Safe Work Method Statement for Manual Lifting and Handling Operations

Manual Handling

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Manual handling operations encompass lifting, carrying, pushing, pulling, and holding loads in construction environments, representing one of the most common causes of workplace injuries. Workers performing manual handling tasks face significant risks of musculoskeletal disorders (MSDs) including back injuries, strains, sprains, hernias, and chronic pain. Construction sites compound these risks with uneven surfaces, confined spaces, repetitive tasks, and heavy building materials. The Work Health and Safety Act 2011 requires PCBUs to identify hazardous manual tasks and implement control measures following the hierarchy of controls. Manual handling injuries account for substantial lost time and workers' compensation costs in the construction industry. Effective SWMS procedures must address proper lifting techniques, mechanical aids, work design, training, and risk assessment to prevent injuries while maintaining productivity. Compliance with Safe Work Australia's hazardous manual tasks code of practice ensures systematic approach to MSD prevention. Construction-specific challenges include working at heights, on ladders, in trenches, and handling oversized materials that require specialized handling protocols.

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Overview

What this SWMS covers

Manual handling operations involve lifting, carrying, pushing, pulling, holding, or restraining objects using muscular force and bodily movement in construction environments. The work encompasses handling building materials, tools, equipment, and supplies with varying weights, shapes, and frequencies. Construction sites present complex manual handling challenges including uneven surfaces, stairs, ladders, confined spaces, and time constraints. Tasks range from lifting bricks and timber to pushing wheelbarrows and carrying tool belts. Risk assessment considers load weight, dimensions, grip points, worker posture, frequency, duration, and environmental factors. Operations require evaluation of individual worker capabilities, training levels, and any physical limitations. Manual handling procedures emphasize proper lifting techniques, mechanical aid utilization, task rotation, and early reporting of discomfort. Construction-specific challenges include working at heights, on scaffolding, in trenches, and handling oversized or awkwardly shaped materials. Safety protocols integrate with other construction activities to prevent conflicts and maintain workflow efficiency. Training programs cover hazard recognition, safe work procedures, and emergency response for manual handling incidents. Documentation tracks activities, injuries, and control effectiveness for continuous improvement and compliance verification.

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Why this SWMS matters

Reinforce licensing, insurance, and regulator expectations for Manual Handling Safe Work Method Statement crews before they mobilise.

Hazard identification

Surface the critical risks tied to this work scope and communicate them to every worker.

Risk register

Back injuries and strains from improper lifting

high

Lifting loads with bent back, twisting motions, or without proper foot positioning causes spinal compression, muscle strains, and disc injuries.

Consequence: Severe back pain, herniated discs, long-term disability, lost work time, and permanent mobility limitations.

Shoulder and arm injuries from overhead lifting

medium

Lifting or carrying loads above shoulder height causes rotator cuff injuries, tendonitis, and nerve compression in arms and shoulders.

Consequence: Chronic pain, reduced range of motion, difficulty with overhead activities, and potential surgical intervention.

Knee and leg injuries from heavy carrying

medium

Carrying heavy loads over distance causes knee strain, ankle sprains, and foot injuries from improper weight distribution.

Consequence: Joint pain, instability, difficulty walking, and increased risk of falls.

Hernias from sudden force or heavy lifting

high

Sudden increases in abdominal pressure from lifting, pushing, or straining cause abdominal wall tears and internal organ protrusion.

Consequence: Surgical repair required, recovery time, potential complications, and restrictions on heavy work.

Repetitive strain injuries from frequent tasks

medium

Repeated lifting, carrying, or handling of loads causes cumulative wear and tear on muscles, tendons, and joints.

Consequence: Chronic pain, reduced strength, decreased work capacity, and long-term health deterioration.

Slips and falls while carrying loads

medium

Reduced visibility and balance while carrying loads increases risk of trips, slips, or falls on construction site hazards.

Consequence: Fractures, head injuries, additional injuries from falling with load, and compound trauma.

Sudden load shifts or loss of grip

high

Loads shifting unexpectedly during lifting or carrying causes loss of control and potential crushing injuries or falls.

Consequence: Sudden injuries from dropped loads, impact trauma, or uncontrolled falls.

Working in confined or awkward spaces

medium

Manual handling in restricted spaces forces awkward postures, reduces leverage, and increases strain on body mechanics.

Consequence: Increased injury risk from poor posture, reduced control, and higher force requirements.

Control measures

Deploy layered controls aligned to the hierarchy of hazard management.

Implementation guide

Comprehensive manual handling risk assessment

Administrative

Systematic evaluation of manual handling tasks to identify hazards and determine appropriate control measures.

Implementation

1. Assess load characteristics (weight, size, shape, grip points) 2. Evaluate task factors (frequency, duration, force requirements) 3. Consider individual factors (worker capability, fitness, training) 4. Analyze environmental factors (space, surfaces, lighting) 5. Document assessment results and required controls 6. Review assessments regularly and after incidents 7. Involve workers in assessment process 8. Use standardized assessment tools (e.g., Snook tables)

Mechanical aids and equipment

Engineering

Use of mechanical lifting devices, trolleys, hoists, and other aids to eliminate or reduce manual handling requirements.

Implementation

1. Provide pallet jacks, sack trucks, and wheelbarrows 2. Install overhead hoists and cranes where possible 3. Use mechanical lifting equipment for loads over 15kg 4. Provide adjustable height work surfaces 5. Implement conveyor systems for repetitive tasks 6. Ensure all mechanical aids are maintained and inspected 7. Train workers in proper equipment use 8. Store heavy items at accessible heights

Safe lifting and handling techniques training

Administrative

Comprehensive training in proper manual handling techniques, posture, and body mechanics.

Implementation

1. Train all workers in correct lifting techniques 2. Teach proper foot positioning and balance 3. Demonstrate safe carrying and lowering methods 4. Cover team lifting procedures 5. Include training on load assessment 6. Provide refresher training annually 7. Document training completion 8. Assess competency through practical demonstrations

Task and workstation design

Engineering

Design work areas and tasks to minimize manual handling requirements and awkward postures.

Implementation

1. Store frequently used items at waist height 2. Design clear pathways for material movement 3. Provide adequate space for safe handling 4. Minimize bending, twisting, and reaching 5. Implement material delivery systems 6. Use gravity-fed systems where possible 7. Design ergonomic workstations 8. Rotate tasks to prevent fatigue

Work organization and rotation

Administrative

Organize work to minimize individual exposure to manual handling tasks through job rotation and rest breaks.

Implementation

1. Rotate workers between heavy and light tasks 2. Schedule regular rest breaks during heavy work 3. Limit continuous manual handling to 2-hour periods 4. Monitor workers for signs of fatigue 5. Provide recovery time between heavy lifts 6. Implement buddy system for heavy tasks 7. Adjust workloads based on individual capabilities 8. Document work rotation schedules

Personal protective equipment for manual handling

PPE

Appropriate PPE to support safe manual handling and protect against injury during handling operations.

Implementation

1. Provide supportive footwear with good traction 2. Supply back support belts for heavy lifting 3. Offer gloves with good grip for handling loads 4. Provide knee pads for kneeling work 5. Ensure appropriate clothing for weather conditions 6. Supply wrist supports for repetitive tasks 7. Provide hydration equipment for hot conditions 8. Ensure PPE is properly fitted and maintained

Health monitoring and early intervention

Administrative

Systems to monitor worker health, identify early signs of strain, and provide timely intervention.

Implementation

1. Encourage reporting of discomfort or pain 2. Provide access to physiotherapy services 3. Implement regular health check-ups 4. Monitor absenteeism patterns 5. Train supervisors to recognize MSD symptoms 6. Maintain injury reporting procedures 7. Provide modified duties for injured workers 8. Document health monitoring activities

Emergency response and first aid

Administrative

Preparedness for manual handling injuries with immediate response and medical support.

Implementation

1. Train workers in manual handling injury response 2. Provide accessible first aid equipment 3. Establish emergency communication procedures 4. Arrange for rapid medical assessment 5. Prepare modified work options for recovery 6. Document injury response procedures 7. Conduct regular emergency drills 8. Coordinate with occupational health services

Download complete control procedures

Personal protective equipment

Supportive footwear

Requirement: Steel toe cap, good arch support, non-slip soles AS 2210.3

When: All manual handling work on construction sites

Back support belt

Requirement: Properly fitted lumbar support belt

When: Heavy lifting and carrying operations

Safety gloves

Requirement: Good grip, appropriate for load type

When: Handling materials and equipment

Knee pads

Requirement: Thick foam or gel padding

When: Kneeling or working on hard surfaces

Wrist supports

Requirement: Adjustable neoprene supports

When: Repetitive lifting or handling tasks

Hard hat

Requirement: AS/NZS 1801 Type 1 or 2

When: Working under potential falling objects

High-visibility vest

Requirement: AS/NZS 4602 Class D

When: Working on construction sites

Inspections & checks

Before work starts

  • ✓Assess load weight and characteristics
  • ✓Check environmental conditions and surfaces
  • ✓Verify mechanical aids are available and functional
  • ✓Confirm worker fitness and training
  • ✓Check PPE availability and condition
  • ✓Assess team lifting requirements
  • ✓Verify emergency equipment accessibility
  • ✓Review work procedures with team

During work

  • ✓Monitor proper lifting techniques
  • ✓Check for signs of worker fatigue
  • ✓Verify mechanical aid usage
  • ✓Monitor environmental conditions
  • ✓Observe for early signs of strain
  • ✓Ensure proper rest breaks
  • ✓Check load stability during movement
  • ✓Verify team coordination

After work

  • ✓Document any incidents or near misses
  • ✓Check for equipment damage
  • ✓Monitor workers for delayed injury signs
  • ✓Clean and store mechanical aids
  • ✓Update risk assessments if needed
  • ✓Report injuries and implement corrective actions
  • ✓Review procedures for improvement
  • ✓Document lessons learned

Step-by-step work procedure

Give supervisors and crews a clear, auditable sequence for the task.

Field ready
1

Task Assessment and Preparation

Evaluate the manual handling task and prepare the work area and equipment.

Safety considerations

Never attempt a lift that feels unsafe or exceeds your capability.

2

Proper Lifting Technique

Execute lifts using correct body mechanics and posture.

Safety considerations

Keep loads close to body, avoid twisting, and use leg muscles for power.

3

Safe Transportation

Move loads safely to destination using proper carrying techniques.

Safety considerations

Maintain clear vision, avoid obstacles, and request assistance for difficult loads.

4

Controlled Lowering

Lower loads safely using proper body mechanics.

Safety considerations

Bend at knees, keep back straight, and avoid sudden movements.

5

Recovery and Monitoring

Allow recovery time and monitor for signs of strain or injury.

Safety considerations

Report any pain or discomfort immediately for early intervention.

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Frequently asked questions

What are the most common manual handling injuries in construction?

Back injuries, strains, sprains, hernias, and musculoskeletal disorders are most common. These occur from improper lifting techniques, overexertion, repetitive tasks, and sudden movements. Early intervention and proper techniques prevent most injuries.

How do I assess if a manual handling task is hazardous?

Evaluate task factors (force, repetition, duration), load factors (weight, size, shape), worker factors (capability, fitness), and environmental factors (space, surfaces, temperature). Use assessment tools like Snook tables and consult Safe Work Australia's hazardous manual tasks code.

What is the correct way to lift heavy objects?

Stand close to the load with feet shoulder-width apart. Bend at knees, keep back straight. Grip load firmly, lift with leg muscles while keeping load close to body. Avoid twisting. Get help for loads over 15kg or when unsure.

When should mechanical aids be used instead of manual lifting?

Always use mechanical aids for loads over 15kg, repetitive tasks, loads that are awkward or unstable, or when working in confined spaces. Mechanical aids include trolleys, hoists, pallet jacks, and lifting equipment.

How often should workers receive manual handling training?

Initial training for all new workers, annual refresher training, and additional training when new equipment or procedures are introduced. Training should include practical demonstrations and assessment of competency.

What should I do if I feel pain during manual handling?

Stop immediately and report the pain to your supervisor. Do not continue working through pain. Early reporting allows for assessment and prevents minor discomfort from becoming serious injury. Modified duties may be available during recovery.

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Overview

Manual handling includes any activity requiring the use of force exerted by a person to lift, lower, push, pull, carry, move, hold, or restrain any animate or inanimate object. Construction work frequently involves manual handling of materials, tools, equipment, and supplies in various environments including building sites, warehouses, and storage areas. Tasks range from lifting bricks and timber to pushing loaded wheelbarrows and carrying tools. The work requires assessment of load characteristics, worker capabilities, environmental conditions, and task frequency. Manual handling operations must consider individual worker factors including age, fitness, training, and any pre-existing conditions. Construction sites present unique challenges with uneven ground, stairs, ladders, confined spaces, and time pressures that can increase injury risks. Operations involve coordination between workers for team lifting, use of mechanical aids, and adherence to safe work procedures. Risk assessment considers task duration, frequency, force requirements, postures, and environmental factors. Training programs emphasize proper techniques, equipment use, and early reporting of discomfort. Documentation tracks manual handling activities, injuries, and control measure effectiveness for continuous improvement.

Why This SWMS Matters

Manual handling represents the leading cause of workplace injuries in construction, accounting for significant lost time, workers' compensation claims, and long-term disability. Musculoskeletal disorders (MSDs) from manual handling include back injuries, hernias, sprains, strains, and chronic pain that can end careers and create permanent disability. The Work Health and Safety Act 2011 requires PCBUs to identify hazardous manual tasks and implement control measures, with specific duties under the model WHS Regulations Part 3.1. Construction sites amplify manual handling risks with heavy materials, awkward postures, repetitive tasks, and environmental challenges. Without proper SWMS procedures, workers risk severe injuries from improper lifting techniques, overexertion, sudden movements, or cumulative wear and tear. The cost of manual handling injuries extends beyond immediate medical treatment to include lost productivity, retraining, and legal liability. Safe Work Australia's hazardous manual tasks code provides specific guidance for risk assessment and control implementation. This SWMS ensures systematic hazard identification, implementation of engineering controls like mechanical aids and work redesign, administrative controls including training and rotation, and PPE for injury prevention. Effective manual handling programs improve worker safety, reduce injury costs, and enhance productivity through proper work design and equipment use.

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Risk Rating

BeforeHigh
After ControlsLow

Key Controls

  • • Pre-start briefing covering hazards
  • • PPE: hard hats, eye protection, gloves
  • • Emergency plan communicated to crew

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