Top 5 Manual Handling Mistakes That Are Costing You Thousands

Let’s not sugar-coat it.

Manual handling injuries are rinsing businesses of cash every single day. Twisted backs. Slipped discs. Days off work. Comp claims. Lost productivity. And the best part? Almost every single one of them could’ve been avoided.

Here are the top 5 manual handling mistakes we see all the time—if any of these are happening in your workplace, it’s not a matter of if someone’s going to get hurt… it’s when.

1. Still Lifting With Your Back, Not Your Brain

You’d think we’d be past this by now. But nope—staff are still bending over like they’re picking up a penny at the pub. No technique. No training. Just brute force and wishful thinking.

The result? Musculoskeletal injuries that wipe workers out for weeks.

👉 Fix it: Proper manual handling training. Not a tick-box e-learning course—real, hands-on training tailored to the tasks at hand.

2. No Trolleys, No Aids… Just Bad Decisions

You’ve got employees carrying 30kg loads across the site by hand because "the trolley’s got a wonky wheel." Meanwhile, management is scratching their heads wondering why absence rates are through the roof.

Sound familiar?

👉 Fix it: Invest in basic handling equipment. It’s cheaper than a lawsuit and a hell of a lot cheaper than long-term sick pay.

3. Throwing the New Guy Into the Deep End

“Here’s the job, mate. Crack on.”

No induction. No risk assessment. Just vibes and a hernia.

Manual handling injuries often happen to the newest staff—because no one bothered to show them how to do it right.

👉 Fix it: Clear processes. Visual guides. Supervision until they’ve got it down.

4. Ignoring the Environment

Wet floors. Tight corners. Uneven surfaces. And you’ve got Dave trying to carry an awkward load while dodging pallets like he’s on Total Wipeout.

It’s not just how they lift—it’s where they lift.

👉 Fix it: Assess the route before the lift. Clear the hazards. Make it safe.

5. Outdated Risk Assessments (Or None at All)

A manual handling risk assessment from 2019 won’t help when the warehouse layout changed last month.

No assessment = no control = wide open risk.

👉 Fix it: Update your risk assessments regularly. Anytime tasks, equipment, or environments change—your paperwork needs to catch up.

Here’s the Truth…

You don’t get bonus points for “toughing it out.”You don’t save money by skipping training or avoiding proper equipment. You lose money. Quietly. Consistently. And painfully.

At SJH Safety Solutions, we don’t do health & safety theatre. We get in, assess the real risks, fix the holes, and make your business safer, leaner, and legally covered.

🛠 Want to stop these mistakes before they turn into payouts and lost time?

📩 Drop us a message or give us a ring. Let’s sort it—before it costs you more than just money.