Safe lifting techniques: Reduce workplace injury risk

Safe lifting is essential in Australian workplaces. Whether you work in construction, retail, or warehousing, manual handling tasks are common and can pose significant risks. Using correct lifting techniques and understanding the hazards can help prevent injuries and keep workplaces productive.

What is a musculoskeletal injury?

The musculoskeletal system includes bones, muscles, tendons, ligaments, and cartilage. Injuries to this system can range from sprains and strains to chronic conditions such as arthritis and back pain. According to the Australian Institute of Health and Welfare, musculoskeletal conditions affect millions of Australians, with back problems and arthritis being the most common. These injuries can result in pain, reduced mobility, and long-term health impacts.

Source: AIHW – Musculoskeletal Conditions

Hazardous manual tasks, musculoskeletal disorders, and your legal duty

Some manual tasks can place stress on the body and lead to musculoskeletal disorders (MSDs). Hazardous manual tasks are those that require a person to lift, lower, push, pull, carry, or otherwise move, hold, or restrain any person, animal, or object. These tasks are considered hazardous when they involve one or more of the following:

• Repetitive movement
• Repetitive or sustained force
• High or sudden force
• Sustained or awkward postures
• Exposure to vibration

When manual tasks involve these risk factors, the likelihood of developing an MSD increases. MSDs can include injuries such as sprains, strains, back pain, and chronic conditions affecting muscles, joints, and connective tissues.

The scale of the problem

Recent data from Safe Work Australia highlights the impact of hazardous manual tasks:

• The largest number of claims is attributed to body stressing, with 50,600 claims, or 34.5% of all serious claims. Body stressing is the most common mechanism across every major occupation group when it comes to work-related injury and illness.
• Musculoskeletal and connective tissue diseases account for 22,500 serious claims, representing 15.3% of all serious claims.

These statistics show that hazardous manual tasks are a major contributor to workplace injury and illness in Australia. By recognising and managing these risks, employers and employees can help reduce the incidence of MSDs and improve workplace safety.

Source: Safe Work Australia – Key WHS Statistics, Safe Work Australia – Manual Tasks, AIHW – Musculoskeletal Conditions

Identifying lifting risks

Recognising risk factors is the first step in preventing injury. According to Safe Work Australia, risks arise from:

• Lifting loads that are too heavy or awkward
• Repetitive movements or sustained force
• Awkward postures or movements
• Environmental hazards such as slippery floors or cluttered spaces
• Lack of appropriate equipment

Employers and employees should work together to identify these risks before starting manual handling tasks.

Source: Safe Work Australia – Manual Tasks

How to mitigate lifting risks

Once risks are identified, steps should be taken to reduce or eliminate them:

• Use mechanical aids such as trolleys or hoists
• Ask for help from a colleague when lifting heavy or awkward items
• Clear walkways and work areas before moving items
• Break loads into smaller, manageable parts
• Avoid tasks that are too risky and seek safer alternatives

Safe Work Australia emphasises that there is no fixed legal weight limit for lifting. Instead, employers must assess each task and implement controls to minimise risk.

Reference: Safe Work Australia – Manual Tasks

Safe lifting techniques: Step-by-step

1. Plan the lift

Ensure the path is clear and the destination is ready.

2. Assess the load

Check if the item is too heavy or awkward for one person.

3. Position yourself

Stand close to the item with feet shoulder-width apart.

4. Bend your knees

Squat down, keeping your back straight and head up.

5. Grip firmly

Hold the item securely with both hands.

6. Lift smoothly

Use your legs to lift, keeping the load close to your body.

7. Avoid twisting

Turn with your feet, not your back.

8. Set down carefully

Lower the item by bending your knees and hips.

For more detailed guidance, see Safe Work Australia’s Hazardous Manual Tasks Code of Practice.

Musculoskeletal disorders: Prevention and management

Prevention is more effective than treatment. Strategies include:

• Redesigning tasks to minimise manual handling
• Providing training and supervision
• Using mechanical aids
• Encouraging early reporting of symptoms

Employers should consult with workers to identify hazards and implement control measures.
Reference: Safe Work Australia – Manual Tasks

Chronic musculoskeletal conditions in Australia

According to the Australian Institute of Health and Welfare:

• One in three Australians has a musculoskeletal condition
• Back problems and arthritis are the most common
• These conditions are a leading cause of disability and lost productivity

Early intervention and workplace adjustments can help manage symptoms and support affected employees.
Reference: AIHW – Musculoskeletal Conditions

Workers Compensation Insurance

A person conducting a business or undertaking (PCBU), has a duty to keep workers and workplaces safe from the risks of manual handling. You must assess and manage the risks of manual tasks. This means identifying hazardous manual tasks, consulting with workers, and implementing effective control measures to minimise the risk of injury.

Workers Compensation Insurance can help protect businesses from the costs of claims related to workplace injuries.

GIO can offer Workers Compensation Insurance for businesses in WA, NT, ACT and TAS. Complimentary training courses are available for GIO customers to help businesses prevent workplace injuries and reduce associated claims costs. Customers also have access to a wide range of discounted training courses provided through our partnership with National Safety Council of Australia (NSCA). For more information on the training courses or if you have any risk management queries, please contact us.

Learn more about GIO Workers Compensation Insurance

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Insurance issued by AAI Limited ABN 48 005 297 807 trading as GIO. In NSW, GIO manages claims as agent for the Workers Compensation Nominal Insurer ABN 83 564 379 108, also known as icare workers insurance.