Cut Manual Handling Injuries with Smarter WHS Controls

Hazardous manual handling continues to be the single largest contributor to workplace injuries in Victoria, with WorkSafe accepting 48,355 injury claims since 2021. More than 60 per cent of these cases involve musculoskeletal disorders (MSDs), including sprains, strains, back and soft tissue injuries, hernias and chronic pain.

To address this ongoing risk, WorkSafe is delivering Manual Handling Basics workshops that provide practical tools and resources to help duty holders identify hazardous manual handling tasks and implement effective risk controls. These sessions support businesses to strengthen their WHS management systems and ensure manual handling risks are properly assessed and controlled.

WorkSafe Chief Health and Safety Officer Sam Jenkin said hazardous manual handling remains a critical focus in efforts to reduce injuries, particularly in high-risk industries.

“When people think of hazardous manual handling, they often picture heavy lifting, but it shows up in countless other ways across all types of workplaces,” Mr Jenkin said.

“Anything that involves awkward postures, repetitive movement or sustained force can place excessive strain on the body and lead to serious injuries which are often debilitating over the long-term.”

Over the past five years, almost 40 per cent of MSDs arising from manual handling have occurred in the manufacturing and healthcare and social assistance sectors. This includes early childhood education and care, where routine tasks such as lifting children in and out of cots, working at floor level, and prolonged computer-based administrative work can all present manual handling risks.

In food manufacturing, tasks such as frequent lifting and carrying, repetitive labelling, packing, or sealing bottle tops can also lead to MSDs where risks are not adequately identified and controlled. These activities highlight the importance of robust WHS policies and procedures that address task design, equipment selection and safe work methods. For businesses seeking structured guidance, documented WHS policies and procedures are available from providers such as BlueSafe.

“On average, about 26 workers are injured as a result of hazardous manual handling every single day across Victoria and no sector is immune,” Mr Jenkin said.

“These injuries can be debilitating, but the good news is they are largely preventable with the right systems, equipment and work setups in place – which is exactly what our workshops are designed to help employers achieve.”

The Manual Handling Basics workshops are aimed at employers, managers and supervisors with OHS responsibilities in small and medium-sized businesses. Participants are supported to review their existing WHS management systems, develop or refine task-specific controls, and integrate manual handling risk management into everyday operations.

By embedding safe work method statements and clear procedures into your WHS framework, you can significantly reduce the likelihood of manual handling injuries and support safer, more sustainable work practices.

For further information on WorkSafe’s manual handling initiatives or to register for workshops, contact WorkSafe Victoria via email at media@worksafe.vic.gov.au or phone 0438 786 968.