Introduction
Tasks involving manual handling are present across all industries and can affect any person at work to some extent. From pushing trolleys to lifting and moving furniture, manual handling tasks are varied and must be specifically risk assessed to prevent permanent damage. Improper manual handling over time can lead to back injuries, upper limb disorders, and lower limb injuries. Depending on the severity of the harm, damage done by manual handling can lead to permanent, life-changing disabilities.
Case Study: Concrete manufacturer prosecuted for failing to reduce manual handling risks
This manufacturer was prosecuted for failing to reduce manual handling risks during the manufacture of concrete posts weighing up to 234kg. All products were lifted manually and there were no measures taken to reduce the risk of injury. The HSE was on site investigating an unrelated incident where they found that this company was failing to properly plan, manage and control manual handling related risks. From this, a prohibition notice was served preventing large weights from being lifted manually by employees, and an improvement notice was served requiring manual handling risk assessments to be carried out. The company was fined for breaches of the Manual Handling Operations Regulations.
Following the HSE's intervention, the company installed roller tables to significantly reduce manual lifting and provided dedicated manual handling training for its staff.
This case study demonstrates the importance of planning manual handling activities, and compliance with the Manual Handling Operations Regulations. It’s important to note here that this was picked up by the HSE when attending site due to an unrelated incident. Poor manual handling practices don’t have to have caused harm for the enforcing authorities to prosecute, so it’s vital to ensure manual handling hazards are controlled.
Common Manual Handling Hazards
Manual handling hazards are factors that increase the risk of injury—specifically musculoskeletal disorders (MSDs)—during tasks like lifting, pushing, pulling, or carrying.
Manual handling hazards can be related to 4 aspects:
Task: These hazards relate to how the work is being performed. Risks increase where the task involves awkward postures, repetitive movements, excessive force or long carrying distances.
Individual: Hazards also arise when a task is not matched to the person performing it. Differences in strength, height, or underlying health conditions can affect the individual capacity of a person to lift and carry safely.
Load: The physical characteristics of the object being moved can create significant danger. The weight and size of the load can be hazardous, or they could be unstable or difficult to grasp.
Environment: The surroundings can influence safe manual handling operations. Floor level obstructions, temperature and poor lighting can all influence how we can safely lift and transport a load. Being unable to see floor level obstructions because of the load or poor lighting can lead to trips and falls. Very hot environments cause early fatigue, while cold conditions can reduce hand sensation and grip strength.
Legal duties
Employers must abide by the following legislation:
Health and Safety at Work etc. Act: This primary piece of health and safety legislation stipulates the employer’s responsibilities for the safety and health of their employees, as well as any other person that could be affected by their work activities.
Management of Health and Safety at Work Regulations: Mandates the requirement for employers to complete suitable and sufficient risk assessments for the activities that their employees complete.
Manual Handling Operations Regulations: Set out a clear hierarchy of duties for employers to prevent musculoskeletal injuries. It is often summarised as the "Avoid, Assess, Reduce" approach.
Control Measures
Employers are required to use a hierarchy of controls approach when planning and managing tasks that involve manual handling.
Avoid: The most effective control there is. Consider first if manual handling tasks can be avoided completely by redesigning the process. This could be as simple as having work materials delivered closer to where the work is taking place, or conveyor systems can be used to move loads without manual intervention.
Assess: If the requirement to manually handle loads can not be avoided, a risk assessment needs to be completed that factors in the task, individual, load, and environment. Special considerations should be made for employees who are pregnant or those with preexisting medical conditions.
Reduce: Lowering the remaining risk. Once the hazards have been assessed, apply controls to make the task as safe as possible. For example:
· Use of mechanical aids like trolleys or pallet trucks.
· Breaking the load down in to more manageable parts.
· Use team lifting.
· Improve the environment with good standards of housekeeping and lighting, ensuring that the temperature is comfortable.
· Ensure those involved in manual handling tasks have access to water and can take regular breaks.
· Providing information, instruction and training.
· Providing PPE where this is appropriate such as gloves for loads that have sharp edges or safety shoes where there is a risk of dropping the load.
Summary
No organisations activities are exempt from manual handling related hazards. Organisations must properly plan and manage tasks that involve manual handling to protect the health of their workforce. In some circumstances, the consequences of poor manual handling task management can result in irreversible damage and can be life changing for a person. Legally, we must take a avoid, assess, reduce approach to controlling manual handling tasks. Morally, we want our employees to be protected from harm. Financially, can we afford to ignore these risks? The enforcing authorities certainly are not ignoring them – and they take them very seriously.
