Manual Handling in the Workplace

How to Identify Risks and Design Safer Workflows

Manual handling is part of almost every workplace. It happens when a person lifts, lowers, pushes, pulls, carries, holds or moves an object, person or load. In warehouses, factories, healthcare facilities and other busy operations, these movements may be repeated hundreds of times across a shift.

Manual handling is not automatically unsafe. The risk increases when a task involves repetitive or sustained force, high or sudden force, awkward postures, repeated movement or exposure to vibration. A load can also present a risk because it is bulky, unstable or difficult to grip – even if it does not appear particularly heavy.

For this reason, safer manual handling is not simply a matter of reminding people to use the right lifting technique. It starts with understanding the task, removing unnecessary physical effort and designing a workflow that gives people greater control over how loads are moved.

The practical principle: Start with the job that needs to be done, then consider the load, the operator, the route and the equipment together.

What is manual handling?

Manual handling includes any work in which a person uses physical effort to lift, lower, push, pull, carry, move, hold or restrain something. Safe Work Australia uses the term hazardous manual task when this work also involves factors such as repetitive movement, sustained force, high or sudden force, awkward postures or vibration.

Common examples of manual handling include:

• lifting cartons from a pallet or placing stock onto shelving
• pushing a loaded trolley or pulling a wheeled cage
• moving pallets frequently with a manual pallet jack
• positioning components, reels, rolls or drums at a workstation
• moving linen, waste bins, hospital beds or supplies through a facility
• loading, unloading, stacking, picking or packing goods repeatedly

Some of these tasks may appear routine. However, the risk is shaped by more than the weight of the load. Frequency, duration, posture, movement, grip, travel distance, floor condition and the force needed to start or control a load can all affect the task.

Why lifting technique alone is not enough

Training and safe operating procedures still matter, particularly when equipment is introduced or a task changes. But they should not be expected to compensate for a poorly designed process.

If a person must repeatedly lift from floor level, reach above shoulder height, control an unstable load or push a trolley that is difficult to start, the underlying task continues to create physical demand. Asking the operator to be more careful does not remove that demand.

Australian guidance places the emphasis on eliminating hazardous manual tasks where reasonably practicable and then reducing the risk through better work design, layout changes, mechanical aids and other controls. Safe Work Australia identifies good work design as a leading way to prevent musculoskeletal disorders, while WorkSafe Victoria advises employers to first eliminate the risk where reasonably practicable, then consider changes to the workplace, the work, the load and the equipment used.

In practice: The aim is not to remove people from every handling task. It is to remove avoidable strain and give them a safer, more reliable way to complete the work.

How to identify manual handling risks

A useful review should focus on the task as it is actually performed – not only on the written procedure. Observe the work, speak with the people doing it and consider the following factors.

1. The load

• What does it weigh, and does the weight change?
• Is it bulky, unstable, sharp, hot, cold or difficult to grip?
• Does the operator have to hold it away from the body or control unexpected movement?

2. The movement

• Does the task involve lifting, lowering, pushing, pulling, carrying or restraining?
• Are people bending, twisting, reaching or working below knee or above shoulder height?
• How much effort is required to start, stop, steer or position the load?

3. Frequency and duration

• How many times is the task completed in an hour or shift?
• For how long is force or an awkward posture sustained?
• Does fatigue build as the shift progresses or when volumes increase?

4. The route and environment

• Are there ramps, thresholds, uneven surfaces or restricted spaces?
• Is the route congested or shared with pedestrians and vehicles?
• Do temperature, moisture, lighting or hygiene requirements affect the task?

5. The current equipment

• Is the equipment suited to the load and the operating environment?
• Are handles, controls and working heights practical for the operator?
• Are wheels, castors, brakes, batteries and other components maintained?

This review often reveals that the problem is not one dramatic lift. It may be a small amount of unnecessary effort repeated throughout the day, an unsuitable travel path or equipment that does not match the load.

How to design a safer manual handling workflow

Once the task is understood, work through possible improvements in a practical order. A combination of changes is often more effective than relying on one control alone.

1. Eliminate unnecessary handling: Look for movements that can be removed completely. Goods may be delivered closer to the point of use, transferred directly between processes or stored in a way that avoids double handling.
2. Simplify the route: Reduce travel distance and avoid unnecessary turns, ramps, doorways and changes in level. Keep access clear and allow enough room to manoeuvre the load and equipment safely.
3. Improve the working height: Where practical, position frequently handled goods between approximately knee and shoulder height. Lift tables, pallet positioners and height-adjustable equipment can help bring work closer to the operator rather than making the operator repeatedly reach down or up.
4. Reduce the force required: Consider the load, wheel and castor selection, floor surface, gradient and starting resistance. For long routes, frequent movements or heavier wheeled loads, powered assistance may be more appropriate than relying on manual pushing or pulling.
5. Match the equipment to the complete task: Capacity is only one part of equipment selection. Check load dimensions, centre of gravity, required lift height, travel path, turning space, floor condition, duty cycle, hygiene needs and how the load will be secured or coupled.
6. Trial the proposed change: Where possible, test the equipment with the real load, operator and route. A solution that works on a flat showroom floor may perform differently on a ramp, across a threshold or within a congested work area.
7. Train, maintain and review: Provide task-specific instruction, keep equipment maintained and check whether the change is working as intended. Review controls when the task, load, layout, volume or workforce changes, and after incidents, discomfort reports or near misses.

Choosing manual handling equipment for the task

Mechanical aids and powered equipment can reduce physical effort, but only when they suit the application. The following examples provide a starting point for matching common handling tasks with potential equipment types.

Important: This table is indicative only. Equipment should be selected through a task-specific assessment and used in accordance with the manufacturer’s instructions and your workplace procedures.

Manual handling examples across different workplaces

Warehousing and logistics

Common tasks include unloading pallets, replenishing stock, picking orders and moving cages or trolleys between zones. Risk may come from repeated low-level lifting, long pushing distances, high starting force or equipment that is difficult to manoeuvre when fully loaded. Pallet positioners, lifting trolleys, electric pallet jacks, conveyors and powered tugs can each address different parts of the workflow.

Manufacturing

Operators may need to lift and position components, drums, reels or finished goods at a workstation. The load may be manageable once but become demanding when repeated across a shift. Bringing the load to a practical height and orientation can reduce bending, reaching and the need to hold components in place manually.

Healthcare and aged care

Manual handling can include moving beds, linen cages, waste, food, medical supplies and other wheeled equipment. These tasks often take place through shared corridors and over long distances. Compact powered movers, suitable trolleys and well-designed coupling systems can reduce pushing and pulling effort while supporting controlled movement around people.

Waste and recycling

Moving full bins and emptying their contents can involve high forces, awkward postures and repeated handling. The complete process should be reviewed: how bins are filled, moved, staged, lifted, tipped and returned. Bin movers, trailer systems and bin lifters or tippers can be combined to reduce separate handling steps.

Facilities management

Tools, consumables, cleaning supplies and waste may need to move across large or multi-building sites. A suitable trolley or utility vehicle can consolidate trips and reduce carrying, while powered assistance may suit longer travel distances, outdoor paths or heavier loads.

Food, pharmaceutical and controlled environments

The solution may need to address hygiene, corrosion resistance, washdown procedures or cleanroom compatibility as well as manual handling. Stainless steel equipment, sealed components and application-specific attachments may be required, depending on the environment and process.

A practical manual handling task review

Use the following questions as a starting point when reviewing a task with operators and health and safety representatives:

• What needs to be moved, and why?
• What are the load’s weight, dimensions and centre of gravity?
• Is it unstable, awkward, difficult to grip or likely to shift?
• How often is the task completed and over what duration?
• What lifting, lowering, pushing, pulling, reaching or twisting is involved?
• How far does the load travel?
• What floor surfaces, slopes, thresholds and space constraints are present?
• Can a handling step be removed or the route shortened?
• Can the load be brought to a better working height or orientation?
• Does the proposed equipment suit the real load, route and duty cycle?
• Have the people who perform the task been involved in the review?
• How will the equipment be introduced, maintained and reviewed?

Look beyond the maximum capacity: A product may be rated for the load but still be unsuitable for the route, gradient, turning space, frequency of use or way the load must be controlled.

When a standard product may not be the right fit

Many manual handling tasks can be improved with readily available equipment. Others need a more considered solution because the load, environment or process is unusual.

A configured or purpose-built approach may be worth considering when:

• the load has an unusual shape, centre of gravity or lifting point
• equipment must work within a restricted footprint or existing production line
• the task requires a specific lift, rotation, tilt or positioning movement
• hygiene, cleanroom, washdown or corrosion-resistance requirements apply
• the solution must connect with existing trolleys, bins, trailers or systems
• the process needs to be repeated consistently across multiple sites

In these cases, the most useful starting point is not a product specification. It is a clear definition of the task, the operating conditions and the outcome the team needs to achieve.

Frequently asked questions about manual handling

What is considered manual handling?

Manual handling includes work that requires a person to lift, lower, push, pull, carry, move, hold or restrain something. It can involve goods, equipment, tools, bins, trolleys, animals or people. The task may become hazardous when it involves factors such as repetition, sustained or high force, awkward postures or vibration.

What are some examples of hazardous manual handling?

Examples include repeatedly lifting cartons from floor level, pushing a heavily loaded trolley, controlling an unstable load, working above shoulder height, moving equipment over a ramp or performing the same forceful movement for a sustained period.

Is there one maximum weight that makes a load safe to lift?

A manual handling risk assessment should not be based on weight alone. The force required, posture, frequency, duration, grip, dimensions, stability, travel path and working environment can all change the level of risk. A lighter item handled repeatedly or in an awkward position may still create a hazardous manual task.

Is manual handling training enough on its own?

Training is important, but it should form part of a broader approach. Where reasonably practicable, first eliminate the hazardous task or reduce the risk through work design, layout changes, mechanical aids and suitable equipment. Training then supports the safe and consistent use of those controls.

When should a mechanical aid be considered?

Consider a mechanical aid when a task involves repeated lifting, awkward positioning, high pushing or pulling force, long travel distances, unstable loads or handling that cannot be completed comfortably and consistently. The selected aid still needs to suit the load, route, environment and operator.

How often should manual handling controls be reviewed?

Review controls when the task, load, layout, equipment, work volume or operating environment changes. They should also be reviewed when workers report discomfort, after a near miss or incident, when equipment is not performing as intended or when new information becomes available.

Start with the job you need to get done

Improving manual handling is not about adding equipment for its own sake. It is about making the movement of goods, materials and equipment safer, simpler and more reliable for the people doing the work.

Sitecraft can help you assess the load, task and operating environment, then identify an off-the-shelf, configured or purpose-built solution suited to the way your operation works.

Discuss your manual handling application

Tell us what needs to be moved, where it needs to go and what is making the current process difficult. Our team can help you work through the practical considerations and recommend suitable equipment.

Contact Sitecraft

General information only: This article is not legal, safety or ergonomic advice and does not replace a workplace-specific risk assessment. Check the requirements and guidance issued by the health and safety regulator in your jurisdiction.