Take the Strain Out of Manual Handling
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Published February 2026 – source: WorkSafe Victoria
Original article: Take the strain out of manual handling (worksafe.vic.gov.au)
The biggest injury problem no one talks about enough
Manual handling isn’t just a back injury waiting to happen. It’s actually the leading cause of workplace injuries in Victoria, with 48,355 injury claims accepted since 2021.
More than 60 per cent of these are musculoskeletal disorders, things like sprains, strains, back injuries, soft tissue damage and chronic pain.
That’s not just a bad day at work. These injuries can stick around for years and seriously affect someone’s quality of life.
It’s not just heavy lifting
Most people hear “manual handling” and think lifting something heavy. Reality is way broader.
WorkSafe points out it includes:
- Awkward postures
- Repetitive movements
- Sustained force over time
Even simple tasks like stacking, reaching or repetitive motions can slowly wreck the body if the risks aren’t managed properly.
So yeah, you don’t need to be in a warehouse to be at risk. Office, healthcare, construction, it shows up everywhere.
Where the risk is highest
Certain industries are getting hit harder than others.
Almost 40 per cent of manual handling related injuries over the past five years came from:
- Manufacturing
- Healthcare and social assistance
Makes sense when you think about it. Repetitive tasks, lifting, supporting people, long shifts, it adds up fast.
What WorkSafe is doing about it
To tackle the issue, WorkSafe is pushing its Manual Handling Basics workshops, which give businesses practical ways to:
- Spot hazardous manual handling
- Understand the risks
- Apply proper controls before injuries happen
These programs are designed especially for small to medium workplaces to build real world safety habits, not just tick a compliance box.
What actually helps
If you strip it back, preventing these injuries isn’t rocket science. It’s just consistency and awareness:
- Redesign tasks to reduce strain
- Use mechanical aids where possible
- Avoid repetitive or awkward movements
- Train workers properly from day one
Employers are also legally required to identify and control manual handling risks as far as reasonably practicable, not just react after someone gets hurt.
The bigger picture
Manual handling injuries are slow burners. They don’t always show up instantly, but once they do, they can stick around for life.
This is one of those areas where doing the basics well actually makes the biggest difference. No fancy systems needed, just smarter work design and proper attention to how tasks are done.
TL;DR
- Manual handling is the top cause of workplace injuries in Victoria with over 48k claims since 2021
- Most injuries are musculoskeletal issues like strains and back injuries
- It’s not just lifting, it includes repetitive work and awkward postures
- Manufacturing and healthcare are hit hardest
- Training, better task design and early prevention are the real fix
Commentary by Ray Boekelaar (Senior certified OHS/WHS Safety Consultant for www.solvesafety.com.au)
Ray Boekelaar is more than just a career “work retired” grandfather, father, and blogger, who loves AWD-SUV semi off road adventure camper traveling the highways and byways throughout the vast states and territories of the Australian continent. When he is not doing some casual OHS Safety or Real Estate Consulting for these respective organisations, as a “key opinion leader” (KOL) you will find him in between times trip planning historical tourist destinations and heading out into the sunset, on his next of many scheduled road touring travel adventures.
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