Manual handling

Lifting, pushing, pulling, lowering or carrying loads beyond worker capacity causing acute injury (strain, hernia) or cumulative musculoskeletal disorder. The single most common injury class in construction.

Controls (hierarchy of controls order)

1. Engineering controls

   Residual LOW

   Mechanical lifting aids (crane, hoist, trolley, vacuum)

   Where load > 25 kg or shape awkward or movement repetitive, use mechanical aid: crane, builder's hoist, pallet trolley, brick clamp, vacuum lifter, gantry crane.

   Cited: WHS Reg 60 · Hazardous Manual Tasks CoP

2. Administrative controls

   Residual MEDIUM

   Two-person lift / load splitting

   Loads above 23 kg single-person limit (or above worker-specific capacity) lifted by two workers or split into smaller units. Lift coordinator nominated for awkward loads.

   Cited: Hazardous Manual Tasks CoP s 3

3. Administrative controls

   Residual MEDIUM

   Manual handling training + warm-up

   All workers complete documented manual handling training including risk assessment, hierarchy of controls, safe lifting technique; daily pre-start warm-up; refresher every 12 months.

   Cited: WHS Reg 39 · Hazardous Manual Tasks CoP s 5

PPE

• Cut-resistant gloves (Level 5) — EN 388 Level 5 cut-resistant gloves for handling sheet metal, glass, sharp tools; replace when worn or contaminated.Standard: AS/NZS 2161.2
• Steel-cap safety boots — Type 1 safety footwear with steel toecap, slip-resistant sole, ankle support; electrical hazard rating where exposed to live electrical work.Standard: AS/NZS 2210.3
• Industrial safety helmet — Type 1 industrial safety helmet with chin strap where required by site rules or wind exposure. Replace at expiry date or after impact.Standard: AS/NZS 1801