Manual Handling Safety at Work

Peter Jones

So, Joe,thanks for joining me on this tool box talk podcast [my pleasure Peter] we’ve all heard about injuries on the job. -It’s almost like a given in some fields, right? -But the ones tied to manual handling—those seem especially tricky. Why is this?

Joe Brown

Yeah, spot on, Peter. Manual handling injuries can be quite serious, and they’re much more common than people realize. Back injuries, for instance, are among the top complaints. Strains, sprains, repetitive motion issues—you name it. Even hernias or pinch point injuries can happen pretty easily when, say, lifting or moving things incorrectly.

Peter Jones

How common are these issues though? Is this just a handful of cases or more widespread than people think?

Joe Brown

They’re alarmingly widespread, actually. Studies show that back injuries alone account for almost a quarter of all workplace injuries. And, if you consider other physical impacts, like slips or twists during lifting—that number really piles up.

Peter Jones

Oh Really? - I didn't know it was that bad

Joe Brown

Most people don't, And the worst part is, many of these injuries are completely avoidable. The message we wanna drive home here is: don’t take unnecessary risks. If there’s a way to avoid manual handling by using machinery or even just getting a colleague to help, then do it.

Peter Jones

Right!. But how can people or teams actually avoid pushing things too far when there’s so much pressure to just get things done?

Joe Brown

Good question. This is where weight limits come into play—50 pounds for one person and 100 pounds for a team lift without machine assistance. If it’s heavier than that, then heavy machinery should absolutely be brought in.

Peter Jones

Fifty for one, a hundred for a team. Got it. Doesn’t sound too hard—although I bet there are some people who think they’re Superman.

Joe Brown

Absolutely. And that’s often when accidents happen. People underestimate just how easy it is to move slightly wrong—twist your back, lose your footing, or just misjudge your grip. Let me give you a quick example—

Peter Jones

please,

Joe Brown

Well, there was this colleague who tried to lift a rather awkward load on his own—a blueprint rack of all things. Figured he’d save time, y’know? Ended up with a serious back strain. Couldn’t work for weeks, and it forced the team to rethink their methods entirely. They brought in better equipment and even updated their safety protocols to prevent something like that from happening again.

Peter Jones

It’s amazing how one injury can lead to changes like that. But you’d hope it doesn’t take a cautionary moment for people to follow the rules in the first place...

Peter Jones

That’s a tough lesson from that blueprint rack incident, Joe. So, thinking about how we avoid issues like that going forward—if someone really does have to lift something heavy manually, what’s rule number one?

Joe Brown

Rule number one is preparation. Before you even think about lifting, you need to think through the task. Check your surroundings, make sure there’s nothing in your path that could trip you up, and ensure you’ve got enough space to move safely.

Peter Jones

Got it—clear the area first. So now I’m standing there with, say, a big box. What’s next?

Joe Brown

Next, you wanna get into a good starting position. Keep the object close to your body—don’t let it dangle out there like you’re carrying a tray. The heavier side should be closest to you, and always keep your feet firmly planted with one slightly ahead for balance. Stable footing makes all the difference.

Peter Jones

Okay, so no awkward balancing acts on one foot then.

Joe Brown

Exactly. And here’s the big one: keep your back straight. If you have to bend, bend at your hips and knees, not your back. And avoid twisting while lifting—it’s one of the most common ways people hurt themselves.

Peter Jones

No twisting. Got it. I mean, it sounds straightforward... but then again, it’s probably easier said than done when you’re in a rush.

Joe Brown

That’s true. Rushing’s often where things go wrong. It’s the little mistakes, like forgetting to check your grip or trying to lift above your waistline, that lead to injuries. And the thing is, Rob, lifting isn’t the only risky manual handling task. Carrying, pushing, pulling—these all come with their own risks.

Peter Jones

Of course and don’t forget throwing. I’ve seen people literally toss stuff off the back of trucks like they’re in the shot put event!

Joe Brown

Oh, don’t even get me started on throwing. That’s a recipe for disaster, especially for back and shoulder injuries. But even pushing and pulling can cause issues. If you’re not in a good position, you might fall, or strain muscles from an awkward angle.

Peter Jones

Right. So basically, it’s all about staying controlled and thoughtful, not just instinctively muscling through it.

Joe Brown

Spot on again. One of the best examples I’ve got is about a table—well, actually, a wardrobe. Picture this: two guys trying to lift a wardrobe up a flight of stairs. They didn’t coordinate properly, tilted it the wrong way, and nearly toppled back down. Luckily, no one was hurt, but the wardrobe? Not so much.

Peter Jones

Oh no! were the guys OK?. I Bet that taught them a valuable lesson!

Joe Brown

It did, they found it funny at first,!like something out of a sit-com, But that’s the thing, Peter—stories like these are funny until they’re not. It’s a reminder that protocols exist for a reason. With proper planning and the right techniques, you can avoid a lot of unnecessary trips... literally and figuratively.

Peter Jones

You know, Joe, hearing those wardrobe and lifting stories really drives home how important proper planning is. But I guess manual handling isn’t the only concern—we’ve got things like Occupational Overuse Syndrome, or OOS, too, right? What’s going on there?

Joe Brown

Exactly right Peter—OOS. It’s a condition that crops up when someone repeats the same movements over and over, especially in tasks that involve lifting or carrying heavy loads. The motions might not seem harmful initially, but over time, they strain muscles, joints, and even nerves.

Peter Jones

So, like wear and tear but on your body instead of machinery?

Joe Brown

Spot on. The most common areas you see it are people’s backs, shoulders, hands, and wrists. Sometimes elbows too. Think about it—if you’re constantly lifting or gripping in the same way every day, it’s only a matter of time before something gives.

Peter Jones

And I bet a lot of folks just ignore the warning signs, don’t they? Like, "It’s just a little ache," and they push through.

Joe Brown

Exactly, which is the worst thing you can do. Pain is your body’s way of telling you something’s wrong. Ignoring it can cause long-term damage, sometimes even permanent injury. It’s why taking breaks and listening to your body is so critical.

Peter Jones

Yeah, but that’s easier said than done, right? You’re mid-shift, there’s a deadline, and stopping feels like admitting defeat.

Joe Brown

True, but here’s the thing, Peter. If you don’t address those early warning signs, you might end up not working at all. Let me share another quick example—a real eye-opener from a health and safety session I ran.

Peter Jones

Please do, these examples really help us to understand the importance of this stuff.

Joe Brown

Sure, There was this guy—highly skilled worker—doing repetitive lifts as part of a warehouse job. He started feeling a slight twinge in his wrist but figured he could push through. Couple of weeks later, that small discomfort had turned into tendonitis. He ended up out of work for months, and rehabilitation was a nightmare for him.

Peter Jones

OH that’s rough. All because he didn’t stop when his body told him to?

Joe Brown

Exactly. And on top of that, the company had to rework their operations during his absence, which was a headache for everyone involved. It’s a stark reminder—whether you’re handling materials or doing repetitive tasks, speak up if something feels wrong. Take those breaks when you can.

Peter Jones

So, prevention-wise, it’s about pacing, taking breaks, and actually, y’know, listening to your body?

Joe Brown

That’s right. And let’s not forget following your company’s safety protocols. They’ve been created to protect you. Whether it’s OOS or any other injury, prevention is always better than trying to fix the damage afterward.

Peter Jones

Well, there it is—you’ve hammered it home, Joe. Listen to your body, follow the rules, and don’t be afraid to take breaks. Honestly, I think that’s a lesson we could apply to life in general, right?

Joe Brown

Absolutely, Peter. Safety first, always. It’s not just about getting the job done, but getting it done without hurting yourself in the process.

Peter Jones

Well said, Joe. And with that, folks, we’re wrapping up. Thanks for tuning in to another essential and, dare I say, engaging episode on workplace safety. Keep those safety practices sharp, and we’ll catch you next time. Take care!

Joe Brown

Stay safe out there, everyone.