Materials handling is one of  most injury-prone industries in the country. Due to the nature of the work, material handlers often perform strenuous manual labor to complete daily tasks. Lifting, pulling, or pushing heavy objects can result in injuries, frequently to the low back. Lumbar pain is the single-leading cause of disability worldwide. Serious back injuries occur most commonly when these improper lifting techniques are used, such as:

• Bending repeatedly and bending from the waist to pick up objects, as this technique puts too much strain on a worker’s lower spine.  Bending at the waist causes strain to supportive soft tissues and moves vertebrae out of alignment. It can also cause the discs that accentuate the spine to be squeezed from the front and move backward.
• Reaching too high and lifting boxes above the chest, as this activity can cause the top of the shoulder blade to pinch at the muscles of the rotator cuff. The repetitive motion can lead to overload on the tendons, eventually developing tendonitis.
• Twisting the body to carry or lift a heavy box or object, as twisting can cause muscle spasms, overstretched ligaments, and spinal injuries. Ongoing inflammation and muscle tightness can persist for extended periods, especially if the worker continues to perform twisting movements repeatedly.

Learning how to lift, pull or push a heavy object correctly is integral in preventing injuries.  Providing a safe environment for employees can curtail accidents from occurring in the workplace and can be achieved by implementing a few safety guidelines:

1. Use Correct Bending Technique

• Advise workers to lift with their legs rather than at the waist. Lifting with the knees and legs provides the power and stability needed to move weights without hurting the back. Try to minimize the need for bending in the workspace by placing heavy objects on shelves, tables, and racks for easier access.
• Use good grip and utilize gloves – if they allow for a better grip. Grasp the load firmly and lift it toward the belt buckle. Hold the load close to the body to avoid putting pressure on the back.
• Center the body weight to provide a powerful line of thrust and good balance.
• Raise, carry and lower the load smoothly. Never try to pick up or lower a load too fast.
• If turning is required while lifting or carrying a load, move the feet to turn the body instead of twisting at the waist. 
• Push rather than pull the load as pulling a load strains the back.

2. Use Materials Handling Gear

• Offer special gear like weight belts to provide extra support to the workers lower backs. Lifting straps could also help control and support irregular items.
• Use machinery or equipment, such as a pushcart, hand truck, wheelbarrow, dolly or front-end loader for lifting large and heavy items.  
• Train the employees in the use of these lifts, hoists and other equipment and require them to do so for appropriate loads.  

3. Plan the Workflow to Eliminate Unnecessary Risks

• Position pallet loads at the right height, so that workers lift and lower within the power zone between waist and chest level. Arrange packaging, processing, delivery and material handling systems so that heavy loads are lifted and carried near the waist, between knee-and-shoulder height. When possible, set heavy objects on pallets, benches or other supports, not on the ground as it is nearly impossible to achieve a good back position when lifting heavy objects from the ground.
• Assess the load to be sure it can be safely carried. Find unstable or heavy loads and tag them for extra care – encourage employees to evaluate the load for stability before picking it up and carrying it.  If the load is too heavy, awkward or bulky to carry alone, get help.
• Reduce the weight of the load, by putting fewer items in the containers, using smaller containers, or repacking the containers. 
• Plan ahead to avoid slip or trip hazards, and to determine the destination of the load.
• Rotate workers between lifting and non-lifting tasks to prevent repetitive overexertion.

Utilizing safe material-handling techniques can help workers safeguard their health and well-being on and off the work site. By protecting employees from injuries with the enforcement of safety guidelines and equipping them with quality tools, a business will enhance morale, productivity, and reduce the costs associated with workplace injuries and labor turnover.

For additional information about this topic, please contact Agnes Stucke or any member of our Workplace Solutions team at Ice Miller.

This publication is intended for general information purposes only and does not and is not intended to constitute legal advice. The reader must consult with legal counsel to determine how laws or decisions discussed herein apply to the reader's specific circumstances.