Manual handling mistakes: Preventing lifting and carrying injuries

Manual handling is one of the most significant causes of workplace injuries across UK factories, accounting for substantial physical harm and financial costs. Understanding common mistakes and implementing proper techniques can reduce injury rates and create safer working environments for all employees.

1.   Understanding Common Manual Handling Mistakes

The most frequent errors in manual handling stem from fundamental misunderstandings about safe lifting practices. Poor lifting technique tops the list, with workers often bending from the waist instead of using their legs, creating excessive strain on the lower back. Underestimating the weight of objects is another critical mistake that leads to sudden, unexpected stress on muscles and joints. Environmental hazards are often overlooked, with workers failing to check for obstacles, slippery surfaces, or insufficient lighting before beginning a lift. Rushing through tasks without proper planning compounds these risks, as does attempting to lift alone when assistance is clearly needed. The Health and Safety Executive reports that 17% of all workplace injuries result from manual handling tasks, highlighting how these seemingly minor mistakes can lead to serious accidents at work. Another common error involves inadequate grip and load positioning. Workers often fail to test their grip on objects or attempt to carry loads away from their body, increasing the risk of dropping items or straining muscles.

2.   Effective Lifting and Carrying Techniques

Proper manual handling technique begins with thorough planning and assessment. Before attempting any lift, workers should evaluate the load’s weight, size, and shape, then determine the safest route and whether assistance or mechanical aids are required. The correct lifting posture is by keeping the back straight, bending at the knees and hips, and maintaining the load as close to the body as possible. The lifting sequence should be smooth and controlled, avoiding jerky movements or sudden changes in direction. Workers should secure a firm grip using both hands when possible, keeping their feet shoulder-width apart for stability. When carrying loads, maintaining good posture and taking regular breaks prevents fatigue-related injuries. For team lifts, clear communication and coordination are important. One person should take the lead, calling out instructions for when to lift, move, and set down the load.

3.   The Role of Training and Safety Culture

Manual handling training is the basis of injury prevention. Recent guidance shows that proper training should cover safe lifting techniques, risk assessment, and equipment usage, with regular refresher sessions to reinforce good practices. Training programmes should be personalised to specific workplace hazards and updated regularly to reflect current best practices. Creating a positive safety culture needs leadership commitment and employee engagement. Regular safety meetings, toolbox talks, and peer-to-peer coaching help embed safe practices into daily routines.

4.   Recognising and Preventing Common Injuries

Manual handling injuries primarily affect the musculoskeletal system, with back injuries representing the most common and serious outcomes. Current statistics show that 500,000 workers suffer from musculoskeletal disorders, with back injuries accounting for 42% of all workplace MSDs. These injuries can range from acute strains and sprains to chronic conditions requiring long-term treatment. Upper limb injuries, affecting shoulders, arms, and hands, often result from repetitive motions, awkward postures, or excessive gripping force. Neck injuries often occur when workers twist or crane their necks during lifting operations. Hand and foot injuries can result from dropped objects or poor load control. Prevention strategies focus on early intervention and proper reporting systems. Workers should be encouraged to report discomfort or pain immediately, before minor issues develop into serious injuries. Employers should provide clear procedures for reporting concerns and ensure swift access to occupational health services.

Effective injury prevention also needs ongoing risk assessment and workplace modification. This includes redesigning workstations to reduce awkward postures, implementing job rotation to prevent repetitive strain, and providing adequate recovery time between physically demanding tasks. When combining proper training, a supportive safety culture, and proactive injury prevention, UK factories can reduce manual handling injuries and create healthier, more productive working environments.