Safe Lifting and Manual Material Handling

Sprains and strains from manual lifting are among the most common recordable injuries in warehousing and logistics — and unlike a lot of hazards, they usually build up from repetition rather than one bad moment. That makes them easy to underestimate.

The good news is that most manual handling injuries are preventable with a few consistent habits, and with knowing when a load needs a second person or a piece of equipment instead of a strong back.

Key points

• Plan the lift before you start: know where you're setting the load down and make sure the path is clear.
• Get close to the load, bend at the knees, and keep your back straight — let your legs do the work.
• Keep the load close to your body instead of extending your arms out.
• Never twist while lifting or carrying — turn your whole body with your feet instead.
• If a load is too heavy, too awkward, or you can't see over it, get help or use equipment (a hand truck, dolly, or lift).
• Take a break between repetitive lifts. Fatigue is when form breaks down and injuries happen.

Discussion questions

• What's the heaviest or most awkward item we regularly move by hand?
• Do we have the right equipment available for the loads we handle, and is it easy to get to?
• Has anyone felt pressure to lift something alone that probably needed two people?