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
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