Quick answer: Manual handling injuries are the most common type of workplace injury in Australia. Employers must identify manual handling hazards using tools like the TILE framework, then apply controls starting with elimination or mechanical aids — not just training or PPE.
Last reviewed: March 2026 by the BlueSafe Technical Team. Reflects current Model WHS Regulations.
Manual handling injuries account for a significant proportion of workplace injuries in Australia. This guide provides a framework for assessing and controlling manual handling risks.
What is Manual Handling?
Manual handling includes any activity requiring a person to:
- Lift, lower, push, pull, carry, or hold an object
- Restrain a person or animal
- Apply force in any way that could cause injury
Common manual handling tasks include moving stock, operating machinery, repetitive assembly work, and patient handling in healthcare.
Identifying Manual Handling Hazards
Use the TILE framework to identify hazards:
Task
- Repetitive movements
- Awkward postures (bending, twisting, reaching)
- Holding loads away from the body
- Sustained effort or static loading
Individual
- Worker fitness and capability
- Pre-existing injuries or conditions
- Training and experience
- Fatigue levels
Load
- Weight and size of the object
- Shape and stability
- Grip points and handholds
- Hot, cold, or hazardous materials
Environment
- Space constraints
- Floor surfaces and gradients
- Temperature and humidity
- Lighting and visibility
Conducting a Risk Assessment
Follow these steps to assess manual handling risks:
- Identify tasks involving manual handling
- Consult workers who perform these tasks
- Observe the task being performed
- Identify hazards using the TILE framework
- Assess the level of risk considering likelihood and consequences
- Determine controls using the hierarchy of controls
- Document findings and communicate to workers
Implementing Controls
Elimination
- Automate the task using conveyors, hoists, or robots
- Redesign the process to remove manual handling
Substitution
- Reduce load weights by splitting into smaller units
- Replace heavy containers with lightweight alternatives
Engineering Controls
- Provide mechanical aids (trolleys, forklifts, pallet jacks)
- Adjust work heights to reduce bending and reaching
- Install handles and grip points
Administrative Controls
- Rotate workers to reduce repetitive strain
- Schedule regular rest breaks
- Provide manual handling training
- Implement team lifting procedures
PPE
- Provide supportive footwear
- Consider gloves for improved grip
- Note: Back belts are generally not recommended as a primary control
Monitoring and Review
Manual handling controls should be reviewed:
- After any injury or near miss
- When tasks or processes change
- When new equipment is introduced
- At regular intervals as part of your WHS program
Key Takeaways
- Manual handling injuries are common but largely preventable
- Use the TILE framework to systematically identify hazards
- Consult workers who perform manual handling tasks
- Prioritize elimination and mechanical aids over PPE
- Monitor and continuously improve controls
State and Territory Variations
The information on this page is based on the Model WHS Regulations published by Safe Work Australia, which have been adopted (with minor variations) by most states and territories.
| Jurisdiction | WHS regulator | Key notes |
|---|---|---|
| NSW | SafeWork NSW | Adopted Model WHS Regulations |
| VIC | WorkSafe Victoria | Uses OHS Act 2004 — manual handling covered under OHS Regulations |
| QLD | Workplace Health and Safety Queensland | Adopted Model WHS Regulations |
| SA | SafeWork SA | Adopted Model WHS Regulations |
| WA | WorkSafe Western Australia | Adopted Model WHS Regulations (2022) |
| TAS | WorkSafe Tasmania | Adopted Model WHS Regulations |
| ACT | WorkSafe ACT | Adopted Model WHS Regulations |
| NT | NT WorkSafe | Adopted Model WHS Regulations |
Always verify requirements with your state regulator, as codes of practice for manual handling may differ.
Related guides
- Hierarchy of Controls: 5 Levels Explained
- How to Use a Risk Matrix to Score Hazards
- WHS Compliance in Australia: Essential Guide
- Incident Reporting in the Workplace: Best Practices
Frequently asked questions
What is manual handling under WHS law?
Manual handling includes any activity requiring lifting, lowering, pushing, pulling, carrying, holding an object, or applying force in a way that could cause injury. PCBUs must identify and control manual handling hazards.
What is the TILE framework?
TILE helps identify manual handling hazards across four categories: Task, Individual, Load, and Environment. It gives a structured way to assess all factors contributing to manual handling risk.
What are the best controls for manual handling?
The most effective controls are elimination (automating the task) and engineering controls (mechanical aids). Training and rest breaks are useful but should not be the primary strategy. Back belts are not recommended as a primary control.
How often should assessments be reviewed?
After any injury or near miss, when tasks or processes change, when new equipment is introduced, and at regular intervals as part of your WHS program.
Need risk assessment templates? Browse our risk assessment collection.