Manual Material Handling Safety
Overview
Manual material handling includes lifting, lowering, pushing, pulling, and carrying objects. These activities cause the majority of workplace musculoskeletal injuries when performed improperly or without appropriate controls and equipment.
Why This Is Important
Manual material handling injuries affect every part of your body—back, shoulders, knees, hands, and more. These injuries develop from cumulative stress over time and from acute incidents during heavy lifts. Understanding proper techniques for all material handling activities prevents injuries that could end careers. Engineering controls, administrative practices, and proper techniques all contribute to safe material handling. No single solution protects workers—comprehensive programs address multiple aspects of material handling hazards.
Best Practices & Safety Tips
- Eliminate manual handling when possible using conveyors, chutes, carts, and automated systems.
- Reduce load weights by using smaller containers, breaking down shipments, and limiting package sizes.
- Modify load characteristics—add handles, improve grip surfaces, reduce awkward dimensions.
- Use two-person teams for heavy, bulky, or awkward loads rather than risking solo handling injuries.
- Push rather than pull when moving wheeled loads—pushing generates more force with less strain.
- Keep load handles between knuckle and shoulder height to minimize reaching and awkward postures.
- Reduce carrying distances by improving workplace layout and material storage locations.
- Use mechanical aids including lift assists, hoists, pallet jacks, and hand trucks whenever available.
- Rotate workers through different tasks to vary muscle use and prevent repetitive strain injuries.
- Report discomfort early before minor strains become serious chronic conditions requiring medical treatment.
Discussion Questions
- What manual material handling tasks cause the most fatigue or discomfort?
- What engineering improvements could reduce manual material handling in our operations?
- Are appropriate mechanical aids available and accessible for all heavy material handling?
- What barriers prevent workers from using mechanical aids instead of manual handling?
Takeaway
Manual material handling injuries are preventable through engineering controls, proper equipment use, and good technique. By eliminating unnecessary manual handling and using best practices for unavoidable tasks, we protect workers from injuries that cause chronic pain and disability.