Top 10 Injuries caused by improper lifting and manual handling

Manual Handling injuries are a leading cause of workplace accidents, particularly in industries like construction, healthcare, retail, and warehousing https://www.hse.gov.uk/statistics/causinj/index.htm . These injuries typically occur when lifting, carrying, pushing, or pulling heavy or awkward loads. Understanding the most common manual handling injuries and how to prevent them can help reduce risks and keep workers safe. Here’s a list of the top 10 most common manual handling injuries, and how you can avoid them happening in the workplace: 

1. Back Strain and Sprains – Lifting heavy objects incorrectly or without proper support, especially with a bent back or twisted torso. You can prevent this by always bending your knees, not your back, and using proper lifting techniques by assessing the loads and considering the weight, shape and size, plan the lift making sure you know where you are going and the path is clear, stand with your feet shoulder-width apart to provide a stable base and bend your knees not your back ensuring you have a strong grip with both hands. If an object is too heavy, then you should ask for help! 

2. Muscle Strains – Sudden, forceful movements or repetitive lifting of heavy objects can overexert muscles. Ensure you stretch and warm up before physically demanding tasks. Take regular breaks to avoid muscle fatigue. 

3. Herniated or Slipped Discs – Improper lifting techniques or lifting loads that exceed your capacity can damage the spine and cause discs to slip. Focus on posture by keeping your spine neutral and avoiding twisting motions while lifting, use mechanical aids when possible. 

4. Shoulder Injuries – Lifting or carrying items above shoulder height or extended arm movements can strain the shoulder joint. Keep a load close to your body and at waist height. Use equipment for tasks that require overhead lifting. 

5. Knee Injuries – Squatting, kneeling, or bending awkwardly during lifting can place excessive pressure on the knees. Ensure you wear knee pads for protection when kneeling. Maintain stable, well-balanced posture, and use lifting aids when appropriate. 

6. Hand and Waist Injuries – Repetitive motion, gripping heavy or awkward loads, or using tools that put stress on the hands and wrists can lead to sprains, strains, or even repetitive strain injuries. Ensure you take frequent breaks, use ergonomic tools, and avoid gripping too tightly. Wear gloves for extra protection when handing over rough or heavy objects.

7. Elbow Injuries – Excessive force or repetitive motions, especially in tasks that involve pushing, pulling, or lifting can lead to tendonitis or bursitis in the elbow. Use correct posture and ergonomic equipment. Avoid excessive repetitive motions without rest periods. 

8. Fracture or Broken Bones – Dropping a heavy load on yourself or from a height, or if an object strikes you, can cause fractures or broken bones. Ensure that loads are secure and within your capability to handle. Use safety footwear to protect your feet and maintain a clear path to prevent accidental drops. 

9. Injuries to the Spine and Neck – Twisting or bending the neck and spine awkwardly while lifting or carrying a load can lead to pinched nerves or even long-term spinal injuries. Keep your neck and head aligned with your spine when lifting and avoid twisting your body during manual handling tasks and keep your back straight. 

10. Cuts and Abrasions – Handling sharp or rough-edged objects without protective gear can lead to cuts, scratches, and abrasions. Always wear gloves when handling sharp or rough materials and check for any potential hazards on the load before moving it. 
    

What are the employer’s responsibilities for reducing Manual Handling injuries?

Employers have several responsibilities to reduce manual handling injuries, primarily under Health and Safety laws such as the UK's Health and Safety at Work Act. This includes risk assessments where employers must assess manual handling risks in the workplace, eliminating manual handling tasks where possible, training employees on safe manual handling techniques and providing appropriate lifting equipment or assistive devices to minimize the need for manual handling.

Manual Handling training is to prevent injuries, poor lifting techniques, improper posture, and listing items that are too heavy or awkward can lead to Musculoskeletal Disorders (MSDs), strains, sprains and even serious conditions like slipped discs or hernias. Training helps workers recognize the risk factors and use proper techniques to avoid these injuries. 

The construction and agriculture sectors continue to account for the greatest number of workers killed in fatal accidents each year with 138 workers killed in work-related accidents in 2023/2024. The most common fatal accidents of workers of 2023-2024 are falls from height, struck by moving vehicles and struck by moving objects between them accounting for around 70% of fatal injuries within the workplace.

Our manual handling course covers the following topics:

• What is manual handling

• Hazards, Risk and Legislation

• Anatomy manual handling activities

• Risk assessments and reducing risks

• Injuries caused by incorrect handling

• The importance of risk assessments and handling plans to reduce the risk of injury

If you are interested in taking part or sending staff to a course run by qualified experts, then book a place now on our Manual Handling course https://www.haswelltraining.co.uk/courses/manual-handing