Part of the SafeHands Employer’s Guide Series – Manual Handling
Manual handling is part of everyday work in many Irish businesses. Employees may lift boxes, carry stock, move equipment, push trolleys, handle deliveries or reposition materials many times during a working day.
Because these tasks are so routine, unsafe practices can easily become part of the normal working routine.
Manual handling injuries are not always caused by one obviously dangerous lift. Repetitive handling, awkward postures, poorly organised work areas, unsuitable loads and inadequate equipment can all contribute to the risk of injury.
This Employer’s Guide looks at 10 common manual handling mistakes and practical steps employers can take to reduce the risks.
For an overview of employer responsibilities, read our Manual Handling Training Requirements in Ireland | Employer’s Guide.
1. Assuming Manual Handling Training Is Enough
One of the biggest mistakes employers can make is treating manual handling training as the complete solution to manual handling risk.
Training is important, but it should form part of a wider approach to managing manual handling safely.
Employers also need to understand the manual handling activities taking place in their workplace, identify the risks associated with those activities and put appropriate controls in place.
Where possible, employers should look for ways to avoid or reduce hazardous manual handling. This could include changing how a task is organised, reducing the weight of loads or introducing suitable lifting or handling equipment.
Training should support these measures rather than replace them.
2. Failing to Assess the Actual Task
Manual handling risks can vary considerably from one workplace – and one task – to another.
A box that is relatively easy to lift from waist height, for example, may present a very different challenge if it has to be lifted from floor level, removed from a high shelf or carried through a confined space.
Employers should consider factors such as:
- The weight and size of the load
- How easy it is to grip
- Where it is being lifted from and placed
- The distance it must be carried
- The frequency of the task
- The posture required
- The amount of space available
- Floor conditions
- Whether twisting, reaching or bending is involved
Our Manual Handling Risk Assessments | Employer’s Guide looks at this process in more detail.
3. Lifting Something That Doesn't Need to Be Lifted Manually
Sometimes the safest manual handling technique is not to manually handle the load at all.
Before employees lift or carry something, employers should consider whether the task could be avoided, reorganised or made easier.
Depending on the workplace, solutions could include trolleys, pallet trucks, lifting equipment, adjustable-height equipment, changing storage arrangements or reducing individual load sizes.
Mechanical aids can reduce the physical demands placed on employees, but staff also need to know how to use the equipment provided correctly.
4. Handling Loads That Are Too Heavy or Awkward
There is no single weight that automatically determines whether every load is safe or unsafe to lift.
A load may be difficult to handle because it is bulky, unstable, difficult to grip or obstructs the employee's view. The height from which it is lifted, the distance it needs to be carried and the employee's posture can also affect the risk.
Employees should not simply attempt a lift because they have managed similar loads previously.
If a load cannot be handled safely, another method should be considered.
5. Poor Workplace Layout
The way a workplace is organised can make a significant difference to manual handling risk.
Frequently used heavy items stored at floor level may require repeated bending and lifting, while items stored too high can require stretching and awkward reaching.
Narrow routes, cluttered storage areas, steps and other obstacles can also make carrying loads more difficult.
Employers should consider whether frequently handled items can be positioned at more suitable heights and whether work areas can be reorganised to reduce unnecessary lifting, carrying, bending and reaching.
Employees should also check that the route and destination are clear before moving a load.
6. Ignoring Repetitive Manual Handling
A load does not necessarily have to be particularly heavy to create a manual handling risk.
Repeated lifting, carrying, pushing, pulling or other physical tasks can place demands on the body, particularly when combined with awkward postures or excessive force.
Employers should therefore consider both the individual handling activity and how frequently it is carried out.
Where repetitive handling is identified, it may be possible to reorganise the task, introduce appropriate equipment or change the work process to reduce exposure.
7. Using Poor Lifting Technique
Familiarity with a task can sometimes lead employees to become less cautious about how they handle a load.
Twisting while lifting, reaching unnecessarily, holding a load away from the body or failing to assess the task before starting can all increase the physical demands involved.
Where possible, employees should position themselves appropriately, maintain control of the load and move their feet rather than twisting their torso while carrying or repositioning it.
However, good technique should not be used as a substitute for dealing with a badly designed manual handling task.
Our Safe Lifting Techniques in the Workplace | Employer’s Guide provides further practical advice.
8. Rushing Manual Handling Tasks
Time pressure can encourage employees to take shortcuts.
A worker may attempt to carry too much at once, lift without properly assessing the load or decide not to use a trolley or other handling aid because moving the item manually appears quicker.
These shortcuts can increase the risk of injury.
Employers should ensure work is organised so employees have sufficient time to carry out manual handling tasks safely.
A safe system of work is only effective if employees can realistically follow it during a normal working day.
9. Failing to Review Manual Handling Risks When Work Changes
A manual handling risk assessment should not simply be completed and forgotten.
Workplaces change. New equipment may be introduced, storage areas reorganised, different products handled or employees moved to different roles.
These changes can introduce new manual handling risks or make an existing assessment outdated.
Employers should therefore review manual handling arrangements when significant changes occur and ensure the controls in place remain appropriate.
10. Treating Manual Handling Training as a One-Off Exercise
Manual handling training should not be something employees complete and then forget about.
Refresher training can help reinforce safer practices and provides an opportunity to address changes in working methods, equipment or manual handling tasks.
Health and Safety Authority guidance recommends refresher training at intervals of no more than three years and where significant changes occur in the work, equipment or handling activities involved.
Employers should therefore maintain appropriate training records and monitor when refresher training may be required.
How Can Employers Reduce Manual Handling Mistakes?
Effective manual handling risk management should focus on how work is actually carried out.
Employers should:
- Identify manual handling activities in the workplace
- Assess tasks that may present a risk
- Avoid unnecessary manual handling where possible
- Introduce appropriate mechanical aids or equipment
- Improve workplace and storage layouts
- Develop safe systems of work
- Provide appropriate information and instruction
- Provide practical manual handling training where required
- Encourage employees to report difficulties with particular tasks
- Review risks when working practices or equipment change
The objective should be to make the task safer – not simply to expect employees to cope with a poorly designed handling activity.
How SafeHands Can Help
SafeHands Health & Safety Solutions provides practical, onsite Manual Handling Training for businesses and organisations throughout Ireland.
Our face-to-face training gives employees the opportunity to learn and practise safer manual handling techniques under the guidance of an experienced instructor.
Onsite training also allows manual handling principles to be considered in the context of the types of tasks employees may encounter during their working day. Contact us to discuss your training and certification options.
Frequently Asked Questions
Is manual handling training enough to prevent workplace injuries?
No. Training is an important part of manual handling safety, but employers should also identify hazardous manual handling activities, assess the risks and introduce appropriate measures to avoid or reduce those risks.
What are the most common manual handling mistakes?
Common problems include attempting unnecessary lifts, handling unsuitable loads, poor lifting technique, repetitive handling, rushing tasks, poor workplace layout and failing to use appropriate mechanical aids.
Is there a maximum weight an employee can lift?
There is no single maximum weight that determines whether every manual handling task is safe. Employers need to consider the load, task, working environment, frequency of handling and physical effort required.
Should employers use mechanical aids instead of manual lifting?
Where hazardous manual handling can be avoided or reduced through appropriate equipment or changes to the work process, employers should consider these options. Trolleys, pallet trucks and other handling aids can help reduce physical demands in suitable situations.
How often should manual handling training be refreshed?
Health and Safety Authority guidance recommends refresher training at intervals of no more than three years, or sooner where significant changes occur in the work, equipment or handling activities involved.
Does manual handling training need to include practical instruction?
Manual handling training should provide employees with appropriate knowledge and practical skills. Employees should be able to demonstrate relevant manual handling techniques and understand how to assess whether a load can be handled safely.