The most common manual handling injuries in the workplace include neck and back injuries, hernias, sprains and strains, and hand injuries.
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What Are The Most Common Manual Handling Injuries?
Manual handling in the workplace involves activities such as lifting, pushing, pulling and carrying loads. If these are performed in an unsafe work environment or with poor technique, they can lead to accidents and injuries.
According to the Health and Safety Executive (HSE), being injured whilst handling, lifting or carrying is the second most frequent type of accident at work. Some of the most common manual handling injuries include sprains and strains, musculoskeletal disorders, back injuries and hernias.
Furthermore, workers may also slip, trip and fall while carrying loads, which can result in various other injuries such as fractures and concussions. This article outlines the most common types of manual handling injuries and provides best practices for their prevention.
Table of Contents
Sprains and strains
Sprains and strains are among the most common manual handling injuries in the workplace. They can result from overstretching or tearing a muscle, tendon or ligament, which can easily happen while handling a load if:
- You twist suddenly.
- You have an awkward posture.
- The load is too heavy.
Strains and sprains account for a third of injuries suffered by construction workers. They commonly affect the back, arms, wrists and shoulders and cause similar symptoms that include pain, swelling, inflammation and reduced mobility.
Musculoskeletal disorders
According to the HSE, 543,000 workers were suffering from musculoskeletal disorders (MSDs) in 2023/24. These accounted for 32% of all work-related ill health cases and 26% of all working days lost during that period. The most commonly affected body parts are:
- The back – 43% of all cases (232,000).
- The neck or upper limbs – 37% of cases (203,000).
- The lower limbs – 20% of all cases (108,000).
Manual handling is the leading cause of MSDs in the workplace. The most common musculoskeletal disorders include lower back pain, tendonitis and carpal tunnel syndrome.
Hernias
A hernia occurs when fatty tissue or a part of an organ pushes through a weak point in your muscle and tissue wall, usually in the abdomen or groin.
Repeated manual handling activities, especially those involving heavy loads, can weaken the abdominal wall over time, creating a weak spot through which organs or fat can protrude. In other cases, a single, excessive strain can cause a tear in the abdominal wall.
Hernias can cause pain, discomfort and can sometimes lead to serious complications such as strangulation. Over 120,000 hernias are operated on each year in the UK, making it the most common surgical intervention.
Back injuries
Back injuries are some of the most common consequences of poor manual handling techniques. Repetitive motions, lifting heavy loads, awkward postures and acute trauma can lead to conditions such as:
- Muscle spasms and stiffness.
- Back sprains and strains.
- Slipped or herniated discs.
- Sciatica, caused by nerve compression.
- Fractured vertebrae.
- Chronic back pain.
In 2023/24, 7,905 back injuries were reported under RIDDOR, accounting for 13% of all reported injuries. 93% of these have kept employees out of work for over 7 days.
Neck and shoulder injuries
Overreaching, lifting incorrectly, excessive load weights and awkward movements can lead to acute or repetitive strain injuries in the neck or shoulders. These include sprains, strains, shoulder dislocations, rotator cuff tears and nerve compression, which could result in:
- Pain and discomfort.
- Inflammation and reduced range of motion.
- Chronic pain and limited mobility.
- Long-term disability.
- Inability to work or engage in daily activities.
Foot injuries
You may not lift with your feet, but hazardous manual handling can lead to severe foot injuries, such as fractures, crushed bones and lacerations. This can happen when a heavy object is dropped on the foot, because:
- It was too heavy.
- It was held incorrectly.
- It slipped from your grip.
- It was incorrectly placed on the ground.
- A load has been dropped from a height.
These types of accidents are common in industries such as construction, warehousing and manufacturing. Wearing protective footwear, such as steel-capped boots, is crucial for preventing severe foot and toe injuries.
Hand and arm injuries
According to RIDDOR, the hands, fingers, wrists, and the rest of the upper arm are the most commonly injured in workplace accidents. They make up 37% of all workplace injuries and could develop in two ways:
- In time, due to overuse and repetitive strain. Such injuries include carpal tunnel syndrome, cubital tunnel syndrome and tennis elbow.
- From a single traumatic event, such as contact with sharp edges, being struck by heavy objects, touching a hot item or getting the hands caught between heavy loads.
Hand injuries range from minor sprains to fractures, dislocations and even amputations in severe cases.
Slip, trip and fall injuries
Slips, trips and falls on the same level are the single most common cause of injuries at work. These accidents can occur at any time, but their risk is even higher when you are involved in manual handling operations.
When carrying a large or heavy load, your visibility is impaired, and it becomes harder to maintain your balance and brace yourself if you encounter an uneven surface, a spillage or another hazard.
Such accidents can lead to numerous other injuries, ranging from minor bruises and ankle sprains to severe head trauma and damage to the spinal cord.
Cuts and lacerations
Manual handling tasks can also result in cuts and lacerations if rough, sharp or heavy objects are mishandled. These can affect not only the hands, but also any other part of the body that comes into contact with a hazardous object.
Deep cuts or puncture wounds carry a risk of infection and may result in permanent scarring. To prevent such injuries, it is essential to wear protective gloves and equipment when the risk of injury is high.
Employer duties to prevent the most common manual handling injuries in the workplace
Under the Health and Safety at Work Act 1974 and the Manual Handling Operations Regulations 1992, employers must take all reasonable measures to prevent manual handling injuries, including:
- Avoid all manual handling operations when possible.
- Assess the risk of manual handling injuries for tasks that cannot be avoided.
- Reduce manual handling risks as much as possible.
- Provide manual handling training and information about the load.
- Supply personal protective equipment and mechanical assistance.
If you suffer a personal injury due to your employer’s breach of duty, you may be eligible to make a manual handling compensation claim.
Best practices for avoiding the most common workplace manual handling accidents
While employers have a legal duty to reduce risks, employees can also take practical steps to protect themselves from manual handling incidents, including:
- Use the available mechanical aids instead of lifting heavy items manually.
- Ensure there is adequate lighting, and the work area is free of hazards.
- Follow the HSE guidelines on safe lifting techniques.
- Use the provided PPE and take regular breaks to avoid fatigue and strain.
- Promptly report hazards and unsafe conditions.
What to do if you suffer a manual handling injury at work
If you suffer an injury from manual handling at work, you should:
- Report the incident to your supervisor immediately and make sure they log it in the company’s accident book.
- Gather evidence, such as photos of the accident scene and witness details.
- Seek medical attention promptly to have your injuries diagnosed and receive treatment.
- Seek legal advice from a specialist personal injury lawyer to discuss your entitlement to make a workplace accident claim.
Key takeaways
Manual handling accidents are a leading cause of workplace injuries. Some of the most common manual handling injuries include back injuries, musculoskeletal disorders, hand injuries, sprains, strains and hernias. Employers and employees must work together to mitigate the risks associated with manual handling and reduce the risk of injuries.
To find out if you can claim compensation for a manual handling injury, call 0800 470 0472 for a free case assessment or request a call back.
