06 Jul What is manual handling?
Manual handling is one of the most common causes of workplace injuries across New Zealand businesses. From lifting heavy boxes to repetitive movements, pushing trolleys, or awkward postures, poor manual handling practices can lead to serious musculoskeletal injuries, lost productivity, and long-term health issues.
For small and medium businesses, understanding and managing these risks is essential for protecting workers and meeting health and safety obligations.
What is manual handling?
It refers to any activity that involves lifting, carrying, pushing, pulling, holding, restraining, or moving objects, people, or animals using bodily force.
This includes tasks such as:
- Lifting stock;
- Moving equipment;
- Carrying tools;
- Pushing carts;
- Pulling loads;
- Repetitive bending; and
- Handling awkward or unstable items.
Manual handling hazards are common in industries like:
- Manufacturing;
- Warehousing;
- Construction;
- Agriculture;
- Retail;
- Healthcare; and
- Hospitality.
Why is manual handling a workplace risk?
Improper manual handling can cause:
- Back injuries;
- Sprains and strains;
- Muscle tears;
- Joint damage;
- Repetitive strain injuries (RSI);
- Fatigue; and
- Long-term musculoskeletal disorders.
These injuries can develop from:
- Heavy loads;
- Poor posture;
- Twisting movements;
- Repetitive tasks;
- Inadequate training;
- Insufficient equipment; and/or
- Rushed work environments.
Common manual handling hazards
Examples include:
- Lifting heavy boxes incorrectly;
- Carrying loads over long distances;
- Repeated bending or reaching;
- Moving unstable objects;
- Working in confined spaces;
- Poorly designed workstations; and
- Inadequate staffing for heavy tasks.
How to control manual handling risks
1. Eliminate the need
Where possible:
- Automate tasks;
- Use delivery systems; and
- Redesign workflows.
2. Use mechanical aids
Examples:
- Forklifts;
- Trolleys;
- Hoists;
- Conveyor belts; and
- Adjustable lifting devices.
3. Improve workplace design
- Better storage heights;
- Clear pathways;
- Reduced carrying distances; and
- Ergonomic workstations.
4. Administrative Controls
- Safe Operating Procedures (SOPs);
- Worker training;
- Team lifting;
- Task rotation; and
- Fatigue management.
5. PPE
While PPE has limited direct impact on manual handling, supportive footwear and gloves may help reduce secondary risks.
Safe techniques
Workers should be trained to:
- Assess load weight before lifting;
- Keep loads close to the body;
- Bend knees, not the back;
- Avoid twisting while lifting;
- Use smooth movements;
- Seek assistance when needed; and
- Report hazards promptly.
A practical example…
Hazard: Warehouse workers repeatedly lift heavy boxes from floor level.
Improved Controls:
- Raise storage shelves;
- Introduce pallet jacks;
- Use team lifts;
- Provide training; and
- Rotate tasks.
This reduces injury risk significantly.
Common mistakes businesses make
Many workplaces:
- Assume workers “know how to lift”;
- Fail to assess repetitive tasks;
- Ignore fatigue;
- Delay equipment upgrades;
- Lack documented SOPs; and
- Underestimate long-term injury costs.
These injuries often develop gradually, making proactive management critical.
Legal responsibilities for businesses
Under the Health and Safety at Work Act 2015, New Zealand businesses must identify manual handling hazards and take reasonably practicable steps to eliminate or minimise risks.
This includes:
- Risk assessments;
- Worker training;
- Suitable equipment;
- Monitoring; and
- Regular reviews.
The importance of handling these risks properly
Manual handling may seem like an everyday part of business, but without proper controls, it can become one of the most costly and harmful workplace hazards.
For New Zealand businesses, improving manual handling practices protects workers, reduces injuries, and strengthens compliance.
Understanding manual handling is not just about lifting safely – it is about building smarter systems that reduce physical strain and support long-term workplace wellbeing.
Other suggested articles:
- How often should you review health and safety documentation?
- Training with Safe Operating Procedures
- Safe Operating Procedures to purchase
- What Should A Health and Safety Budget Include?
Please contact us if you would like to discuss.