Manual Handling — Definition, Hazards, Controls and Best Practices

 

1. Definition

Manual handling means any activity requiring a person to lift, carry, lower, push, pull, hold or move a load by hand or bodily force.

It includes:

• Lifting boxes, tools or materials

• Moving drums or equipment

• Pushing/pulling carts or trolleys

• Holding awkward or heavy objects

2. Why Manual Handling Is Important

• Around 30–40% of workplace injuries are due to poor manual handling.

• It can cause musculoskeletal disorders (MSDs) such as:

  • Back strain

  • Shoulder and neck injuries

  • Hernias

  • Joint or ligament damage

3. Common Manual Handling Hazards

Hazard	Example	Potential Injury
Heavy loads	Bags of cement, toolboxes	Back strain, slipped disc
Awkward posture	Bending, twisting, reaching overhead	Muscle fatigue, joint injury
Repetitive movement	Repeated lifting on conveyor line	Tendonitis, chronic pain
Poor grip	Slippery or uneven objects	Finger injury, dropping load
Long carrying distance	Moving drums between areas	Fatigue, tripping
Sudden movement	Catching falling object	Sprain, back injury

4. Manual Handling Risk Assessment (HSE “TILE” Method)

To evaluate risk, use the TILE factors:

Factor	Example Question
T – Task	Is the lifting repetitive, twisting or long-distance?
I – Individual	Is the person trained, physically fit and capable?
L – Load	Is the object too heavy, bulky or unstable?
E – Environment	Is the floor uneven, slippery or poorly lit?

5. Control Measures (Hierarchy of Control)

A. Elimination

• Avoid manual handling where possible.
  → Use forklifts, conveyors, hoists or pallet jacks.

B. Engineering Controls

• Provide mechanical aids or lifting equipment.

• Use adjustable-height tables, ramps or dollies.

C. Administrative Controls

• Conduct manual handling training.

• Plan lifts in advance (clear path, good lighting).

• Rotate jobs to avoid repetition.

• Display safe lifting posters and signs.

D. PPE (Personal Protective Equipment)

• Safety gloves for grip.

• Steel-toe boots to protect feet.

• Back support belts (for temporary use, not a substitute for safe technique).

6. Safe Manual Lifting Technique

1. Plan the lift: Check the load, path, and destination.

2. Get a firm base: Feet shoulder-width apart.

3. Bend knees, not back: Keep your spine straight.

4. Grip securely: Use whole hand, not fingertips.

5. Lift smoothly: Use leg muscles; don’t jerk.

6. Keep load close to body: Avoid reaching.

7. Avoid twisting: Turn your feet, not your waist.

8. Put down carefully: Reverse the lifting steps.

7. Weight Guidelines (HSE Reference Values)

Gender	Ideal Safe Lifting (at elbow height)
Male	Up to 25 kg
Female	Up to 16 kg

(These are general guidelines; actual safe limits depend on distance, posture and frequency.)

8. Training and Awareness

Workers should receive manual handling training that covers:

• Correct posture and lifting methods.

• Recognizing high-risk tasks.

• Use of mechanical aids.

• Reporting unsafe conditions or discomfort early.

9. Emergency Considerations

• If injury occurs: Stop work, report immediately and seek medical evaluation.

• Maintain incident records for trend analysis.

• Conduct refresher training annually or after incidents.

Summary

Aspect	Key Points
Definition	Physical movement of loads by hand or body
Main Risks	Back injury, muscle strain, fatigue
Controls	Eliminate, mechanize, train, use PPE
Safe Technique	Bend knees, keep back straight, load close
Assessment Tool	HSE TILE (Task, Individual, Load, Environment)