Manual Handling of Equipment

1. Conduct a Risk Assessment Before Any Manual Handling Task

A risk assessment is the first line of defence against injury. Before any equipment is moved, an organisation should evaluate the weight and shape of the item, the distance it needs to be moved, the physical ability of the handler, and the environmental conditions. This means if the floor is slippery, there’s poor lighting, or stairs might be a factor.

Using a structured approach, such as a manual handling risk assessment template, helps identify potential hazards and implement control measures. The HSE provides comprehensive guidelines to help businesses assess and mitigate risks in accordance with the Manual Handling Operations Regulations 1992.

2. Train Employees on Proper Manual Handling Techniques

No equipment should be handled without proper training. Staff need to understand not only what to lift, but also how to lift it. Effective manual handling training should cover:

• Safe lifting posture (bending knees, not the back)
• Controlled lifting and lowering
• How to push rather than pull when possible
• Use of lifting aids or team handling for heavy items.

The goal is to instill muscle memory that defaults to safe practices, reducing the likelihood of momentary mistakes that could cause injury.

3. Use Mechanical Aids Wherever Possible

Eliminating and/or reducing the need for manual lifting is an easy way to reduce the risk of injury. Equipment such as trolleys, pallet jacks, hoists, and conveyor systems can drastically reduce physical strain.

Using manual handling aids reduces physical exertion and muscle fatigue, particularly during repetitive tasks or those involving heavy or awkward items. Employers should ensure these tools are readily available and regularly maintained. 

4. Plan the Route and Clear Obstacles Before Moving Equipment

Planning isn’t just for logistics. It’s a key safety step. Before moving equipment, consider:

• Is the path clear of obstructions?
• Are there slopes, uneven floors, or low ceilings to consider?
• Is there sufficient lighting throughout the route?

Unexpected obstacles can lead to sudden movements or shifts in balance, increasing the risk of musculoskeletal strain or falls. A quick route check can significantly improve handling safety. 

5. Know Your Limits and Ask for Help

A major cause of manual handling injuries is overestimating personal strength. Pride of urgency should never override safety. Workers should be encouraged to ask for help, whether from a colleague or using mechanical assistance when handling objects heavier than 25kg (depending on the individual’s capacity), bulky or irregularly shaped items, and equipment located at awkward angles or difficult heights. 

Workplace culture plays a big role here. Employers must cultivate an environment where seeking help is encouraged, not stigmatised. 

6. Use Proper PPE for Manual Handling Tasks

Personal protective equipment (PPE) is vital for manual handling, not just chemical or electrical hazards, as most people might think. Depending on the task, appropriate PPE might include:

• Steel-toe boots for foot protection
• Gloves for grip and abrasion resistance
• Back supports for added spinal support (used cautiously, not as a crutch).

PPE should never be used as a substitute for proper handling technique. It is an additional layer of protection. Employers must also ensure that PPE is correctly fitted for every worker, regardless of gender or body type. A one-size-fits-all approach, particularly with gloves or boots, can compromise safety.

7. Rotate Tasks to Minimise Repetitive Strain

Repetitive handling of equipment, even if the items are not particularly heavy, can lead to cumulative trauma disorders over time. To combat this, the workplace should implement task rotation systems. 

By switching roles involving different muscle groups, employees can reduce the risk of overuse injuries and maintain greater focus. This also has the added benefit of improving employee engagement and reducing burnout. 

8. Monitor and Review Incidents and Near Misses

Safety isn’t static. Continuous monitoring of manual handling-related incidents, including near misses, is essential. These reviews should ask:

• What went wrong?
• Could it have been prevented?
• What changes are necessary to avoid recurrence?

Employers should log every incident in a risk register, review it during safety meetings, and update their training, tools, or procedures accordingly. This approach is crucial for creating a culture of continuous improvement.