Work-related injuries caused by manual handling are common across many UK manufacturing and construction industries. Manual handling injuries can be detrimental to workers and manufacturers. From strained muscles to severe conditions, the impact of improper manual handling can be profound.
Fostering a safe work environment and prioritising its workforce’s well-being is paramount to mitigating work-related injuries. Dive into our blog as we explore the top most common manual handling injuries in the workplace and offer insight on the best prevention methods to create a safer and more productive working environment.
- What is Manual Handling?
- Most Common Manual Handling Injuries
- UK Manual Handling Legislation
- How to Prevent Work-Related Injuries
- Manual Handling Injuries FAQs
What is Manual Handling?
Manual handling is defined as ‘transporting or supporting a load by hand or bodily force’ by the Health and Safety Executive (HSE). Manual handling is the most common cause of injury in the workplace, and accidents can have long-lasting impacts on personal and professional lives.
From office environments to warehouses, the potential for manual handling injuries exists in diverse settings, as these injuries can occur in any occupation where you must lift and move heavy items at some point.
Most Common Manual Handling Injuries
According to HSE stats, an average of one out of three workplace injuries result from poor manual handling methods. Understanding these injuries is the first step to preventing them. Delve into the most common manual handling injuries below:
Back Injuries
Many of these incidents cause damage to the back. Up to 300,000 people in the UK every year suffer back, neck or spine damage, leading to severe pain, temporary incapacity or permanent injury. Back injuries are commonly caused by incorrectly lifting heavy loads, pushing and pulling wheeled loads, poor posture, and repetitive movements. Many back injuries are minor but can become ongoing health problems if left untreated, especially in occupations with frequent heavy lifting.
Musculoskeletal Disorders (MSD)
Musculoskeletal disorders refer to various conditions that affect the bones, muscles, joints, and connective tissues. Work-related MSDs are categorised as either upper or lower-limb disorders. Repetitive movements, over-exertion, and pushing and pulling heavy loads are examples of manual handling activities that can lead to musculoskeletal disorders in the workplace. The most common MSD associated with manual handling injury is lower back pain.
Strains and Sprains
Strains and sprains are prevalent injuries resulting from improperly handling a heavy load, especially if it is cumbersome. Sprains and strains occur when musculoskeletal tissues become overloaded from manual handling activities. Although sprains and strains are deemed minor injuries, it can take up to 2 weeks to feel better and strenuous exercise should be avoided for up to 8 weeks.
Hand and Foot Injury
When an incorrect manual handling technique is used, the pressure of the load is often concentrated on the hands and feet. Hands and feet are, therefore, at a greater risk of injury from sprains and strains to broken bones. A worker’s hands and feet can also be crushed if a heavy load is dropped, which can cause severe pain and significant damage.
Slips, Trips and Falls
Uneven surfaces and poor visibility can increase the risk of slips and falls while handling heavy loads. Carrying a large object can obscure your line of sight, increasing the likelihood of tripping over. These types of accidents can cause severe injury as there is added concern that the object being carried may fall on the person holding it or someone close by.
Hernias
A hernia is a significant injury in which part of an organ protrudes through a weakness in the abdomen’s muscle or surrounding tissue wall. Hernias can be caused by overstraining to lift, pull or push a heavy object through manual handling. In most cases, a hernia will cause few symptoms, but if the overstraining is persistent, the condition may become painful and require surgery.
UK Manual Handling Legislation
Manual Handling Operations Regulations 1992, as amended by the Health and Safety (Miscellaneous Amendments) Regulations 2002, is a crucial piece of legislation detailing manual handling. The regulations cover both employees and employers, stating that:
- Employers must avoid the need for dangerous manual handling “so far as reasonably practicable”. Any unavoidable hazardous manual handling that could pose a risk of injury must be subject to a full risk assessment. Employers are responsible for reducing the risk of injury from dangerous manual handling as much as reasonably possible.
- Employees are responsible for taking reasonable care of their health and safety in the workplace and immediately communicating with their employers regarding any potentially hazardous manual handling jobs.
Although the weight of a load is an essential factor in manual handling, the regulations do not set specific weight restrictions on loads, as different weights will be appropriate for various loads, individuals and circumstances.
How to Prevent Work-Related Injuries
Risk Assessment
Risk assessments are mandatory under the Manual Handling Operations Regulations 1992 and essential for mitigating workplace manual handling risks. Different risk assessments may be required depending on the type of manual handling task being performed. The HSE differentiates between “lifting and carrying” and “pushing and pulling”, suggesting a different risk assessment per approach.
Conduct a risk assessment by following these 5 steps:
- Identify a hazard – consider elements like the weight of the load and the distance the load must be carried.
- Assess the risk – consider who is at risk of an injury, what is already in place to mitigate the risks and what further action could be taken to control them.
- Control the risks – consider controls currently in place; if they are not effective enough, look at redesigning the job, replacing the process or providing personal protective equipment for workers.
- Record findings – if you employ at least 5 people, you must record your significant findings, such as hazards, who might be harmed, and how you will control the risks.
- Review controls – once new controls have been implemented, review them to ensure they are working or if there are changes in the workplace, such as new staff members.
Manual Handling Training
Manual handling training can substantially reduce the risk of manual handling injuries in the workplace. Employees should be trained on how to properly handle a heavy load by following the below stops:
- Assess the task before handling – determine whether the route is clear and obstruction-free, if help is needed, and if any tools could make the task easier and safer.
- Ensure stability – wear appropriate clothing and footwear to protect yourself from injury. Keep your feet slightly apart and move them as needed with the load to maintain stability.
- Holding the load – for many loads, it is vital to hug the load close to the body and keep the heaviest part at the waist. While moving, keep your head up, looking at the route rather than the load. Move the load slowly; if this is a struggle, it is unsafe to handle it alone.
- Correct posture – bend your back, knees and hips slightly to pick up the load. Do not twist or lean sideways, especially when your back is bent. To turn around, use the feet rather than the back.
- Unloading – when unloading a heavy load, place it down first and then slide it into position. Do not attempt to precisely position a load while handling it, as this can cause injury.
Use Lifting Equipment
In some cases, the safest way to handle a load is through material handling equipment. Electric and vacuum lifting equipment can offer numerous advantages in workplaces where manual handling is frequent. Lifting equipment ensures a safer and more efficient way to manual handling.
Tow Tugs and Electric Movers
Electric tow tugs and tug vehicles are high-quality solutions to manual handling that are ideal for many UK industries, such as construction, building, and horticulture. Tow tugs are designed to handle various loads and are suitable for tight spaces and narrow aisles where objects must be moved from one area to another. Maximise the safety of your workforce with appropriate lifting equipment.
Vacuum Lifting and Handling
Vacuum lifting equipment puts safety first. Protect your workforce by using AL vacuum lifting devices for heavy lifting tasks. AL lifters are engineered to handle various materials in many shapes and sizes, which results in quicker material handling with reduced physical exertion and a safer and more cost-effective approach to making your workplace more productive.
Manual Handling Injuries FAQs
What should I reasonably lift?
While there are no legal limits, you should only lift a comfortable load. If a load feels unstable, it is vital to protect your health and safety by requesting help from another worker or using lift equipment.
What causes the majority of manual handling injuries?
A handler carrying an uneven load can cause muscle fatigue as the object’s centre of gravity is not in the middle of the worker’s body. This can lead to unpredictable movements that require sudden force to stabilise the load, which is the leading cause of manual handling injuries.
Can manual handling be avoided?
Manual handling can be avoided in most workplaces by introducing lifting equipment instead. By replacing manual handling tasks with machines such as tow tugs or vacuum lifters, the safety and productivity of a workplace can increase.
Maximise Material Handling Safety with Industar
The impacts of improper manual handling can be profound. Make material handling safer and more efficient with Industar lifting equipment. Whether you need to transport heavy loads across a site or require robust lifting solutions for your work environment, our range of lifting equipment has the answer. At Industar, we provide material handling solutions tailored to your specific requirements. Contact our team to learn more about our lifting equipment.