy load is, ‘Does the load really need to be moved?’ After this it is important to consider the option of breaking the load down into smaller constituent parts, as doing so can be an easy step towards avoiding manual handling injuries.
How should you plan for unusual, heavy or awkward loads?
Plan for awkward loads separately and agree the approach with staff before the load arrives. Loads that are unusual in shape, weight or packaging can be classed as unwieldy and are difficult to handle using normal, planned systems. Modified planning should be undertaken and agreed with staff before such loads arrive on site.
How does worker fatigue contribute to manual handling injuries?
Fatigue contributes to injuries because tired workers lose concentration and strength, making mistakes more likely. Employees who are over-tired are more likely to be affected by injuries when manual handling. Fatigue factors include poor load layout, longer shifts or over frequent deliveries, and avoidance of these should be built into risk planning.
Why is communication about deliveries at client sites important?
Communication about deliveries matters because you cannot control a client site the way you control your own. No matter how strict manual handling arrangements are at the home site, it is harder to control issues such as lack of appropriately distanced parking at a client site. The writing of agreed delivery parameters can alleviate these risks but not necessarily eliminate them. Employees should be given instructions on how to handle external site delivery issues.
Why does a lack of dynamic movement raise injury risk?
A lack of movement raises risk because holding one position for long periods puts sustained strain on the body. If a worker is not given suitable opportunity for free or dynamic movement, the risk of manual handling injuries is increased. Jobs that involve long shifts of seated activity would be included in this.
How do the main causes of manual handling injury compare with their controls?
The quickest way to prioritise action is to see each common cause next to the control that prevents it. The table below summarises the causes above and a practical step for each.
| Cause | Main control |
|---|---|
| No or poor risk assessment | Assess tasks regularly and act on the findings |
| Lack of training | Train staff, supervisors and managers in safe technique |
| Poor systems planning | Plan loading, access and housekeeping |
| Aids unavailable | Provide and maintain the correct handling aids |
| Existing injury | Encourage reporting and train supervisors to spot issues |
| Loads not broken down | Question the move, then split heavy loads |
| Unusual or awkward loads | Plan and agree an approach in advance |
| Worker fatigue | Manage shift length, layout and delivery frequency |
| Client-site deliveries | Agree delivery parameters and give instructions |
| No dynamic movement | Build in movement breaks for static roles |
By far the best way to ensure the successful mitigation of manual handling risks in the workplace is to provide regular training to managers, supervisors and staff. The emphasis for this aspect of health and safety is very much on employer responsibility. Workplace manual handling injury is the cause of 33% of work related injuries and far too many missed work hours each year. Failure to deal with these issues may result in unfortunate litigation.
Frequently Asked Questions
What is manual handling?
Under the 1992 Manual Handling Operations Regulations, manual handling is any transporting or supporting of a load, including lifting, putting down, pushing, pulling, carrying or moving it, by hand or bodily force. It covers a wide range of everyday workplace tasks. Because it is so common, it is one of the three most frequent causes of workplace injury.
What are an employer’s duties under the MHOR?
Under the MHOR an employer must avoid hazardous manual handling operations so far as is reasonably practicable, assess any hazardous operations that cannot be avoided, and reduce the risk of injury so far as is reasonably practicable. These three duties form the framework for managing manual handling. Meeting them is a legal responsibility that sits with the employer.
How common are manual handling injuries?
Manual handling injury is a major cause of workplace harm, accounting for 33% of work related injuries and many missed working hours each year. It is the main work activity that causes back disorders. This scale is why it is treated as a priority in health and safety planning.
How can manual handling injuries be prevented?
The best prevention combines regular risk assessment, proper training, good systems planning and the right mechanical aids. Breaking down heavy loads, managing fatigue and planning for awkward loads all help further. Providing regular training to managers, supervisors and staff is the single most effective step.
Is manual handling training a legal requirement?
Employers must reduce the risk of injury from manual handling, and training is a central way to meet that duty under the MHOR. A lack of manual handling training is frequently cited in injury and compensation cases. Training staff in risk awareness and correct technique is therefore both a legal safeguard and a practical one.
Who is responsible for manual handling safety?
The main responsibility rests with the employer or manager, who must protect staff against manual handling injuries. Employees share the duty by reporting existing health problems and following safe systems of work. Supervisors also play a part by spotting risks before they cause injury.
What mechanical aids help with manual handling?
Common aids include a counterbalance or forklift truck, a sack truck and a hand pallet truck, each removing some of the load from the worker. The right aid must be available for the job, because workers who cannot access it may lift by hand or use the wrong equipment. Providing and maintaining suitable aids is part of reducing risk.
Why does fatigue increase manual handling risk?
Fatigue increases risk because over-tired workers lose concentration and strength and are more likely to be injured. Contributing factors include poor load layout, longer shifts and over frequent deliveries. Avoiding these should be built into risk planning.
Does AFTT offer manual handling training?
Yes. AFTT offers a comprehensive range of manual handling and forklift safety training courses, with packages at instructor, manager and workforce level. As an AITT-accredited training provider, we can discuss your requirements and tailor training to your workplace. You can contact us to find out more.
At Advanced Forklift Training we offer a comprehensive range of both manual handling and forklift safety training courses. We have packages at instructor, manager and workforce level and are happy to discuss your requirements with you. Please contact us today for more information.
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