What Counts as Manual Handling?
Under the Manual Handling Operations Regulations 1992 (MHOR), manual handling is any activity where a worker moves or supports a load by hand or bodily force.
A load can be:
A box, package, or piece of equipment
A person or animal
Materials such as bricks, timber, or bags of cement
Manual handling covers more than just lifting. It includes:
Carrying or lowering a load
Pushing or pulling objects
Holding, supporting, or even throwing a load
When done incorrectly, these tasks can cause serious musculoskeletal injuries.
Why Do Manual Handling Injuries Happen?
Manual handling injuries often occur when:
Poor technique is used, such as bending at the waist instead of the knees.
Loads are too heavy, awkward, or unstable, making them hard to hold.
Repetitive movements or long hours cause fatigue.
Awkward postures such as twisting or reaching are used.
Environmental hazards like slippery floors, poor lighting, or cramped spaces make handling more dangerous.
What are some key statistics about manual handling injuries in the UK?
Manual handling injuries are one of the leading causes of workplace accidents in the UK, with the Health and Safety Executive (HSE) reporting that handling, lifting and carrying accounted for 17% of all non-fatal injuries in 2022/23.
Work-related musculoskeletal disorders, many linked to poor manual handling, caused 7.8 million lost working days. The back, shoulders, and upper limbs are most often affected. Construction, healthcare, manufacturing, and retail remain high risk industries.
Key UK Statistics on Manual Handling Injuries
17% of all workplace injuries reported in Great Britain in 2022/23 were caused by manual handling (lifting, carrying, or moving loads).
7.8 million working days were lost due to work-related musculoskeletal disorders (MSDs).
543,000 workers suffering from work-related musculoskeletal disorders (new and long-standing) in 2023/24, with back injuries being the most common (43%).
Manual handling injuries affect all industries, but rates are highest on construction sites, and in transportation and storage.
(Source: HSE Health and Safety Statistics)
What Are the Most Common Types of Manual Handling Injuries?
Back, Neck, and Shoulders
Back injuries are the most common, including pulled muscles, slipped discs, and long-term back pain.
Neck strains can develop from poor posture or supporting loads incorrectly.
Shoulder injuries, such as dislocations or rotator cuff damage, often happen when lifting above shoulder height or twisting while carrying.
Hands, Arms, and Wrists
Cuts and fractures from dropped loads.
Repetitive strain injuries (RSI) from frequent, repeated tasks.
Tendonitis or carpal tunnel syndrome, often caused by long-term repetitive movements.
Feet and Lower Limbs
Crushing injuries if a heavy load is dropped.
Sprains and strains from slips, trips, or carrying loads on uneven ground.
What Are the Common Symptoms of Manual Handling Injuries?
Manual handling injuries don’t always appear straight away. Sometimes the pain builds gradually, and other times it happens suddenly after one bad lift. Recognising symptoms early is important so that you can get help before the problem becomes worse.
Common symptoms include:
Ongoing pain in the back, neck, shoulders, or arms.
Tingling, numbness, or a “pins and needles” feeling.
Muscle stiffness, aching, or swelling.
Reduced movement or strength.
Fatigue and disturbed sleep due to discomfort.
If you notice these signs, report them as soon as possible and avoid repeating the task until you have advice from your employer or a medical professional.
Acute vs. Chronic Manual Handling Injuries
Acute injuries happen suddenly; like a sprain, cut, or broken bone from dropping a heavy object.
Chronic injuries build up over time, often from incorrect manual handling or repetitive tasks. Examples include long-term back pain, lower limb disorders, upper limb disorders, disorder of the joints, carpal tunnel syndrome, and other musculoskeletal disorders.
Both types of injury can be serious, and early reporting is important.
How Can Manual Handling Injuries Be Prevented?
Recognising Early Warning Signs
Workers should pay attention to:
Sudden, extreme pain
Persistent aches or stiffness
Tingling, numbness, or weakness
Pain that worsens after lifting or carrying
Reporting symptoms early helps prevent long-term damage.
HSE Resource: MSD Body Mapping Tool
Early reporting makes a big difference when it comes to preventing long-term musculoskeletal disorders (MSDs). One useful resource from the Health and Safety Executive is the MSD Body Mapping Tool.
This tool helps workers record and discuss any aches, pains, or discomfort that might be caused, or made worse, by their work activities. It can also support safety teams in spotting patterns and addressing risks before they lead to injury.
You can register to access the MSD Body Mapping Tool directly through the HSE website. It’s a simple way to open up conversations about health, identify emerging problems, and take early action.
Safe Lifting Techniques
The HSE recommends following good lifting technique:
Assess the load before lifting. If it looks too heavy, ask for help or use equipment.
Stand close to the load with feet apart for balance.
Bend your knees, not your back. Keep your back straight and use your legs to lift.
Hold the load close to your waist and ensure good grip.
Lift smoothly without jerking.
Avoid twisting while carrying. Move your feet instead.
Organisational and Environmental Controls
Employers have a legal duty to reduce risk of injury by:
Providing mechanical aids like trolleys, pallet trucks, or hoists.
Making sure there are enough staff for team lifts.
Keeping floors, pathways, and work areas clear and free from risk of slips.
Giving workers proper footwear and protective equipment.
Offering online manual handling training or in-person courses to reinforce safe practice.
Which Industries Are Most at Risk?
Manual handling injuries can happen anywhere, but some industries are more exposed:
Construction: workers often carry heavy or awkward materials like bricks, timber, or cement.
Healthcare: nurses and carers frequently move or support patients.
Retail and Warehousing: tasks like shelf stocking or unloading deliveries involve repetitive lifting.
Manufacturing: production lines often require repetitive movements and handling loads for long periods.
What Other Factors Can Lead to Musculoskeletal Disorders?
While lifting and carrying are the main causes of musculoskeletal disorders (MSDs), other work activities can make the problem worse. These include:
Using hand-held vibrating tools for long periods.
Sitting at a desk or using display screen equipment (DSE) without proper posture.
Long-distance driving or driving heavy vehicles.
Working in extreme temperatures – too hot or too cold.
High work pressure, stress, or lack of proper breaks.
These factors don’t always cause MSDs on their own, but combined with poor manual handling, they can increase the risk.
What Workplace Adjustments Can Reduce the Risk?
Employers and workers can make simple changes that reduce the chance of injury. These include:
Improving lighting and flooring so hazards are easier to spot and slips are reduced.
Wearing correct footwear with good grip and covered toes.
Reducing carrying distances or re-organising work areas so items are easier to reach.
Using mechanical aids like trolleys, hoists, or pallet trucks.
Taking regular breaks to rest muscles and avoid fatigue.
Small adjustments like these make manual handling tasks much safer and less tiring.
Conclusion
Manual handling injuries are common but preventable. The most frequent problems affect the back, shoulders, arms, and legs, often leading to long-term musculoskeletal issues.
Employers must follow the Manual Handling Operations Regulations 1992 to reduce manual handling accidents, and workers should use safe techniques, report hazards, and take training seriously. By working together, organisations can keep injuries to a minimum and protect everyone’s health and safety.
FAQs About Manual Handling Injuries
1. How can I tell if I’m developing a manual handling injury?
Early signs include aches, stiffness, tingling, or weakness. Report these symptoms quickly to prevent more serious problems.
2. What should I do if I get injured at work?
Tell your manager, get medical help, and make sure the injury is recorded. This helps improve safety and ensures the right support.
3. Are employers legally required to provide manual handling training?
Yes. Under the Manual Handling Operations Regulations 1992, employers must give workers information and training so they can handle loads safely.
4. Can all manual handling tasks be avoided?
Not always. But employers must try to avoid hazardous manual handling where possible, and if it can’t be avoided, they must take appropriate steps to reduce the risk of manual handling injuries.
5. What types of injuries are covered by the regulations?
Any injury from lifting, carrying, pushing, pulling, or supporting a load. This includes musculoskeletal injuries, sprains, strains, and injuries caused by sharp edges, awkward shapes, or extreme temperatures.
