Common Manual Handling Injuries and How to Prevent Them in the Workplace

Description

 Learn about the most common manual handling injuries in Australian workplaces and how to reduce the risks. Protect your team with accredited training in Perth.

Introduction

Manual handling might seem simple, but it’s a major cause of workplace injuries across Australia. In fact, over 30% of workplace injuries are linked to manual handling tasks like lifting, carrying, pushing, and pulling. These everyday movements can lead to a wide range of physical injuries—many of which are avoidable with the right knowledge and training.

At Perth Training, we provide accredited Manual Handling (HLTWHS005) training that empowers workers in healthcare, disability support, aged care, and more to carry out tasks safely and confidently.

Here are 13 common manual handling injuries and the workplace hazards that can cause them:

1. Back Injuries

Back strain is one of the most frequently reported injuries in manual handling roles. Poor posture, heavy lifting, or twisting while carrying can cause muscle tears, spinal disc issues, or long-term chronic pain.

Prevention Tips:

• Use your legs, not your back, to lift

• Avoid twisting

• Keep the load close to your body

• Ask for assistance or use mechanical aids

  
  

2. Neck Strain

Lifting heavy items awkwardly or repeatedly working in a strained posture can lead to neck stiffness, pain, or tension.

Prevention Tips:

• Maintain a straight neck and avoid overreaching

• Reposition yourself rather than twisting or turning awkwardly

  
  

3. Shoulder Injuries

Shoulder injuries occur when loads are too heavy or awkward to carry. This can cause torn ligaments, muscle strain, or even dislocations.

Prevention Tips:

• Avoid lifting items above shoulder height

• Push, don't pull, wherever possible

• Limit repetitive overhead tasks

  
  

4. Joint and Limb Pain

When manual handling tasks are performed incorrectly or too frequently, joints in the knees, elbows, wrists, and hips can be affected.

Prevention Tips:

• Use proper lifting techniques

• Reduce repetitive strain through rotation and rest

  
  

5. Strains and Sprains

These soft tissue injuries often result from overstretching, sudden movements, or lifting unstable or heavy loads.

Prevention Tips:

• Stabilise loads before lifting

• Warm up before physically demanding tasks

• Wear gloves for better grip

  
  

6. Musculoskeletal Disorders (MSDs)

MSDs affect the muscles, bones, and joints, typically caused by repetitive tasks or poor ergonomic practices. These injuries can take time to develop and are common in long-term support roles.

Prevention Tips:

• Limit repetitive motions

• Ensure proper workstation setup

• Incorporate micro-breaks

  
  

7. Hand Injuries

Your hands are the first point of contact with most loads. Sharp edges, heat, or chemical exposure can cause cuts, burns, and crush injuries.

Prevention Tips:

• Wear appropriate gloves

• Check the load for sharp or hot surfaces before handling

  
  

8. Crush Injuries

When placing or lowering loads, there’s a risk of trapping hands, feet, or fingers between objects. This can lead to bruises or even fractures.

Prevention Tips:

• Be aware of pinch points

• Communicate clearly in team lifts

• Lower loads slowly and steadily

  
  

9. Cuts and Lacerations

Handling broken, sharp, or poorly packed items increases the risk of deep cuts or abrasions.

Prevention Tips:

• Inspect items before moving

• Use protective gear

• Don’t rush the task

  
  

10. Burns

Unexpected burns can occur when lifting hot materials or handling hazardous substances such as cleaning agents or wet cement.

Prevention Tips:

• Let hot materials cool before handling

• Use thermal or chemical-resistant gloves when necessary

  
  

11. Slips, Trips and Falls

While not strictly caused by lifting, manual handling often increases the chance of slips or trips due to obscured vision or blocked paths.

Prevention Tips:

• Keep walkways clear

• Wear non-slip footwear

• Check surroundings before moving loads

  
  

12. Hernias

Hernias occur when internal tissue pushes through weakened muscle—often a result of repeated lifting or overexertion.

Prevention Tips:

• Don’t lift beyond your capacity

• Use lifting aids

• Engage your core properly during movement

  
  

13. Foot Injuries

Dropped loads can cause serious injuries to the feet, including fractures and bruises, particularly if safety footwear isn’t used.

Prevention Tips:

• Wear steel-capped boots

• Maintain a firm grip on the load

• Avoid carrying items that obstruct your view

  
  

Train with the Experts

Protect yourself and your team with practical, hands-on manual handling training. Our accredited courses are designed to reduce workplace injuries and improve compliance. We deliver flexible training across Perth suburbs, including Morley, Cannington, Belmont, Midland, Kewdale, and Perth CBD.

📞 Call us on 0421 201 201 or visit Perth Training to book your HLTWHS005 – Conduct Manual Tasks Safely course today.

Need training for your team? Ask us about group rates and onsite options.

Disclaimer:

The information in this article is for general purposes only and is not intended as specific medical advice. While we aim for accuracy, we cannot guarantee the information's completeness or reliability. Always consult a healthcare professional for medical concerns. Relying solely on this content without seeking expert advice is not advised.

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