Manual Handling remains one of the most common causes of workplace injury. It refers to transporting or supporting a load by hand or bodily force, including lifting, carrying, pushing, or pulling. The risks are well recognized, yet injuries linked to manual handling continue to account for a significant proportion of work-related ill health in the UK. The consequences are often musculoskeletal disorders such as back strain, shoulder injuries, or repetitive strain conditions, many of which develop gradually and can develop long-term health problems.
Hazards of Manual handling
· Lifting loads that are too heavy.
· Carrying items that are bulky or awkward in shape.
· Repetitive lifting or moving that strains muscles and joints.
· Twisting, bending, or reaching while lifting, which puts stress on the spine.
· Handling in cramped or unstable spaces increases the chances of slip, trips, or falls.
· Working undertime pressure, which can cause shortcuts or unsafe movements.
These hazards often lead to back pain, joint injuries, and other musculoskeletal disorders. They may not appear immediately but can develop over time, reducing a person’s ability to work safely.
Case study Links
A recent prosecution illustrates this connection. Workers were injured after falling from equipment during loading activities. Injuries occurred when workers were lifting and moving baggage while working on raised platforms on an aircraft. The platforms were poorly designed, with gaps and incomplete extensions. While the incident was categorized as falls from height, they occurred during manual handling tasks. Workers were lifting and moving baggage while balancing on raised equipment, demonstrating how handling tasks and fall hazards can combine in practice. The case underlines the importance of recognizing that manual handling rarely occurs in isolation and that assessments must consider how tasks interact.
Legal Requirements
The Manual Handling Operations Regulations 1992 specifically address manual handling. These regulations require employers to:
· Avoid hazardous manual handling where possible by redesigning tasks or using mechanical aids.
· Assess unavoidable handling tasks to identify the nature and level of risk.
· Reduce risk so far as reasonably practicable through equipment, task redesign, and safe systems of work.
These duties align with the broader obligations set out in Health and Safety at Work etc. Act 1974, which requires employers to ensure, so far as reasonably practicable, the health, safety, and welfare of employees.
Control Measures
To prevent manual handling injuries, employers should focus on a hierarchy of controls:
· Elimination- Remove the need to handle loads manually by using mechanical handling systems, conveyors, or automated equipment.
· Reduction – Where elimination is not possible, reduce the weight, size, or awkwardness of loads. Break loads into smaller units where feasible.
· Task design- Plan work so that handling occurs at a safe height, in sufficient space, and on stable surfaces. Avoid twisting, reaching, or long carrying distances.
· Training and Information- Offer guidance on safe lifting techniques and task- specific risks, but recognize that training is a supporting measure, not a primary control.
· Supervision and review- Ensure that safe systems are followed, equipment is used correctly, and risk assessment remains current.
Considerations:
Manual handling risks are not limited to obvious heavy lifting tasks. Smaller loads handled repeatedly can be just as harmful over time. Poor ergonomics, such as fixed workstations or restricted movement, add to strain. Fatigue and poor physical fitness also increase the likelihood of injury. Employers should consider workplace design, workload management, and even wider health initiatives that support worker’s musculoskeletal health.
Conclusion
Manual handling continues to present risks that are often underestimated because tasks appear routine. The case study shows how handling activities, when combined with other hazards, can lead to severe incidents. The regulatory framework requires employers to avoid, assess and reduce risks, placing emphasis on eliminating hazards at the source. By applying engineering controls, redesigning tasks, and ensuring timely implementation of improvements, organizations can prevent both short-term injuries and long-term health problems.
