Hazardous Manual Tasks

• Sustained force – occurs when force is applied continually over a period of time (e.g. pushing or pulling trolleys, carrying objects over long distances, holding down trigger on power tool, supporting plaster sheet while fixing to ceiling etc.)
• High force – occurs when increased muscle effort is required in response to a task (e.g. physically demanding jobs, requires stronger person or two people to complete or worker needs help to complete because a greater force is required)
• Sudden force – jerky or unexpected movements while handling an item or load (e.g. impact recoil of large nail gun, throwing or catching objects, cutting reinforced steel with bolt cutters etc.)
• Repetitive movement – using the same parts of the body to repeat similar movements over a period of time (e.g. painting, using tool to unscrew long bolts etc.)
• Sustained posture – where part of or the whole body is kept in the same position for a prolonged period (e.g. supporting plasterboard sheeting while it is nailed into place etc.)
• Awkward posture – where any part of the body is in an uncomfortable or unnatural position (e.g. squatting while doing a task, working with arms overhead etc.)
• Whole body vibration – occurs when vibration is transmitted through the whole body (e.g. operating mobile plant etc.)
• Hand-arm vibration – occurs when vibration is transferred through a vibrating tool, steering wheel or controls in heavy machinery to the hand and arm (e.g. using chainsaws, jackhammers, grinders, drills etc.)

Where Hazardous Manual Tasks are identified by subcontractors, consultants, suppliers, plant manufacturers, details of controls must be provided in the form of one or more of the following:

• Risk Assessment
• SWMS
• Skills and Competency Records
• Safe Work Instructions

When determining controls, consideration should be given to the following:

• Work tasks and how they are performed
• Work design and management
• Tools, equipment and objects handled
• Physical work environment

Hierarchy of Control

The hierarchy of control must be applied when considering controls to manage the risk associated with hazardous manual tasks.

• Elimination (e.g. automate the manual task by using technology; deliver goods directly to the point of use to eliminate multiple handling etc.)
• Substitution (e.g. replace heavy items with lighter, smaller or easier to handle items; replace hand tools with power tools; coordinate with suppliers to replace packaging with packaging designed to allow goods to be handled using powered plant etc.)
• Isolation (e.g. isolate vibrating machinery from the user e.g. fully independent seating on mobile plant etc.)
• Engineering (e.g. use mechanical lifting aids and trolleys; design the workplace to minimise the need to lift and move things etc.)
• Administrative (e.g. rotate workers between different tasks, provide training etc.)
• Personal Protective Equipment (e.g. anti-vibration gloves; shock-absorbent shoes for work on hard concrete floors etc.)

Work Area and Environment

Work areas and tasks should be designed and set up to assist in eliminating or minimising the risk factors associated with a hazardous manual task (e.g. the degree of reaching, twisting or bending).  The following should be considered:

• Tasks with high visual demands should be performed above elbow height and work surfaces may need to be tilted
• Tasks where the hands make a narrow range of movements and can rest on the work surface should be performed at, or just above, elbow height
• Tasks incorporating a range of arm movements using the shoulder should be performed at between hip and shoulder height
• Tasks requiring considerable muscular effort or use of the body for leverage should be performed at hip height and no higher

Where possible, place items used in manual tasks so they are:

• In front of the worker
• Between waist and shoulder height
• Close to the middle of the worker’s body, facing towards the worker and balanced
• On the worker’s preferred side
• Within comfortable reaching distance, and
• Positioned to avoid double handling and to avoid moving loads manually over long distances

Work should be organised to minimise multiple handling and improve the flow of work.  This may include:

• Having raw materials delivered, located or transferred mechanically to the location or work area where they will be used
• Using mobile plant to deliver materials, tools and items
• Locating storage areas close to distribution areas
• Distributing work across the shift or week to avoid high peak workloads 
• Asking suppliers to deliver items in a way that allows them to be used without the need for additional handling (e.g. use of a vertical frame)
• Allowing workers to control the pace for critical or physically demanding tasks

Handling Items and Loads

Control measures should minimise the risks to workers when handling loads including:

• Purchasing products in smaller loads for manual handling or arranging for larger loads to be shifted mechanically
• Reducing the size or capacity of containers
• Using handheld hooks or suction pads to move loads like sheet materials
• Using grip devices adapted to the particular object to be carried

Mechanical equipment may eliminate or reduce the need for workers to lift, carry or support items and may include:

• Cranes
• Lifting hoists
• Forklifts, platforms trucks, pallet trucks, telehandler, brick cages, lifting cages
• Lift tables, mechanical and hand stackers, lift trolleys, two-wheel elevating hand trucks, vacuum or magnet assisted lifters
• Glass panel, duct and plaster lifters
• Conveyors

Administrative Controls

Administrative control measures do not address the risk factors or source of the risk but can reduce risk by reducing workers’ exposure.  They include work methods such as:

• Job Rotation – Rotating people between different tasks to increase task variety.  Job rotation requires the tasks to be sufficiently different to ensure different muscle groups are used in different ways so they have a chance to recover
• Rest Breaks – Regular rest breaks provide opportunities for workers to prevent the build-up, or recover from the effects of, fatigue in muscle groups.  Generally, the greater the force required, or the longer a posture is sustained, the greater the recovery time needed.  More frequent and shorter rest breaks are better for rest and recovery than fewer, longer breaks.
• Team Handling – Manual handling of a load by two or more workers.  Team handling brings its own risks and requires coordination.  It should only be used until a more effective control can be implemented or for tasks that are undertaken rarely.

Definitions and Abbreviations

Hazardous manual task – a task that requires a person to lift, lower, push, pull, carry or otherwise move, hold or restrain any person, animal or thing that involves one or more of the following:

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

Musculoskeletal Disorder (MSD) – an injury to, or a disease of, the musculoskeletal system, whether occurring suddenly or over time.  It does not include an injury caused by crushing, entrapment or cutting resulting from the mechanical operation of plant.

References

• Work Health & Safety Regulation 2011 (QLD), 2012 (SA/TAS) and 2017 (NSW) – Part 4.2 Hazardous Manual Tasks
• Occupational Health and Safety Regulations 2017 (Victoria) – Part 3.1 Hazardous manual handling
• Hazardous manual tasks (Model Code of Practice)