Why Hazardous Manual Tasks Matter 

Hazardous manual tasks are one of the most common causes of workplace injuries in Australia. Workers across many industries – including manufacturing, warehousing, hospitality, construction, healthcare, transport, and office environments – are exposed to tasks that can lead to musculoskeletal disorders (MSDs). 

Musculoskeletal disorders can include: 

• Back injuries 
• Muscle strains and sprains 
• Joint injuries 
• Shoulder and neck pain 
• Repetitive strain injuries 
• Damage to muscles, tendons, ligaments, nerves, or discs 

These injuries can develop suddenly from a single task or gradually over time due to repeated exposure. 

The Hazardous Manual Tasks Code of Practice provides practical guidance for businesses on identifying, assessing, controlling, and reviewing risks associated with hazardous manual tasks in the workplace. 

What Is a Hazardous Manual Task? 

A hazardous manual task is a task that requires a person to lift, lower, push, pull, carry, move, hold, or restrain an object, person, or animal and involves one or more risk factors that may contribute to injury. 

Examples include: 

• Lifting heavy boxes 
• Repetitive packing work 
• Pushing loaded trolleys 
• Handling patients or residents 
• Working in awkward positions 
• Repeated bending, twisting, or reaching 
• Carrying tools or materials over long distances 
• Using forceful movements repeatedly 

The Legal Requirements 

Under Work Health and Safety (WHS) legislation in Australia, businesses have a duty to eliminate risks to health and safety so far as is reasonably practicable. 

If risks cannot be eliminated, they must be minimised. 

The Hazardous Manual Tasks Code of Practice supports these legal obligations by providing guidance on how organisations should manage the risks associated with hazardous manual tasks. 

This includes: 

• Identifying hazardous manual tasks 
• Assessing the risk of injury 
• Implementing control measures 
• Reviewing the effectiveness of controls 
• Consulting workers throughout the process 

Identifying Hazardous Manual Tasks 

Businesses should regularly review work activities to identify tasks that may pose injury risks to workers. 

Common warning signs include: 

• Workers reporting discomfort or fatigue 
• Frequent lifting or carrying tasks 
• Repetitive work performed for long periods 
• Tasks requiring awkward body positions 
• High force activities 
• Workers rushing due to production demands 
• Previous incidents or injury reports 
• Staff absenteeism linked to physical strain 

Consulting workers is critical during this process because they often understand the challenges and risks involved in their day-to-day tasks. 

Understanding the Key Risk Factors 

The Code of Practice identifies several common risk factors that increase the likelihood of injury. 

Repetitive Movements 

Tasks that involve the same movement repeatedly over extended periods can place strain on muscles and joints. 

Example: 

A worker is repeatedly packing products on a production line for several hours without rotation or breaks. 

Sustained or Awkward Postures 

Working in awkward positions can place stress on the body. 

Example: 

A worker bending repeatedly to access materials stored at floor level. 

Forceful Exertions 

Tasks requiring high force increase the risk of injury. 

Example: 

Pushing heavy carts across uneven surfaces. 

Exposure to Vibration 

Using vibrating tools or equipment for extended periods may increase the risk of injury. 

Example: 

Operating jackhammers or vibrating hand tools. 

Handling Unstable or Difficult Loads 

Loads that are difficult to grip, awkwardly shaped, or unpredictable increase the risk. 

Example: 

Handling large sheets of material or moving patients without assistance. 

Assessing the Risks 

Once hazardous manual tasks are identified, the business should assess the risks to determine: 

• How likely is an injury to occur 
• The severity of potential injuries 
• Which workers are exposed 
• How often the task is performed 
• Whether existing controls are effective 

Risk assessments should consider: 

• The nature of the task 
• The work environment 
• The equipment used 
• The load being handled 
• The individual performing the work 

Controlling Hazardous Manual Task Risks 

The Code of Practice encourages businesses to apply the hierarchy of control when managing risks. 

Eliminate the Hazard 

The most effective control is removing the hazardous task entirely. 

Example: 

Using automated lifting equipment instead of manual lifting. 

Substitute the Task or Equipment 

Replace hazardous processes or equipment with safer alternatives. 

Example: 

Using smaller containers to reduce lifting weight. 

Engineering Controls 

Modify the workplace or equipment to reduce physical strain. 

Examples include: 

• Adjustable workstations 
• Mechanical lifting aids 
• Conveyor systems 
• Trolleys and pallet jacks 
• Improved storage layouts 

Administrative Controls 

Implement safe work procedures and work practices. 

Examples include: 

• Job rotation 
• Safe work procedures 
• Task variation 
• Adequate rest breaks 
• Training and supervision 
• Planned lifting techniques 

Personal Protective Equipment (PPE) 

PPE should not be relied on as the primary control for hazardous manual tasks, but may support other controls where appropriate. 

The Importance of Consultation 

The WHS legislation and Codes of Practice emphasise the importance of consulting workers when identifying and managing risks. 

Workers should be involved in: 

• Identifying hazardous tasks 
• Discussing practical solutions 
• Trialing new equipment or controls 
• Reviewing whether controls are effective 

Consultation helps improve worker engagement and increases the likelihood that controls will be followed. 

Training and Supervision 

Workers should receive appropriate training on: 

• Hazardous manual task risks 
• Safe work procedures 
• Correct use of equipment 
• Reporting hazards and injuries 
• Early reporting of discomfort or pain 

Supervisors should monitor work practices and ensure controls are being followed consistently. 

Reviewing Control Measures 

Control measures should be reviewed regularly to ensure they remain effective. 

Reviews should occur when: 

• An injury or incident occurs 
• Workers report discomfort or concerns 
• Work processes change 
• New equipment is introduced 
• A review identifies that controls are not working effectively 

Continuous improvement is an important part of managing risks associated with hazardous manual tasks. 

Practical Examples of Hazardous Manual Task Controls 

Manufacturing Workshop 

Risk: Workers manually lifting heavy steel components. 

Control Measures: 

• Install overhead lifting devices 
• Use adjustable workbenches 
• Store materials at waist height 
• Rotate workers between tasks 

Hospitality Industry 

Risk: Staff carrying heavy boxes and repetitive tray handling. 

Control Measures: 

• Use trolleys for deliveries 
• Reduce box weights 
• Improve storage layout 
• Provide manual handling training 

Healthcare Environment 

Risk: Manual patient handling. 

Control Measures: 

• Use patient lifting equipment 
• Implement team lifting procedures 
• Provide ongoing competency training 

Why Businesses Should Take Hazardous Manual Tasks Seriously 

Poor management of hazardous manual tasks can result in: 

• Workplace injuries 
• Lost productivity 
• Workers’ compensation claims 
• Increased absenteeism 
• Reduced worker morale 
• Regulatory investigations or penalties 

Effective management helps create a safer workplace while improving productivity and worker wellbeing. 

Final Thoughts 

The Hazardous Manual Tasks Code of Practice provides businesses with practical guidance to help reduce injuries and improve workplace safety.

Managing these risks is not just about compliance—it is about protecting workers from preventable injuries that can have long-term impacts on their health and ability to work.

Businesses should take a proactive approach by identifying hazardous tasks early, consulting workers, implementing practical controls, and regularly reviewing workplace practices.

If your organisation needs support in managing hazardous manual task risks or improving workplace safety systems, you can contact our WHS specialists for guidance and support: https://www.chdpartners.com.au/contact-us/

By doing so, organisations can create safer and more productive workplaces while meeting their legal obligations under Australian Work Health and Safety legislation.

References 

• Safe Work Australia – Hazardous Manual Tasks Code of Practice https://www.safeworkaustralia.gov.au/doc/model-code-practice-hazardous-manual-tasks  

• Safe Work Australia guidance materials relating to musculoskeletal disorders and manual handling https://www.safeworkaustralia.gov.au/safety-topic/hazards/lifting-pushing-and-pulling-manual-tasks 

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