Despite advances in awareness and technology, manual handling injuries remain one of the leading causes of workplace absence and compensation claims in the UK, the Royal Society for the Prevention of Accidents (RoSPA) said.
According to the Health and Safety Executive (HSE), 543,000 workers suffered from musculoskeletal disorders (MSDs) in 2023-2024, resulting in 7.8 million lost workdays. Many of these MSDs are directly linked to poor manual handling practices, with 32% of work-related ill health attributed to MSDs and 17% of non-fatal injuries resulting from lifting, carrying, or handling activities.
Once organisations have taken steps to avoid, assess, and reduce manual handling risks, it is crucial to provide thorough and ongoing training for all employees involved in essential handling tasks. One of the most common mistakes is offering training only once, typically at induction, without any follow-up. Good practices can fade quickly under real-world working pressures, and without regular refresher sessions, unsafe habits and injury risks increase.
Key challenges
Another frequent issue is failing to tailor training to specific sectors or roles. Generic training that does not reflect the tasks employees perform—whether in a warehouse, on a construction site, or in care settings—fails to connect and protect staff effectively. Using real-life scenarios and investing in trainers who can customise sessions to different departments improves relevance and impact.
Organisations also risk relying on outdated techniques that do not align with current understanding of biomechanics and risk. Working with qualified trainers who follow up-to-date HSE and evidence-based guidance, and regularly auditing training materials, ensures employees learn safe and effective methods.
It is equally important to include team leaders and supervisors in training. Managers influence workplace behaviour and, if untrained, unsafe practices can become the norm. Training supervisors to recognise poor technique, correct unsafe practices, and support injured staff fosters a culture of safety rather than simply enforcing productivity.
Finally, organisations often overlook the need to develop internal expertise. Relying solely on external trainers can be inefficient, especially in industries with high staff turnover. Identifying internal staff to complete recognised qualifications allows consistent, cost-effective delivery of manual handling training across teams.
Manual handling training is not just a compliance requirement, it is essential for protecting workforce wellbeing, maintaining productivity, and reducing costly claims. Investing in the right training, at the right time, and for the right people can significantly reduce both risk and cost. The information in this article is provided by
