MANUAL HANDLING

DEFINITION
 Manual handling is any transporting or
supporting of a load by one or more workers.
which includes operations like lifting, holding,
putting down, pushing, pulling, carrying or
moving of a load. The load can be an animate
(people or animals) or inanimate (boxes, tools
etc) object.
 Manual handling is also sometimes called
‘manual material handling’ (MMH).
MANUAL HANDLING OPERATIONS
SOME EXAMPLES OF MANUAL HANDLING OPERATIONS

 Manual handling occurs in almost all working environments (factories,

warehouses, building sites, farms, hospitals, offices etc).
 It can include lifting boxes at a packaging line, handling construction
materials, pushing carts, handling patients in hospitals, and cleaning.
 According to the Fourth European Working Conditions Survey
2carried out in the EU-27 in 2005, 35% of all workers are exposed to
the risk of carrying or moving heavy loads for at least a quarter of their
working time. The highest exposure rates are found amongst skilled
agriculture and fishery workers, craft and related trades workers, plant
and machine operators and assemblers. Young workers reportedly are
the most exposed of all age groups.
 A sectoral breakdown of rates of exposure to manual handling shows
that workers in agriculture, construction, hotels and restaurants are
most likely to be exposed to heavy loads (68%, 64% and 48%
respectively), followed by workers in the sectors of manufacturing and
mining, wholesale and retail trade (close to 42%), and transport and
communications (35%).
 CAUSES FOR MANUAL HANDLING
1. overloading the upper and lower back. For example:
 lifting or holding heavy items
2. improper posture during work.
For example:
 stooping
 reaching upwards
 bending sideways
 twisting;
3.moving loads away from the trunk
4.loss of balance while lifting
5. unexpected weight bearing
6.restricted room to manoeuvre
7. insecure grip on heavy, awkward, hot, cold, sharp or slippery objects
8. slippery, uneven floors or obstructions along the transport
routes;
9. uncoordinated team lifting or shifting weight to one party;
10. lifting beyond capability;
11. frequent or prolonged repetitive movements, such as
stooping, twisting the trunk, stretching, twisting the wrist
or neck;
12.working hastily;
13.insufficient rest or time to
recover.
FACTORS THAT MAKE MANUAL HANDLING HAZARDOUS

 The load
 The task
 The environment
 The individual
THE LOAD

The risk of back injury increases during lifting, carrying, pushing and pulling of loads,
if the load is:
• Too heavy
There is no exact weight limit for manual handling. A weight of 20 to 25
kg is heavy to lift for most people, especially if the load is handled several times in
an hour. Note that pushing or pulling often imposes less loading on the body than
lifting or carrying.
• Too large
One basic rule for lifting and carrying is to keep the load as close to the
body as possible. In order to get a broad load close to the body, the worker has to
open the arms to reach and hold the load. The arm muscles cannot produce force
when reaching as effectively as with the arms held in close. Thus, the muscles will
get tired more rapidly when handling a large bulky load.
• Difficult to grasp
Loads that are difficult to grasp can result in the object slipping, causing
sudden movement of the load. Gloves usually make grasping more difficult than
with bare hands. Providing the objects with handles or using aids for gripping (e.g.
when carrying plate material) reduces the load on the worker. Loads with sharp
edges or of dangerous materials (solids or liquids) can injure workers, especially in
the event of a collision.
• Unbalanced, unstable or if the contents can move
With unbalanced objects, it is difficult to hold the centre of gravity
of the load close to the middle of the body. This leads to uneven loading of
muscles, and fatigue. Unstable or moving content, such as a liquid, causes
uneven loading of the muscles and sudden movements of the load can make
workers lose their balance and fall.

• Difficult to reach
Loads that can only be reached with outstretched arms, or by
bending or twisting the trunk, require more muscular force. The spine may
easily be hurt if the trunk is bent or twisted while lifting.
THE TASK
The risk of back injury increases if the task:
• Is too strenuous
Tasks may be very demanding if they have to be carried out
too frequently or for too long with insufficient rest or recovery
time (e.g. continuous lifting or carrying for long distances, or
activities where the working speed is imposed by a process which
cannot be altered by the worker).
• Involves awkward postures or movements
Working with a bent and/or twisted trunk, raised arms, bent
wrists, a bent neck and turned head increases the risk of back
injury and should be avoided, as should twisting, turning and
bending movements of the trunk, overreaching, sudden
movements and repetitive handling.
Posture
Manual handling involves muscular work. There are two
main types of muscular work:
• static work: when maintaining a posture (holding the
body or part of the body in a fixed position), certain skeletal
muscles remain contracted
• dynamic work: when moving body parts, active skeletal
THE ENVIRONMENT
The following characteristics of the work environment may increase
the risk of back injury:
• Space available
A lack of space to carry out manual handling may lead to
inappropriate body postures and dangerous imbalance in the loads.

• Floor
Handling loads on different working levels or on floors that are
slippery, uneven or unstable (such as working platforms or fishing
boats) may increase the risk of accidents and back injury.
• Climate
The physical climate (temperature, humidity and ventilation) may
affect the risk of back injury. Heat makes you feel tired, and sweat
makes it hard to hold tools, requiring more force. Cold can make
your hands numb, making it hard to grip.
• Lighting
Insufficient lighting may increase the risk of accidents when
handling loads. It may also make you work in awkward positions
to see clearly what you are doing.
 THE INDIVIDUAL

There are also some individual factors that can influence the risk of back injury:
• Experience, training and familiarity with the job (for example, new episodes of low back pain
are common in the first year of employment)

• Age (the risk of low back disorders increases with the number of years at work: the first episode of
low back pain occurs in most people by the age of 30)

• Physical dimensions and capacity (length, weight, strength, etc.)

• Personal lifestyle (smoking may, for example, increase the risk of low back disorders)

• History of back disorders (this is a predictor of future back injuries)

• Willingness to use personal protective equipment (for example, clothing and footwear).
MANUAL TASK INJURIES
Manual tasks can lead to injury through the
development of Musculoskeletal Disorders (MSD).

An MSD is an injury affecting the bones or soft

tissue structure (other than organs) of the body
that is caused by manual handling at work.

Examples include sprains of ligaments; strains of

muscles or tendons; injuries to the spine, joints,
bones or nerves and abdominal hernias.
SYMPTOMS
 Back or neck pain
 Pain in wrists shoulder or
arms
 Stabbing pains in arms or
legs
 Painful joints Weakness or clumsiness
 Pain, tingling or numbness Heaviness
in hands or feet Burning sensations
Stiffness
Swelling
RISK ASSESSMENT OF MANUAL HANDLING
ACTIVITIES
Employers are required to assess the health and safety risks resulting from
working tasks and activities, and including manual handling. A risk assessment is a
careful examination of what in the work could cause harm to people. It can then be
decided whether sufficient precautions have been taken, or whether it is necessary to
do more to prevent harm. The challenge is to eliminate, or at least reduce, the
potential for accidents, injury or ill health that arise from working activities and tasks.
Simple steps can be followed to carry out an effective risk assessment in the
workplace:
• Look for the hazards that could cause accidents, injuries or ill health, taking into
account the load, the task, the environment and the operatori
• Decide who might be harmed and how: evaluate the potential consequences of the
hazards
• Decide whether the existing precautions are adequate or whether more should be
done: find ways to reduce the risk
• Monitor the risks, and review preventive measures.
IDENTIFYING HAZARDS
 look at historical data
 look at historical data
 workers compensation statistics
 record of injury
 inspection reports
 consultation with employees
 workgroup survey results
 observation of tasks - video or photos can help
ASSESS THE RISKS
Factors for the assessment
 actions or movements

 layout

 posture and position

 load location and distance moved

 weights and forces

 characteristics of load and equipment

 work organization

 work environment

 skill and experience

 age

 clothing

 special needs
CONTROLLING THE RISKS

 The Manual Handling Code requires employers to

eliminate the risks if at all possible.
 Other risk reduction methods are only to be used if
elimination is not possible.
 Training and administrative controls are to be used
alone only where all other avenues have been
unsuccessful in controlling the risk
Types of Risk Control Options
 Task Redesign
 Mechanical Aids
 Training
 Administrative
Examples of Task Re-Design and Mechanical Aids

Task Re- Design

1.Modify layout (e.g.). Adjustable tub base that raises as the load lightens
2.Modify work flow or process (e.g.). Reach a hose from a tap to a bucket to
limit bucket lifting and holding
3.Tool design (e.g.). Look for designs that keep joints at neutral position
when in use
4.Change actions and forces ( e.g.). Add a castor that can be flipped up out of
the way to allow for wheeling action rather than carrying or pulling

Mechanical Aids

1.(e.g.). Mechanical hoist to take weight of loads in lifts eg. Pneumatic lift
trolley
2.(e.g.). to ease load of lifting pcs off desk by raising trolley to desk height
and using sideways transfer not lift and carry
3.(e.g.). Items frequently access on wheeled platform to avoid awkward
THE LEGAL ISSUES
As per UK manual handling regulations 1992
Employer’s duties
 avoid-the need for hazardous manual handling

assess-the risk of injury from any hazardous manual handling that cannot be
avoided.
 reduce-the risk of injury from hazardous manual handling so far as reasonably

practicable.
Employee’s duties
 follow appropriate systems of work laid down for their safety.

 make proper use of equipment provided for their safety.

 co-operate with their employer on health and safety matters.

 inform their employer if they identify hazardous handling activities.

 take care to ensure that their activities do not put others at risk.
STEPS TO PREVENT INJURIES
1.Think about all the activities in your workplace which involve staff moving
materials and assess whether such manual handling is really necessary, for
example could you use lifting aids such as trolleys, lift trucks, hoists,
chutes or roll cages?
2. If you can’t avoid manual handling, then you need to assess the risks
associated with each task involving movement of materials, considering
steps 3 - 7 below.
3. Think about the load
• if it is heavy, - consider breaking up or ordering smaller packages?
• if it is difficult to grasp or could shift during carrying - consider placing
the load in a container for carrying or binding it together before moving
• if it is awkward - consider using another
person to assist, or the use of a trolley
4.Think about the task
• if it involves twisting, stooping or reaching - consider
rearranging the storage facilities by providing more space or
shelving or reorganizing shelves so that the heaviest items are kept
at a height between mid thigh and mid-chest. Consider also the use
of stepladders or platforms for access to higher shelves.
• if it involves long distance carrying - consider rearranging the
layout of the workplace to minimize travel by arranging delivery
and storage to be as near as possible to the point of use or consider
using a trolley or powered truck.
• if it involves repetitive movements – consider varying the
work to ensure that one set of muscles can rest while an other works
5. Think about the working environment
• remove any obstructions in the areas where people need to
carry materials and ensure that there are no tripping hazards.
• ensure that lighting levels are adequate.
• if there are steps or ramps - consider use of more than one person
or the use of chutes, hoists, or conveyors.
6.Think about the physical capability
of your staff
• ensure the staff you are asking to handle materials are capable of
doing so – consider those who are pregnant, or who have a physical
weakness.
• train all staff in the safe lifting technique and in the safe procedures
you have identified for moving materials.
• instruct staff on the correct clothing and footwear to use.
• provide protective shoes, hats and gloves
where necessary.
7. Remember to assess any new manual handling tasks.
BEST MANUAL HANDLING PROCEDURE
Step 1 - Stop & Think
 Plan the lift

 Where is the load going to be placed?

 Are there any handling aids I can use?

 Is the load safe can it damage me?

 Is it stable can the contents move?

 Will I need a rest mid-way or to adjust my grip?

 Do I need help?

 What is my route like?

 How can I get close to the load?

Step 2 - Place the Feet
 Have the feet apart giving balance and a stable base
for lifting(tight clothing and unsuitable footwear
makes this difficult).
 Place the leading leg as far forward as is comfortable
Step 3 - Adopt Good Posture
 Bend the knees and grasp the load as near level with
the waist as possible
 Do not kneel or overflex the knees
 Keep a straight back maintaining its natural curve
 Tuck in the chin while gripping the load helps
 Lean forward over the load if necessary to get a good
grip
 Avoid twisting, try to keep the shoulders level and
Step 4 - Get a Firm Grip
 Try to keep the arms within the boundary formed
by the legs
 Ensure you get a firm grip
 The grip depends upon the circumstances and
personal preference
 A hook grip is less fatiguing than keeping the
fingers straight
 Alter the grip if necessary but do it as smoothly as
possible
Step 5 – Don’t Jerk
 Carry out the lifting movement smoothly
 Raise the chin as the lift begins
 Use your legs

Step 6 – Move the Feet
Don’t twist the trunk when turning to the
side
Step 7 – Keep the Load Close
 Keep the load close to the trunk for as

long as possible
 Keep the heaviest side of the load next

to the trunk
Step 8 – Put Down Then Adjust
 If a precise position of the load is

necessary, put it down first and then

Maximum Loads
 The regulations do not stipulate a maximum load
 The maximum load an individual can safely handle depends upon
their physical capabilities
 At Pop-Up Products Limited we recommend as a general
guideline
that a reasonable load for an individual should not be more than
25kg
 For example if the load weighs 40kg and all other steps have been
considered to eliminate or reduce the risk of injury, then it
should be handled by at least 2 people using the correct
handling technique
 Unwieldy loads such as a long pole ladder should not be handled
by 1 person only
 Maintaining good standards of housekeeping is very important in
reducing the risk of injury in the workplace environment
 Slips, trips and falls when carrying out manual handling
operations
are all too common
CHECKLIST FOR SAFE MANUAL HANDLING