Preventing Manual Handling Injuries: Strategies, Examples, and Common Mistakes

Manual handling tasks, such as lifting, carrying, and moving loads, are integral to many workplaces but pose significant risks if not managed properly. These activities are a leading cause of work-related musculoskeletal disorders (MSDs), which can lead to decreased productivity and increased absenteeism. By implementing effective strategies and learning from real-world examples, businesses can create safer environments and reduce injury rates.

Understanding Manual Handling Risks

Manual handling involves any activity requiring human force to lift, lower, push, pull, carry, or move objects. Common risk factors include:

• Awkward Postures: Bending, twisting, or reaching during tasks can strain the musculoskeletal system.
• Repetitive Movements: Frequent repetition of motions can lead to overuse injuries.
• Forceful Exertions: Handling heavy loads or applying significant force increases the risk of acute injuries.
• Environmental Conditions: Poor lighting, uneven flooring, or confined spaces exacerbate manual handling risks.

The Scope of Manual Handling Injuries: Key Statistics

• In 2020/21 in Great Britain, 21% of workplace injuries were directly attributable to manual handling tasks such as lifting, carrying, or moving objects.
• 39% of musculoskeletal disorders (MSDs) were related to the back, with manual handling being a primary cause.
• Over 9 million working days were lost annually due to MSDs caused by manual handling injuries.

These statistics highlight the significant impact of manual handling injuries on both individuals and businesses.

Case Studies: Real-World Success Stories

1. Telstra Corporation Limited

Telstra implemented a “Musculoskeletal Health Strategy” that emphasized understanding how tasks, environments, and lifestyles contribute to injury risks. This holistic approach encouraged workers to take ownership of their health by addressing both workplace and personal factors. The initiative led to improved awareness and reduced injury rates.

2. VOS Construction and Joinery

VOS introduced “Back Care Sessions” led by an exercise physiologist. These sessions focused on strengthening core muscles and maintaining proper posture during tasks. Workers reported reduced pain after implementing personalized exercise plans. The company also observed a decline in Lost Time Injuries (LTIs).

3. Dinmore to Goodna Joint Venture (D2GJV)

D2GJV conducted extensive risk assessments for the Ipswich Motorway upgrade project. They identified manual handling as a major risk and implemented Onsite Health Solutions’ injury prevention program. This proactive approach significantly reduced sprains and strains among workers.

Strategies to Prevent Manual Handling Injuries

1. Conduct Thorough Risk Assessments

Identify tasks involving manual handling and evaluate associated risks. Engage employees in the process to gain practical insights and foster a culture of safety.

Learn how digital checklists enhance workplace safety, streamline reporting, and reduce risk in our post How Digital Checklists Improve Workplace Safety.

2. Redesign Tasks and Workspaces

• Eliminate Unnecessary Handling: Streamline processes to reduce manual movement.
• Use Mechanical Aids: Introduce trolleys, hoists, or conveyors for heavy loads.
• Ergonomic Workstations: Design workspaces that promote neutral postures.

3. Provide Comprehensive Training

Educate employees on:

• Proper lifting techniques
• Effective use of mechanical aids
• Ergonomic principles for safe workspaces

Workplaces with regular training programs report up to 50% fewer injuries.

4. Promote Employee Health

Encourage fitness programs that include stretching exercises and strength training to support musculoskeletal health.

Common Manual Handling Mistakes (and How to Avoid Them)

1. Poor Lifting Technique

• Mistake: Using improper posture when lifting heavy objects.
• Solution: Bend at the knees instead of the waist, keep the load close to your body, and avoid twisting while lifting.

2. Overestimating Strength

• Mistake: Attempting to lift loads beyond personal capacity.
• Solution: Assess the weight beforehand and seek assistance or use mechanical aids when needed.

3. Poor Planning

• Mistake: Rushing tasks without considering the safest way to execute them.
• Solution: Plan the route and clear obstacles before starting the task.

4. Ignoring Ergonomics

• Mistake: Working in poorly designed spaces that force awkward movements.
• Solution: Adjust workstations to minimize bending or reaching.

5. Inadequate Training

• Mistake: Employees lack knowledge about safe manual handling practices.
• Solution: Provide regular training sessions tailored to workplace-specific risks.

Learn more about workplace accidents and how to prevent them in our post Workplace Safety: Preventing Common Accidents.

The Role of Digital Solutions in Enhancing Safety

Digital solutions can streamline safety and compliance processes, making it easier to manage manual handling risks. With mobile forms and digital tools, organizations can:

• Digitize Risk Assessments: Conduct and document manual handling risk assessments efficiently using customizable digital forms.

• Monitor Compliance: Track the implementation of control measures and ensure adherence to safety protocols.

• Facilitate Training: Distribute training materials and gather feedback to continuously improve manual handling practices.

By integrating digital tools, like DIGI CLIP mobile forms,  into your safety management system, you can enhance oversight and foster a proactive approach to manual handling safety

Conclusion

Preventing manual handling injuries requires a comprehensive approach combining risk assessments, task redesign, employee training, and health promotion initiatives. Learning from successful case studies like those of Telstra or VOS Construction demonstrates how proactive measures can significantly reduce injury rates.

By addressing common mistakes and leveraging innovative strategies such as ergonomic design or digital tools for monitoring compliance, businesses can foster safer workplaces while improving productivity.

Try DIGI CLIP mobile forms Free Today!

Transform your compliance and safety processes with DIGI CLIP, risk-free:

✅ Set Up in Minutes – Get started quickly and easily with no technical experience required.
✅ No Credit Card Needed – Enjoy a no-commitment trial with zero upfront costs.
✅ Ready-Made Form Library – Use industry-specific templates to hit the ground running.
✅ No Lock-In Contracts – Stay only if DIGI CLIP works for your business.

Experience how DIGI CLIP simplifies compliance and saves you time and money.

Trial the DIGI CLIP mobile forms checklist & inspection app today for free!