Manual Handling - Frequently Asked Questions- Responses

What legislation covers manual handling?

The Safety, Health and Welfare at Work, (General Applications) Regulations 2007, Chapter 4 of Part 2, outline the requirements that must be adhered to in relation to manual handling. The key requirements include:

Employers are bound duty- to manage manual handling risk; this means:

• Understanding the manual handling activities that take place in their workplace
• Being able to collect important technical information including load weight data, information on work area setup, work postures, data on frequency of lifting, floor quality, grip on load, etc.
• Being able to use evidence-based risk assessment tools to quantity evidence of risk exposure and
• Putting appropriate measures in place to address risk exposures including introducing lifting equipment, changing how the work area is organized, or reducing load weight specification.

Regulation 69 (a)

An employer shall take appropriate measures, or use the appropriate means particularly mechanical means, to avoid the need for the manual handling of loads

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Regulation 69 (b)

An employer shall where the need for manual handling of loads cannot be avoided, take appropriate organizational measures, use appropriate means or provide the employer's employees with such means in order to reduce the risk in the manual handling of loads

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Regulation 69 (c) (i)

Wherever the need for manual handling of loads by the employer’s employees cannot be avoided, organize workstations in such a way as to make such handling as safe and healthy as possible and taking account of the risk factors in Schedule 3, assess the health and safety conditions of the type of work involved and take appropriate measures to avoid or reduce the risk, particularly of back injury.

The Risk Assessment Process

Relevant Links:
Managing Ergonomic Risk to improve musculoskeletal health
Ergonomic Risk Assessment Tools
Introduction to Ergonomics Risk Assessment online learning course

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Do I need to assess every manual handling task?

Manual Handling is a physical activity that takes place in every workplace, and in some cases the activity does not pose problem. However it can be a potential workplace hazard when an employee is required to handled very heavy loads, which could result in a back injury. The type of manual handling activity that needs to be assessed is defined in Regulation 68 of the Safety, Health and Welfare at Work, (General Application) Regulations 2007:

“Manual Handling involves any transporting or supporting of any load by one or more employees, and includes lifting, putting down, pushing, pulling, carrying or moving a load, which by reason of its characteristics or unfavourable ergonomic conditions, involves risk, particularly of back injury, to employees.”

These characteristics or unfavourable ergonomic conditions are the risk factors which are outlined in Schedule 3 of the 2007 Regulations and have the potential to cause harm.

A first step would be to carry out an audit of the workplace in consultation with managers and employees to identify manual handling tasks that may result in risk exposure. It may also be useful to review accident data and have an understanding of the main risk factors that can result in musculoskeletal injury including back injury.

Not all manual handling tasks are hazardous, but because most jobs involve some form of manual handling, most workers are at some risk of manual handling injury. result of injury and damage to a disc. Bending over results in pressure on the discs and may also cause a disc to bulge backward towards the spine. Twisting and bending together put the greatest stress on the spine, especially on the discs, and are examples of work conditions that increase the risk of back injury.

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What are the main risk factors that can result in musculoskeletal injury and ill health?

Physical ergonomic risk factors can be harmful to the body and can lead to people developing musculoskeletal injury or illness. There are several physical ergonomic risk factors, including:
Force, for example, a heavy load that has to be lifted, pushed, pulled or carried

The main problems with work activities where there is a requirement to lift heavy loads are the excessive loading of the muscles and also the wear and tear on the back, especially on the lumbar intervertebral discs. The increased force due to the manual lifting of a heavy load brings about a sudden and steep increase in internal pressure in the discs and can quickly overload them. The force from a lifted load becomes ten times larger in the spine.

Awkward posture, for example, twisting, reaching, or bending
Poor or awkward posture can lead to local mechanical stress on the muscles, ligaments, and joints, which in turn results in complaints of the neck, shoulder, and other parts of the musculoskeletal system. When maintaining a posture or moving, the joints ought to be kept in the neutral position (see Figure 6), as far as possible. In the neutral position, the muscles and ligaments that span the joints are stretched to the least possible extent

Repetition and lack of recovery time,
Using the same muscles, tendons, and joints, can result in injury. The more repetitive the task, the more rapid and frequent the muscle contractions. Therefore, tasks requiring high rates of repetition involve more muscular effort and require more time for recovery. The human body has great powers of recovery if given sufficient intervals of rest time between periods of repetitive work. When the recovery time is insufficient, and when high repetition is combined with forceful and awkward posture, the person is at greater risk of developing a musculoskeletal injury.

Static work,
Static work involves maintaining the same posture for a long period. Static loading of the muscles requires continuous muscle contraction, which can result in reduced blood flow to the muscles and muscle compression and lead to increased fatigue. Such fatigue often forces an individual to abandon the tiring static posture to relax and recover – this is generally achieved by the person introducing ‘disguised breaks’. It makes good sense, for both the operator’s health and business productivity, to design tasks in such a way that they allow the person to move about and adjust their posture.

Environmental factors,

for example, lack of space, uneven work surfaces, poor workstation design, and poor lighting.
Environmental factors that increase ergonomic risk include lack of space, an uneven floor, ramps and poor workstation design. Restricted space will result in adopting a stooped posture and obstructions may increase the need for twisting, reaching or leaning.

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Why is it important to avoid or reduce exposure to physical ergonomic risk factors including excessive force, awkward posture, high repetition, etc.?

Musculoskeletal disorders (MSDs) are injuries or disorders that affect any part of the musculoskeletal system. MSDs are associated with ergonomic risk factors such as excessive force, awkward posture, and repetition. Symptoms of MSDs can include aches and pains, swelling, numbness, and weakness. It is useful to look at an example of ergonomics in practice. Figures 1 and 1a show a work activity that involves a person manually lifting a metal part (a billet) into a CNC machine for drilling. The ergonomic risk factors include the heavy weight of the billet (up to 130kg) and the awkward twisting posture involved in the manual transfer of the metal part into the machine, which results in the load having to be manipulated at a distance from the trunk. It is clear that carrying out this task exposes the worker to physical stress due to these ergonomic risk factors.

Good ergonomic interventions will reduce the adverse health effects on the person who carries out the task and can positively impact their ability to carry out the work activity effectively. Figure 2 shows an innovative engineering intervention that was implemented to eliminate the need for the worker to manually lift the heavy part into the CNC machine. This intervention was developed and introduced through consultation with the people who do the task. A custom-engineered billet loader was fixed to the floor at each CNC machine center and, most importantly, all operators were trained on its use. The billet loader eliminates the manual lifting of the billet and the billet loader can be operated with a neutral standing posture.

As the above example illustrates, good ergonomic practice ensures that work activities take account of the human input in completing the work task by:

•  studying how the task is carried out,
• identifying ergonomic risk factors and recognizing their impact on human health, and
• making engineering and/or organizational interventions to minimize or eliminate these risk factors.

Many workplaces fail to place sufficient emphasis on managing ergonomic risk. Where there is an intervention for risk reduction, it is often limited to the provision of manual handling training on safe lifting techniques. Such training is important, but it is evident from the example above that manual handling training would have had no impact in avoiding or reducing the risk of injury involved in lifting the heavy metal part into the CNC machine.

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How do I carry out a risk assessment of manual handling tasks?

Introduction to Ergonomics Risk Assessment course is a short course suitable for practitioners including managers, supervisors, safety officers, and occupational health professionals who may be assessing work activities that involve manual handling and/or repetitive tasks involving the upper limbs. The course has a particular emphasis on the 5-step risk assessment process.

The revised five-step risk assessment process to manage unfavourable ergonomic conditions when carrying out manual handling tasks or highly repetitive tasks of the upper limbs. The five-step risk assessment case study illustrates the ergonomic approach to identifying and controlling ergonomic risks in the workplace. It makes good business sense to address ergonomic risks in this manner and evidence has shown that a proactive and systematic ergonomic approach will provide a work environment where people can develop new skill sets, including communication, critical thinking, creative thinking, problem-solving, brainstorming, technical and influencing skills. These skills are very important in managing ergonomic risk effectively but can also be applied to other aspects of the business.

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Are there appropriate guidance documents to refer to for advice and direction in relation to the management of manual handling risk?

Yes, there are several guidance documents available that provide advice on managing manual handling risks, these resources outline best practices for assessing and reducing the risks associated with manual handling tasks to ensure the safety and well-being of employees by providing guidance on safety measures.

Relevant Links:

Managing Ergonomic Risk to improve musculoskeletal health
Ergonomic Risk Assessment Tools
Introduction to Ergonomics Risk Assessment online learning course

Manual Handling and Musculoskeletal Documents

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Are there risk assessment tools for manual handling tasks?

Yes, there are several risk assessment tools available for manual handling tasks that can help identify potential hazards and determine appropriate control measures to reduce the risk of injury. These tools often involve assessing factors such as the weight of the load, frequency of handling, posture required, and environmental conditions. Such as the Variable Manual Handling Assessment Chart (V-MAC) tool to help assess complex manual handling operations where load weights vary. The Risk Assessment of Pushing and Pulling (RAPP) tool. The Assessment of Repetitive Tasks (ART) tool if the task involves repetitive work using the upper limbs.

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Where can I find information about manual handling case studies?

 For information on manual handling case studies, visit HSA Ergonomics Case Studies. These case studies provide real-life examples of successful manual handling practices and offer valuable insights for improving workplace safety.

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Where can I learn more about Manual handling and ergonomics?

We have a wide range of resources available on our website, including articles, guides, and webinars that cover various aspects of ergonomics and workplace safety Manual Handling and Musculoskeletal Documents

Introduction to Ergonomics Risk Assessment online learning course

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Can I complete manual handling training online?

No, the Health and Safety Authority does not endorse or approve individual Manual Handling Training programmes developed by different training providers including new ways of delivering training using Zoom or other social media platforms.
Schedule 3 of the Safety Health and Welfare at Work (General Application) Regulations 2007 (SI no 299 of 2007) details the risk factors for the manual handling of loads and states that an employee may be at risk if he or she does not have adequate or appropriate knowledge or training. It is the position of the Health and Safety Authority (H.S.A.) that the employee will receive appropriate knowledge and training where:
Manual Handling Instructors who deliver manual handling training in the workplace have attained the NFQ Level 6 Manual Handling Instruction and/or NFQ Level 6 People Handling Instruction Award. If those who deliver manual handling training do not have such a qualification they need to be able to demonstrate their competence in terms of training, experience, and knowledge of the subject matter.
The practical element of manual handling training delivered to employees by a QQI-certified people and/or manual handling Instructor needs to be carried out in an appropriate manner. It must be completed through classroom tuition and practical demonstrations to allow the instructor to interact with trainees in the physical work environment and ensure that participants can demonstrate both theoretical and practical knowledge and skills
The Level 6 Manual Handling Instruction and People Handling Instruction Awards are managed by Quality and Qualifications in Ireland (QQI). (QQI) Guidance on the Manual Handling Training System -
For more details on training providers offering the QQI Level 6 Manual Handling Instruction and People Handling Instruction Awards, visit the Quality and Qualifications Ireland (QQI) website at www.qqi.ie

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Can I refer to any guidance document for information on the Manual Handling Training System?

Download the Guide on the Manual Handling Training System - 2010 Revision

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What is the current guidance on course content for a manual handling training course for employees? 

Refer to Appendix 3 in the Guide on the Manual Handling Training System - 2010 Revision

How often do employees need refresher training?

HSA Guidelines currently state “Refresher training will be at intervals of not more than every three years or when there is a major change in the work involved or equipment used or when an employee is transferred to a new work area.”

Are there minimum requirements for the duration of a manual handling training course for employees?

The Health and Safety Authority does not specify the time duration for manual training courses. The duration of the training course should be tailored to the number and complexity of the handling procedures being taught. The employers must satisfy themselves that the instructor who delivers the course covers the relevant topics comprehensively.

What accreditation is recognized in Ireland for manual handling training and who can carry out training?

The HSA developed a Framework for Manual Handling Training in conjunction with QQI and as part of that Framework, the position of the Authority is that the Instructor who delivers manual handling training should have a QQI Level 6 Manual Handling Instructor Award. This is our guidance on the appropriate competence for Manual Handling Instructors.