MANUAL HANDLING TOOLBOX TALK
Assess loads correctly, lift safely and prevent unnecessary strain.
Use before lifting, carrying, pushing, pulling or manually positioning loads.
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Toolbox Topic
MANUAL HANDLING TOOLBOX TALK
Duration
8–10 MINUTES
Date
Site / Area
Supervisor
Company
Participants
Document No
OBJECTIVE
Prevent musculoskeletal injuries during lifting, lowering, carrying, pushing and pulling by assessing the task, load, working environment and individual capability before starting and by using mechanical assistance wherever practicable.
TOPIC EXPLANATION
Manual handling includes lifting, lowering, carrying, pushing, pulling, holding and repetitive movements.
The load's shape, grip points, stability, travel distance and effect on visibility must be considered, not only its weight.
Use forklifts, pallet trucks, cranes, trolleys or other mechanical aids whenever reasonably practicable.
Workers must not be pressured to lift a load that cannot be handled safely.
REALISTIC SITE SCENARIO
A worker attempts to lift an irregular 30-kilogram equipment part from the floor without assistance.
The load has poor grip points and materials obstruct the carrying route.
The worker twists while lifting and suffers a back injury.
REMEMBER
Being physically able to lift a load does not mean it should be lifted manually. If the load, distance, grip, working height or route is unsafe, use mechanical assistance or ask for help.
MAIN HAZARDS
Heavy, bulky, unstable or difficult-to-grip loads.
Bending, twisting or sudden lifting movements.
Long carrying distances or unsuitable working heights.
Hands and fingers trapped between the load and surrounding surfaces.
Loads restricting the worker's field of vision.
Slippery, uneven or obstructed carrying routes.
Repetitive lifting, pushing or pulling.
Tasks or loads exceeding individual physical capability.
KEY CONTROLS
Assess the task, load, environment and individual capability before starting.
Use forklifts, pallet trucks, cranes, trolleys or other mechanical aids wherever practicable.
Confirm the load weight, size, centre of gravity and grip points.
Inspect the carrying route and remove obstacles before movement.
Keep the load close to the body and maintain a stable stance.
Avoid sudden lifting and twisting the torso while carrying a load.
Plan team lifts in advance and use one person to coordinate movement.
Keep hands and fingers clear of trapping and pinch points.
Obtain assistance or change the method when the load restricts visibility.
Stop and reassess if fatigue, pain or loss of control develops.
SUPERVISOR SCRIPT
Team, today we will assess more than the weight of anything we move manually. Consider the load shape, grip points, centre of gravity, carrying distance, route and working height. Use mechanical assistance whenever it is available and suitable. If the load blocks your view, cannot be controlled safely or requires more than one person, do not force the lift. During team handling, one person will coordinate the movement and everyone will keep hands clear of pinch points.
QUESTIONS FOR THE TEAM
Can you safely control this load alone?
Where is the load's centre of gravity?
Is the carrying route clear?
Is mechanical assistance or a second worker required?
Does the load restrict your view?
VERIFY BEFORE STARTING
The load and handling method have been assessed.
The carrying route is clear.
Required mechanical aids are available.
Team-lifting roles are agreed where required.
Suitable PPE is being used.
ATTENDANCE AND RECORD
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Signature
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Supervisor Signature
HSE Approval
SERNEM HSE Resource — Ergonomic assessments, mechanical-handling options, risk assessments and site procedures take priority.