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Hazardous Manual Tasks

What are Hazardous Manual Tasks?​

Hazardous manual tasks are tasks that require a person to lift, lower, push, pull, carry or otherwise move, hold or restrain any person, animal or thing that involves risk of musculoskeletal disorder (MSD).

Common Construction Examples:

  • Lifting and carrying materials (bags of cement, timber, bricks)
  • Placing and tying reinforcement steel (rebar)
  • Laying pavers or blocks
  • Operating jackhammers or compactors (vibration)
  • Repetitive nail gunning or screwing
  • Prolonged awkward postures (overhead work, confined spaces)

What are Musculoskeletal Disorders?​

MSDs are injuries or disorders of muscles, tendons, ligaments, joints, nerves, blood vessels or related soft tissues.

Common MSDs in Construction:

  • Back injuries (strains, disc problems)
  • Shoulder injuries (rotator cuff, bursitis)
  • Neck pain
  • Knee problems
  • Hand/wrist injuries (carpal tunnel syndrome, tendonitis)

[!warning] Long-Term Impact MSDs develop over time through repeated exposure. Early symptoms (discomfort, aching) indicate risk and need addressing.

Risk Factors for MSDs​

Characteristics of Hazardous Manual Tasks​

1. Repetitive or Sustained Force

  • Lifting heavy loads repeatedly
  • Sustained gripping or pinching
  • Repetitive movements (hammering, cutting)

Repetitive force - bricklaying

2. High or Sudden Force

  • Lifting very heavy items
  • Jerking or snatching loads
  • Catching falling objects
  • Impact forces (jackhammer vibration)

3. Repetitive Movement

  • Performing same movement repeatedly
  • Example: Repetitive bricklaying, screw driving, grinding

4. Sustained or Awkward Postures

  • Bending forward (tying steel, placing pavers)
  • Reaching overhead (ceiling work)
  • Kneeling or squatting (tiling, waterproofing)
  • Twisting (turning with load)
  • Working in confined spaces

Sustained posture - plasterboard

5. Exposure to Vibration

  • Hand-arm vibration (grinders, drills, breakers)

Vibration

  • Whole-body vibration (operating heavy plant)

Who Has Duties?​

PCBUs​

Must:

  • Identify hazardous manual tasks
  • Assess MSD risks
  • Eliminate or minimize risks
  • Consult with workers
  • Provide information and training
  • Review controls

Designers, Manufacturers, Suppliers​

Must:

  • Design to eliminate/minimize manual handling
  • Consider weight, size, shape of products
  • Provide handling information

Risk Management Process​

1. Identify Hazardous Manual Tasks​

Methods:

  • Observe work activities
  • Talk to workers (discomfort surveys)
  • Review injury/incident reports
  • Check design/planning documents

Construction-Specific Indicators:

  • Materials supplied in heavy units (cement bags, pavers)
  • Repetitive tasks (bricklaying, fixing)
  • Confined or restricted work areas
  • Overhead or below-knee work required

2. Assess Risks​

When to Assess:

  • When hazardous task identified
  • Before introducing new tasks, equipment, layouts
  • After MSD injuries reported
  • When workers report discomfort

What to Consider:

  • Loads: Weight, size, shape, stability
  • Actions: Postures, movements, duration, frequency
  • Workspace: Layout, heights, access, lighting
  • Environment: Surfaces, weather, space constraints
  • Worker: Training, experience, fatigue

3. Control Risks: Hierarchy of Control​

Level 1: Elimination

  • Eliminate need for manual task entirely
  • Example: Pre-mixed concrete delivery eliminates mixing bags on-site

Level 2: Substitution/Engineering

Mechanical Aids:

  • Forklifts, cranes, hoists for lifting
  • Trolleys, wheelbarrows for transporting
  • Conveyors for moving materials
  • Elevated work platforms instead of ladders

Example: Use telehandler to lift pallet of bricks to upper level instead of manual carrying.

Redesign Task:

  • Reduce weight/size of loads (smaller cement bags, lighter blocks)
  • Improve layout (materials closer to work area)
  • Adjust work heights (raise/lower to reduce bending)
  • Provide better access (platforms, pathways)

Example: Store formwork materials at waist height on racks instead of on ground.

Use Tools and Equipment:

  • Mechanical lifting devices
  • Slide sheets or rollers
  • Adjustable height benches
  • Power tools to reduce force

Level 3: Administrative Controls

  • Job rotation to vary tasks and postures
  • Task pacing (rest breaks, varied work)
  • Team lifting for heavy/awkward loads
  • Training in safe lifting techniques

[!tip] Team Lifting For loads that are heavy, awkward, or exceed individual capacity (risk assessed), use two or more workers. Coordinate lift with clear signals.

Level 3: PPE

PPE does not control manual handling risks. Focus on higher-level controls.

(Note: Supportive devices like back belts are not effective and not recommended)

4. Review Controls​

Review when:

  • Control measures not effective
  • MSDs or discomfort reported
  • Work processes change
  • New equipment or layout

Practical Construction Examples​

Example 1: Laying Concrete Blocks​

Hazard:

  • Blocks weigh 15-20kg each
  • Repetitive lifting from ground level
  • Bending and twisting
  • Several hundred blocks per day

Controls:

Engineering:

  • Deliver blocks on pallets with forklift
  • Position pallet close to work area (reduce carrying distance)
  • Elevate pallet on trestles to waist height (eliminate bending)
  • Provide adjustable scaffold for working at height

Administrative:

  • Job rotation (alternate between laying and other tasks)
  • Two workers team-laying for speed and reduced individual load
  • Adequate breaks

Result: Significantly reduced bending and twisting, load easier to grasp from waist height.

Example 2: Tying Reinforcement Steel​

Hazard:

  • Sustained bending and squatting
  • Repetitive twisting motion (thousands per day)
  • Awkward hand positions

Controls:

Engineering:

  • Use clip-on bar ties instead of manual wire tying (faster, less repetitive)
  • Battery-powered rebar tying gun (eliminates manual twisting)
  • Work platforms to raise worker position where practicable

Administrative:

  • Job rotation to reduce daily exposure
  • Training in neutral postures

Result: Manual twisting eliminated, reduced bending time.

Example 3: Moving Plasterboard Sheets​

Hazard:

  • Sheets 2.4m x 1.2m, weight 20-30kg
  • Awkward to handle (large, unwieldy)
  • Carrying required (often up stairs/ladders)

Controls:

Engineering:

  • Panel hoist/lifter to move and position sheets
  • Storage racks at appropriate height
  • Material hoist to upper floors (eliminate manual carrying up stairs)

Work Organization:

  • Deliver materials as close to installation point as possible
  • Two-person team for manual handling when hoist unavailable

Result: Eliminates most manual carrying, significantly reduces awkward postures.

Special Considerations​

Working Overhead​

Risks:

  • Shoulder and neck strain
  • Arm fatigue
  • Difficulty controlling loads above head

Controls:

  • Elevate work platform to bring work to chest/waist height
  • Use mechanical aids (ceiling panel lifters)
  • Limit duration of overhead work
  • Provide armrests or supports

Working at Ground Level​

Risks:

  • Prolonged bending, kneeling, squatting
  • Back and knee strain

Controls:

  • Raise work height (platforms, adjustable benches)
  • Knee pads for kneeling tasks
  • Kneeling stools or creepers
  • Vary postures regularly

Confined Spaces​

Risks:

  • Restricted postures
  • Difficulty using mechanical aids
  • Limited access for materials

Controls:

  • Pre-assemble components outside confined space where possible
  • Use smaller, lighter materials
  • Provide adequate access for material delivery
  • Limit time in confined space

Information and Training​

Workers should be trained in:

  • Recognizing hazardous manual tasks and MSD risks
  • How to use mechanical aids and equipment
  • Safe work practices for unavoidable manual tasks
  • Importance of reporting discomfort early
  • Warm-up and stretching (supplement to controls, not substitute)