MANUAL HANDLING OF
MATERIALS
A TRAINING FOR THE
METALWORKING INDUSTRIES
Updated on June 2015
Table of Contents
Introduction
Risk management on manual handling
Hazards associated with manual handling
Common injuries & occupational diseases
Proper manual handling methodology
Use of personal protective equipment (PPE)
Job design to prevent injuries
Case study
Introduction
Manual handling is a common activity in most
workplaces
It includes lifting, lowering, pulling, pushing, carrying,
moving, holding or restraining an object
Injuries and musculoskeletal disorders affect the back,
neck, shoulder, arms & hands
It can be prevented through a systemic approach of
identification, assessment and control of risks
associated with manual handling.
Occupational Diseases in
Singapore
Source: Ministry of Manpower
Risk Management on Manual
Handling
Required to manage risks under WSH (Risk
Management) regulations
Assess the risk
Take all reasonably practical steps
Eliminate any risks
Risk Management on Manual
Handling
Step 1: Identification of hazard
Picture source:
http://www.safetyworld.com/images/101.gif
Risk Management on Manual
Handling
Step 2: Assess the risk
Dependent on severity of risk and likelihood
of hazards
occurring
severity X likelihood = risk level
Risk Level = Low, Moderate or High
Risk Management on Manual
Handling
Rare Remote Occasional Frequent Almost
(1) (2) (3) (4) Certain
(5)
Catastrophic (A) Medium Medium High High High
Major (B) Medium Medium Medium High High
Moderate (C) Low Medium Medium Medium High
Minor (D) Low Medium Medium Medium Medium
Negligible (E) Low Low Low Medium Medium
Risk Management on Manual
Handling
Step 3: Select Measures to Control and Reduce Risk
Based on hierarchy of hazards control
1st – Remove the hazard
2nd – Guard the remaining hazards
3rd – Mitigate impact of hazard
Risk Management on Manual
Handling
Hazards Associated with Manual
Handling - Heavy
Lifting over 25kg load can result in back injury
Picture source: http://www.masterlift.ie/images/HealthAndSaftey/HandS.jpg
Hazards Associated with Manual
Handling - Heavy
Hazards Associated with Manual
Handling - Sharp
Potential Cuts on the fingers
Hazards Associated with Manual
Handling – Odd shapes
Absence of grip to hold the load
Obstruction of walking view
Picture source: http://make-a-box.com
Picture source: http://www.fork-lift-
http://www.fork-lift-
trucks.info
Hazards Associated with Manual
Handling – Toxic substances
Skin exposure to chemicals
Picture source:
http://discountpowerparts.com
Coolant
Lubricants
Picture source: http://www.vacmagic.com/images/fixture%20macchining%20scene.jpg
Hazards Associated with Manual
Handling – Toxic substances
Exposure to chemical dust, fumes & vapours
Picture source: http://www.railcamp.com
Picture source: http://www.airborncoatings.com/images/air3.gif
Common Injuries From Manual
Handling
Neck Strain
Picture source:
http://www.abcbodybuilding.com/exercise2/neckspra.jpg
Common Injuries From Manual
Handling
Wrist Sprains Back Sprains
Picture source: http://athleticscholarships.net/back
%20pain.jpg
Picture source:
http://www.drfoot.co.uk/pictures/wrist.jpg
Common Injuries From Manual
Handling
Shoulder Upper back
pain pain
Picture source: http://www.gotosee.co.uk
Picture source: http://medicineworld.org
Common Injuries From Manual
Handling
Slips, trips and fall
Picture source: http://www.istockphoto.com
Picture source:
http://www.greenbergmassarelli.com/Images/slip_fall.jpg
Common Injuries From Manual
Handling
Cuts
Picture source :
http://krismarkel.com/eclaircie/photos/uncategorized/ouch.JPG
Picture source: http://www.thealmightyguru.com/Boffer/Images/FA-
MinorCut.jpg
Health Hazards Resulting From
Chemical Handling
Skin dermatitis
Picture source: http://www.osh.govt.nz
Health Hazards Resulting From
Chemical Handling
Skin dermatitis
Picture source: http://www.ascc.gov.au
Health Hazards Resulting From
Chemical Handling
Occupational respiratory & lung diseases
Picture source: http://content.revolutionhealth.com/contentimages/images-
Picture source: http://myweb.lsbu.ac.uk/dirt/museum/simon/68-776-gse15.jpg
image_popup-ww5r370.jpg
Health Hazards Resulting From
Chemical Handling
Occupational eye diseases
Picture source: http://content.revolutionhealth.com/contentimages/images-image_popup-
r7_conjunctivitis.jpg
Proper Manual Handling - Individual
ALWAYS KEEP YOUR BACK STRAIGHT WHILE LIFTING
Step 1: Hold Step 2: Keep Step 3: Lift the Step 4: Ensure
the load firmly the load close load by your legs are
to you pushing up stable before
your leg moving off
Proper Manual Handling - Individual
Lifting aids
Proper Manual Handling - Individual
Lifting aids
Proper Manual Handling - Individual
Lifting aids
Proper Manual Handling – Team
Team/buddy lifting
Picture source: www.fork-lift-trucks.info
Proper Manual Handling – Team
Team/buddy lifting
Picture source:
http://www.atlasstraps.com/example2.gif
Selection of PPE for Manual Handling
Are there any sharp or point edges?
Is it enough to prevent injuries or occupational
diseases?
Does the PPE fit you correctly?
Does the PPE wear out easily?
Is it based on chemical properties of the substance?
Does it minimize contact with chemicals?
Is it easy to clean and maintain?
Selection of PPE for Manual Handling
Safety boots
Protective gloves
Helmets
Working apron or
overalls
Goggles or safety
glasses
Face mask or respirators
Picture source: http://www.osha.gov
Selection of PPE for Manual Handling
Safety boots
Picture source: http://www.hse.gov.uk
Picture source: http://www.veganline.com/safety-
boot-big.jpg
Selection of PPE for Manual Handling
Protective gloves
Picture source: http://www.hse.gov.uk
Picture source: http://www.dkimages.com
Selection of PPE for Manual Handling
Helmets
Picture source: http://www.hse.gov.uk
Picture source:
http://myweb.datahalland.se/w-15080/admin/picture/20050919154156.jpg
Selection of PPE for Manual Handling
Working apron or safety overalls
Picture source: http://www.hse.gov.uk
Picture source: http://www.anzic-int.com
Picture source: http://www.dashackoutdoors.com
Selection of PPE for Manual Handling
Goggles or safety
glasses
Picture source: http://www.hse.gov.uk
Picture source: http://teachertech.rice.edu
Picture source:
http://www.wintex.ca/english/Images/PPE026b.gif
Selection of PPE for Manual Handling
Face mask or respirator
Picture source: http://www.ammex.com
Picture source: http://www.shingleberrysigns.com
Picture source: http://www.toolrage.com
Job Designs to Prevent Manual
Handling Injuries
Team handling for heavy or odd shape loads
Breaks to reduce muscular fatigue
Handlers job rotation between heavy and light
activities
Rearrange workplace to reduce twisting, stretching
& stooping
Job Designs to Prevent Manual
Handling Injuries
Keep heavy loads around waist level
Use of mechanical handling aid
Package heavy materials into smaller container
Picture source: http://www.osha.gov
Picture source: CP 92 : 2002
Job Designs to Prevent Manual
Handling Injuries
Provide handles, hand grips or indents for loads
Loads to be free from dust, oil, corrosive deposits,
sharp corners, jagged edges or rough surfaces
Picture source : http://www.saylorsfarm.com
Picture source : http://www.powerwheel-usa.com
Indents &
Handles
Job Designs to Prevent Manual
Handling Injuries
Provide secondary containment for chemicals
Picture source : http://www.smithsofthedean.co.uk
Picture source : http://www.fuelproof.co.uk
Case Study
The Case of Peter
Peter injured his back while moving some large drums. He has
previously suffered from back problems but felt that it was under
control. His doctor had advised him not to lift anything above 20 kg but
he had not passed this information to his boss.
The injury was serious enough to land Peter in the hospital.
Subsequently Peter was diagnosed with a torn disk. Peter admitted the
drums were heavy, but wanted to have the job done.
What should Peter have done?
Picture source : http://education.qld.gov.au/health/injury/casestudy.html
Summary of Key Points
Hazards from manual handling
Common injuries and occupational diseases
Proper manual handling methods
Use of PPE
Job designs to prevent manual handling injuries
Musculoskeletal injuries
and Occupational diseases
is preventable
Be proactive: it is up to
US to prevent it
Thank You
References:
1. CP 92: 2002 Code of Practice for Manual Handling
2. Ministry of Manpower – Guidelines for Manual Handling
3. SS 437 : 1999 Part 2 : Specification for personal eye-
protectors part 2 : selection, use and maintenance
4. SS 513 : 2005 Part 1 : Personal protective equipment –
footwear. Part 1: Safety footwear
5. CP 74 : 1998 Selection, use and maintenance of respiratory
protection devices
Appendix 1
Appendix 1
Appendix 1
