Manual Handling: A Guide for NZ Workplaces

Manual handling is the way we lift, carry, push, pull, or move objects by hand or with the help of tools. It might sound simple, but poor manual handling can lead to serious injuries at work. In fact, sprains, strains, and back injuries are some of the most common workplace issues in New Zealand.

For NZ businesses, manual handling is more than just a safety matter. It is a compliance requirement under the Health and Safety at Work Act 2015 and the WorkSafe NZ code of practice for manual handling. Employers have a duty to protect staff from manual handling hazards. This means making sure employees know safe manual handling techniques and have the right training to do their jobs without unnecessary risk.

In this guide you’ll learn:

• What manual handling means in New Zealand workplaces
• Why safe manual handling is important for both employers and staff
• The main hazards, risks, and injuries linked to poor handling
• Practical safe manual handling techniques and LITE principles
• What the law and Worksafe manual handling rules say about compliance

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What Is Manual Handling

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Manual handling is any activity where a person uses their body to lift, lower, push, pull, carry, hold, or move a load. This could be as simple as lifting a box in a warehouse or repositioning a patient in healthcare.

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The five types of manual handling tasks often seen in New Zealand businesses include: lifting, lowering, pushing, pulling, and carrying. Each one has its own risks, especially if the task is repetitive or the load is heavy.

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Why Manual Handling Matters for Employers

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Employers across Auckland and wider New Zealand know the impact of manual handling injuries. A local construction company once shared that a simple box lift gone wrong cost them weeks of lost time for one employee and added costs in replacement staffing.

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Manual handling injuries are not only painful for employees, but they also cost businesses through lost productivity, sick leave, and ACC claims. That is why having safe manual handling procedures and compliance in place is critical.

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Manual Handling Hazards and Risks

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Common manual handling hazards include:

• Heavy loads above the safe manual handling weight limit of 25kg
• Awkward postures such as twisting while lifting
• Repetitive movements over long shifts
• Slippery or uneven flooring
• Poorly designed equipment or workstations

When hazards are not managed, employees are at risk of strains, sprains, and long-term musculoskeletal injuries. A manual handling risk assessment is the best way for businesses to identify these hazards and put controls in place.

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Safe Manual Handling Techniques

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Using safe manual handling techniques reduces risk and helps prevent injury. Some core steps include:

• Plan the lift before starting
• Keep the load close to your body
• Bend your knees, not your back
• Avoid twisting while lifting
• Ask for help with heavy or awkward loads
  

WorkSafe NZ provides guidance on maximum lifting weights for employees, but it is important to remember that limits can change depending on the type of task, load shape, and employee capability.

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The LITE Principles of Manual Handling

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In many training courses, employers are encouraged to use the LITE principles of manual handling:

• Load – know the weight and shape of the object
• Individual – consider the worker’s strength and physical ability
• Task – understand how the task is carried out
• Environment – check the workspace, flooring, and conditions

Applying LITE principles helps keep manual handling safe and practical for both employers and employees.

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Compliance and Code of Practice

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New Zealand businesses must follow the code of practice for manual handling under WorkSafe NZ. Compliance involves:

• Completing a manual handling risk assessment
• Training staff in safe manual handling techniques
• Monitoring injuries and reporting serious cases
• Following the rules on hazardous work, including WorkSafe notification of particular hazardous work
• Keeping in mind other laws that may apply, such as the Gas Act 1992 for certain industries

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Key Takeaways for Employers

• Manual handling injuries are common in NZ workplaces and cost businesses time and money
• Employers must follow the Worksafe manual handling code of practice and provide training
• Using safe manual handling techniques and LITE principles reduces risks
• Risk assessments and posters help keep manual handling top of mind
• Compliance is not just about ticking boxes, it is about protecting people and supporting culture

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