Manual Handling – Reducing the load

Manual handling relates to the movements of loads by human effort, as opposed to the use of mechanical handling equipment such as lift trucks, etc.

It is estimated that in the order of one third of all reported workplace accidents arise from some form of manual handling activity. The associated risks include:

• musculoskeletal disorders (MSD), such as back strain
• injuries caused by the load falling onto or trapping part of the handler
• injuries caused by the handler falling.

The exact proportion varies across different industry sectors and is highest in nursing care, where it accounts for about 50% of all reported accidents.

Employers’ Duties

Under the Manual Handling Operations Regulations 1992 (as amended), a clear hierarchy is established:

1. avoid
2. assess and
3. reduce.

The employer has a duty to avoid the risk of injury to employees arising from manual handling operations, where this is reasonably practicable. Where this is not reasonably practicable, the employer must assess the risks arising from the manual handling operation and reduce this risk down to as low a level as is reasonably practicable.

Consideration must also be given to the:

• information
• instruction and
• training

given to employees and to the provision of appropriate personal protective equipment.

Reducing the risk, Call LRB Consulting on 01509 550023

Avoiding (the need for) manual handling

Consideration should be given to automation or mechanisation of the handling operation. This may involve the use of:

• lift trucks
• cranes
• hoists
• conveyor systems
• powered pallet trucks
• pneumatic transfer systems
• pumped pipe work systems
• gravity feed systems (such as debris chutes) and
• goods lifts, etc.

The effectiveness of automation is greater if it is incorporated into the original design for the process.

Potential solutions include: Caveat: although avoiding manual handling is important, it is of little benefit if the resultant risks (such as from fork lift truck operation) are greater than the original risks from manual handling.

Mechanical assistance

With the use of appropriate mechanical assistance, some manual handling is retained, but that the bodily forces are applied more efficiently, hence reducing the risk of injury. Examples include (but are not limited to):

• simple handling aids, such as grab hooks or suction pads (to reduce the problem of handling a load that is difficult to grasp)
• a simple lever can decrease the amount of bodily force needed (reducing the risk of injury)
• specialist fabric or paper roll lifters (to reduce the amount of handling involved in routine operations such as roll changing in a production environment)
• a hoist can be used to support the weight of a load, leaving the handler free to control its position
• a trolley, pallet truck, sack truck, cylinder trolley, wheel barrow or roller conveyor (to reduce the effort required to move a load horizontally)
• specialist drum hoists, trolleys and dollies (for the handling of barrels, etc)
• pneumatic and rollered tables (to reduce the amount of bodily force needed in the fine positioning of items for machining, etc)
• star-wheeled sack trucks (for use on stairs)
• specialist devices, such as Arjo lifts (in the health care industry)
• Etc.

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Changing the task and/or premises layout

Improvements in the flow and storage of products and materials as well as the design of the premises can reduce the risks to employees and may also lead to improvements in efficiency and productivity.

With certain heavy loads, the risks associated with the task can be reduced by splitting the load up into smaller, lighter loads (e.g. boxed components may be packed in 10 Kg load rather than 20 Kg loads, etc.).

Where heavy items must be moved in and out of storage, the optimum position for storage of such loads is around waist height. Storage much above or below this height should be reserved for loads that are lighter, more easily handled, or are handled infrequently. Designing the working area such that the distances that materials need to be carried are reduced will improve productivity as well as reducing the risks of injury. Similarly, reducing or eliminating the need to open doors, etc. while carrying loads will make similar improvements.

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Where the task requires poor handling techniques and posture

Where the task requires poor handling techniques or poor posture to be adopted, efforts must be made to reduce the negative effects of these.

The effects of the distance and position of the load from the body, twisting of the trunk and poor posture can be mitigated through changing the task, altering the lay out of the task and effective use of the body.

Tasks that are designed to permit the load to be held closer to the body reduce risks of injury. The approach, grasping and placing of the load should be carefully controlled by:

• designing the lay out so that the handler can get close to the load without twisting
• designing the lay out so that the handler’s feet can get as close as possible to the centre of gravity of the load
• storing objects so they can be picked up and carried without an immediate change of direction or twisting

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Where the task involves greater distances of lifting, lowering and travel

The stresses on the (lower) back during:

• lifting
• lowering
• stooping,

as well as those from having to travel long distances with a load, can be reduced through changes to the task and to the use of the body.

The following measures could be considered:

• giving emphasis to storing, or otherwise providing, loads at waist height (this being the optimum height for lifting)
• providing a suitable platform to assist employees to reach items safely (but must be balanced against the increased risks of trips or stumbles)
• avoiding storing heavy loads such that they require the employee to reach above head height
• fitting, where appropriate, shelves with rollers or with rollered shelves
• providing suitable handling aids (such as levers) for lifting objects off the ground to remove the need for stooping and lifting
• giving consideration to changing the task, such as by replacing carrying with controlled pushing or pulling
• diving loads could to enable lifting half with each hand (allowing the weight to be distributed evenly
• using conveyor or rollered table systems to get the load as close to the handler as possible
• providing suitable resting points (such as tables) where loads must be carried over long distances

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Where the task involves excessive effort, fixed posture and insufficient rest and recovery

Building in variation of the work routine is beneficial in reducing the stresses and strains on backs of those involved in manual handling. Consideration should be given to:

• arranging for the weight to be borne by other means, such as a sling or hoist, when the same posture is maintained for a long period
• conducting handling activities at the pace of the individual (not of a machine)

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• adopting a system that allows for flexible work breaks, to reduce fatigue
• encouraging the handler o take breaks and move around at convenient times (when the task involves heavy static loads)
• introducing job rotation to avoid fatigue, especially if the different operations use different muscle groups.

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