8 Most Common Types of Manual Handling Injuries

It is very common to sustain injuries at work for people who have a job in construction, warehouses, healthcare, manufacturing, retail, factories and many other industries. When you constantly perform a lot of lifting, carrying, pushing, pulling, or supporting, the chances of something going wrong and sustaining an injury are high, especially when you need to do the tasks quickly or under pressure. 

Manual Handling Injuries Statistics

This is why manual handling injuries are a common cause of time off work, reduced productivity, and long-term discomfort or injuries. Below, we look at the injuries that occur most often, how they happen, and what they can mean for workers.

According to the Health and Safety Executive approximately 120,000 people were injured at work from manual handling incidents last year. Over 30% of food and drink industry injuries reported to HSE are manual handling injuries such as back injuries, this represents around 1700 acute injuries per year. Manual handling injuries are caused by handling and lifting – 60% of the injuries involve lifting heavy objects.

1. Back Injuries

Back injuries are the most common type of manual handling injuries. This is because this area absorbs the majority of the strain when lifting heavy or awkward loads, twisting suddenly, or working in poor postures for long periods. Back injuries can create ongoing health issues when not treated on time, and items are handled incorrectly. This is why it’s important to ensure your employer provides adequate manual handling training and you do not lift more than the recommended weight compared to your own weight and size.

2. Neck Injuries

You risk damaging your neck if you have a role that involves repetitive lifting, you use poor posture, or hold loads away from the body. Sudden movements or jerking motions can also strain the neck muscles and surrounding joints. Some common neck injuries are:

• Muscle strains
• Whiplash-type injuries
• Nerve compression
• Stiffness and reduced movement
• Headaches linked to neck tension

Even if some neck injuries might start as mild discomfort, they can worsen over time if not addressed and lead to long-term pain and mobility issues.

3. Shoulder Injuries

The shoulders take on much of the force during lifting and carrying tasks, making them highly vulnerable during manual handling work. If you lift a load incorrectly or one that’s too heavy, you could pull or tear muscles and ligaments, potentially leading to a shoulder dislocation. 

4. Strains and Sprains

Strains affect muscles or tendons, while sprains involve ligaments around joints. They often occur when lifting items that are too heavy, moving loads suddenly, working in cramped spaces, or losing grip on an object. If you suffer from any of these two, it could lead to a chronic condition. This often happens to the arms, wrists or back.

5. Slips, Trips and Falls

Manual handling increases the risk of slips, trips, and falls, especially if workers carry loads that block their view, walk on uneven or wet surfaces, rush to meet deadlines, or work in cluttered areas. 

Falls can cause a wide range of injuries, such as head trauma, broken bones, spinal injuries, and damage to soft tissue such as muscles and ligaments.

6. Musculoskeletal Disorders (MSDs)

Musculoskeletal disorders develop gradually due to repetitive tasks, sustained force, vibration, or awkward working positions. They are among the most common long-term manual handling injuries and are not obvious immediately. 

Some conditions are tendonitis, carpal tunnel syndrome, chronic back pain, shoulder bursitis, and joint inflammation. Symptoms often begin as mild aches and progress over time if working conditions do not improve or you keep handling items incorrectly.

7. Lacerations and Cuts

Handling tools, machinery, packaging materials, or sharp objects can result in cuts, bruising, crushed fingers or toes, and broken bones in the arms, legs, wrists, or ribs. These injuries can happen if loads shift unexpectedly, are dropped, or if proper protective equipment is not used. If you want to avoid this, try to lift the objects only allowed based on your size and weight carefully and correctly, without rushing.

8. Hernias

Hernias occur when internal tissue pushes through a weak area of muscle. They are commonly caused by lifting heavy objects incorrectly, sudden increases in pressure on your body, or repeated physical strain over time. A hernia may start as mild discomfort but can become painful and often requires medical treatment or surgery.

Get Legal Advice If You’ve Suffered A Manual Handling Injury

If you’ve experienced any of the injuries above as a result of manual handling at work, you may be entitled to claim compensation. ASD specialises in workplace injury claims and can advise you on your options in clear, practical terms.

Contact us and get help with your compensation claim on a no-win no no-fee basis.

Other Common Manual Handling Injuries

Some additional injuries that could occur while handling items at work are:

• Knee injuries from squatting and lifting
• Wrist and hand injuries from gripping heavy or vibrating equipment
• Foot injuries from dropped objects
• Fatigue-related injuries due to long shifts and poor recovery time

Duties of Employers

4.—(1) each employer shall—

(a) so far as is reasonably practicable, avoid the need for his employees to undertake any manual handling operations at work which involve a risk of their being injured; or

(b) where it is not reasonably practicable to avoid the need for his employees to undertake any manual handling operations at work which involve a risk of their being injured—

1. i) make a suitable and sufficient assessment of all such manual handling operations to be undertaken by them, having regard to the factors which are specified in column 1 of Schedule 1 to these Regulations and considering the questions which are specified in the corresponding entry in column 2 of that Schedule,

(ii) take appropriate steps to reduce the risk of injury to those employees arising out of their undertaking any such manual handling operations to the lowest level reasonably practicable, and

(iii) take appropriate steps to provide any of those employees who are undertaking any such manual handling operations with general indications and, where it is reasonably practicable to do so, precise information on—

(aa)  weight of each load, and

(bb) the heaviest side of any load whose centre of gravity is not positioned centrally.

(2) Any assessment such as is referred to in paragraph (1)(b)(i) of this regulation shall be reviewed by the employer who made it if—

(a) there is reason to suspect that it is no longer valid; or

(b) there has been a significant change in the manual handling operations to which it relates;

And where as a result of any such review changes to an assessment are required, the relevant employer shall make them.

“Manual handling operations” = any transporting or supporting of a load (including the lifting, putting down, pushing, pulling, carrying or moving thereof) by hand or by bodily force.

Duty of Employees

5.  Each employee while at work shall make full and proper use of any system of work provided for his use by his employer in compliance with regulation 4(1)(b)(ii) of these Regulations.

What do the Manual Handling Operations Regulations require?

The Regulations require employers to:

• Avoid the need for hazardous manual handling, ‘so far as is reasonably practicable’;
• Assess the risk of injury from any hazardous manual handling that can’t be avoided;
• Reduce the risk of injury from hazardous manual handling, ‘so far as is reasonably practicable’.

The Regulations do not set specific requirements such as weight limits.

While weight is an important factor, there are many other risk factors which you need to take into account. Where hazardous manual handling cannot be avoided, the Regulations require a risk assessment to determine the risk of manual handling injury and to help identify what remedial action is required. Medical and scientific knowledge stress the importance of an ergonomic approach to manual handling, taking into account the nature of the task, the load, the working environment and individual capability, and this approach requires worker participation. It is central to the European Directive on manual handling and to the Regulations.

Why Manual Handling Injuries Happen So Often

Manual handling injuries can happen due to various reasons. This could be:

• Inadequate training
• Heavy workloads
• Poor workplace layout
• Lack of lifting aids
• Time pressure
• Fatigue
• Inadequate work environment
• Wet or uneven surfaces

Even experienced workers are vulnerable when safety procedures are overlooked or proper training is not provided.

How To Reduce The Risk Of Manual Handling Injuries

Prevention is always better than treatment. You can lower the risk of getting injured:

• Providing regular manual handling training
• Using mechanical aids where possible
• Improving workstation design
• Keeping walkways clear
• Encouraging regular breaks
• Promoting early reporting of discomfort

FAQs 

What is the most common manual handling injury?

Back injuries are the most common, particularly lower back strain and disc problems caused by lifting heavy or awkward loads. They need to be treated on time or there is risk of becoming chronic

Can manual handling injuries become long-term?

Yes. Many injuries caused by wrong or repetitive manual handling, especially musculoskeletal disorders and spinal damage, can become chronic if not treated early or if the same work conditions continue.

What jobs have the highest risk of manual handling injuries?

High-risk roles include warehouse workers, construction workers, nurses and carers, delivery drivers, factory workers, and retail stock handlers.

What should I do if I think I have a manual handling injury?

If you sustained a manual handling injury, you should report the injury to your employer as soon as possible, seek medical advice, and avoid continuing tasks that worsen the pain.