Manual Lifting and Material Handling
The Problem
Manual lifting and material handling are among the most common tasks on Kiwi worksites, yet improper lifting techniques cause countless injuries every year. Back strains, sprains, and musculoskeletal disorders can have lasting impacts on your health and your ability to work. Today, we’ll discuss how to lift safely, when to use mechanical aids, and how team lifting can prevent injuries while staying compliant with WorkSafe New Zealand guidelines.
Identify the Hazards
- Overexertion: Lifting loads that are too heavy or awkward.
- Improper Technique: Bending at the waist, twisting, or using poor hand grips.
- Unstable Loads: Oversized, unbalanced, or shifting loads.
- Team Lift Failures: Poor communication or lack of coordination during team lifts.
- Failure to Use Aids: Ignoring available mechanical lifting equipment.
Safety Practices and Preventative Measures
1. Proper Lifting Techniques
Body Positioning:
- Keep feet shoulder-width apart for stability.
- Bend at your knees and hips, not your back.
- Keep your back straight and maintain its natural curve.
- Hold the load close to your body.
- Avoid twisting—pivot your whole body instead.
Weight Assessment:
- Test the weight before lifting.
- Know your limits—anything over 20–25kg should involve help or a mechanical aid.
- Consider load size, shape, and balance.
Movement Planning:
- Clear the path of obstacles and tripping hazards.
- Plan the route, identify rest points, and ensure the area is well-lit.
2. Use of Mechanical Aids
Equipment Selection:
- Use trolleys, hoists, pallet jacks, or forklifts for heavy or awkward loads.
- Ensure the lifting equipment is rated for the load.
Inspection:
- Check equipment before use for damage or faults.
- Inspect wheels, brakes, handles, and load restraints.
Training and Operation:
- Only trained workers should operate lifting equipment.
- Never exceed load limits.
3. Team Lifting
Communication:
- Use clear instructions—assign a leader and agree on timing.
- Count down together to lift in unison.
Coordination:
- Practice if needed and match pace to the slowest team member.
- Ensure workers are of similar height or adjust positions accordingly.
Weight Distribution:
- Ensure the load is balanced.
- Rotate roles to reduce fatigue during repetitive tasks.
Real-Life Case or Scenario
A worker on a building site attempted to lift a 40kg beam on their own without checking the weight or asking for help. They twisted awkwardly and suffered a herniated disc, resulting in weeks off work and ongoing back pain. This could have been avoided with a mechanical aid or team lift.
Employee Responsibilities
- Always use safe lifting techniques.
- Assess the load before lifting.
- Use mechanical aids and check they’re in good condition.
- Communicate clearly during team lifts.
- Report unsafe practices or damaged gear immediately.
Employer Responsibilities
- Provide training on safe lifting techniques and equipment use.
- Supply and maintain mechanical lifting aids.
- Assess tasks for lifting risks and implement controls.
Discussion & Questions
- "Have you seen lifting injuries that could have been avoided?"
- "Do you know how to use the mechanical lifting aids on site?"
- "Are there jobs where we need better lifting support or teamwork?"
Encourage staff to share and discuss improvements.
Commitment/Action Plan
From today, let’s commit to assessing every lift, using the correct lifting gear, and asking for help when needed. No load is worth a lifetime injury.
Wrap-Up
Manual handling injuries are preventable. Whether it’s lifting with the right posture, using the right equipment, or working as a team, taking a few extra moments can protect your long-term health. Let’s work together and lift smart—kia ora for putting safety first.
Standards Overview
Under the Health and Safety at Work Act (HSWA) 2015, PCBUs must ensure risks associated with manual handling are eliminated or minimised.
- Workers must be trained in safe lifting practices.
- Engineering and administrative controls (e.g., team lifting, mechanical aids) must be used where possible.
- Manual tasks must be risk assessed, and control measures reviewed regularly.
Disclaimer
These toolbox talks are provided for informational and educational purposes only and are not a substitute for professional legal, health and safety, or regulatory advice.
The content reflects recognised best practices and general industry standards as at the date of publication. However, it may not be applicable to all workplace environments or specific operational contexts.
It is the responsibility of the Person Conducting a Business or Undertaking (PCBU), as well as officers, workers, and other duty holders under the Health and Safety at Work Act 2015 (HSWA), to ensure compliance with all relevant laws, regulations, and WorkSafe New Zealand guidance.
The authors, presenters, and distributors of this toolbox talk disclaim all liability for any loss, damage, or injury arising from the use or reliance on the information provided. Users should seek advice from a suitably qualified health and safety professional or legal advisor for guidance tailored to their specific circumstances.
Always follow your organisation’s policies, procedures, and safe work practices to manage risks and maintain a safe and healthy workplace.
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