Editor's Note: This article was originally published on 5/15/2024. It was updated on 6/7/2026 to become a more detailed guide on manual handling injuries. 

 

Work-related injuries are a concern around the world. Many countries have an internal organization that oversees workers’ health and safety, like OSHA in the USA, and there are some global groups, such as the International Labour Organization (ILO). 

Accidents at work hurt the employee(s) involved and the company. Severe injuries lead to time off work, which leads to available less labor and the potential for slowdowns in operations. Let’s explore some statistics.

In 2020 alone, the U.S. Bureau of Labor Statistics found that the private transportation and warehousing industry reported 206,900 total recordable cases of nonfatal injuries and illnesses. Of these: 

• 99,800 resulted in days away from work (DAFW) 
• 57,000 led to job transfer or restriction (DJTR) 
• 50,100 were other recordable cases (ORC) 

The total recordable case incidence rate was 4.0 per 100 full-time equivalent (FTE) workers.

In this article, we'll explore:

• Where do most accidents occur in a warehouse?
• Three common types of injuries
• Understanding manual handling injuries in the workplace
• Steps to improve safety & prevent injuries
  
  

Where do most accidents occur in a warehouse?

The top five are docks, forklifts, conveyors, materials storage, and manual lifting and handling.

Benchmark US statistics detail out the specifics of non-fatal occupational injuries and illnesses which involved days away from work in the transportation and warehousing sector:

Case Characteristic                                                                Number of Cases

Nature of Injury or Illness

Sprains, strains, tears                                                               42,280
Soreness, pain                                                                           15,630
Bruises, contusions                                                                   10,370
Fractures                                                                                    7,790
Cuts, lacerations                                                                        3,900

Part of the Body Affected

Back                                                                                            16,910
Shoulder                                                                                     9,840
Knee                                                                                            9,370
Multiple body parts                                                                    8,540
Hand                                                                                            8,030

Event or Exposure Leading to Injury or Illness    

Struck by object or equipment                                                  12,100
Overexertion in lifting or lowering                                             11,950
Fall on the same level                                                                  10,940
Fall to a lower level                                                                      6,750
Roadway incidents involving motorized land vehicles             6,430

U.S Bureau of Labor Statistics, Transportation and Warehousing, 2016 - 2020.

These statistics reveal the tangible risks faced by workers in this sector, with an alarming 206,900 cases of nonfatal occupational injuries and illnesses.

 

Three Common Types of Injuries

The top three events leading to injury are being struck by an object or equipment, overexertion in lifting or lowering and falling on the same level.

The top three impacts on workers are sprains, strains, tears, soreness, pain, and bruises, contusions, particularly affecting the back, shoulder and knees.

Common manual handling injuries include:

• Musculoskeletal disorders.
• Strains and sprains, or other soft tissue injuries.
• Hand injuries, such as broken fingers or other broken bones in the hand.
• Back injuries, spinal damage or slipped discs.
• Shoulder injuries.
• Cuts and lacerations.
• Ankle and foot injuries.

However, they can be divided into three main categories:

1. Being Struck by Object or Equipment: This cause accounts for almost a third of these types of injuries, with a significant portion of workers being hit by trucks. Research has found that every year, one in five workplace fatalities and over 12,000 injuries are caused by forklifts and other industrial vehicles. These statistics underscore the importance of regular forklift training for employees. However, accidents are not solely caused by forklifts. Incorrectly stacked items can lead to them tumbling, falling and hitting employees. Staff should be well-trained in safe loading and unloading of pallets, safe stacking heights and weights, and the importance of not climbing, leaning or walking on pallets.
2. Overexertion in Lifting or Lowering: Manual handling accounts for over a third of all workplace injuries, including strains, sprains, back injuries, cuts, bruises and broken bones. Although there might be occasions when your staff must handle heavy materials, such tasks should be avoided as much as possible.
3. Falls on the Same Level: Falls on the same level are a common cause of workplace accidents that result in injury, these typically include slips and trips on the floor you’re working on. To prevent accidents like these, adequate training and robust processes are needed to ensure that staff know how to secure and move objects stored at height safely. Personal Protective Equipment (PPE) like hard hats is often necessary, as well as warning signs in areas of potential hazard.

Common causes can also include lack of training which can lead to an employee suffering from a back injury from incorrectly lifting a heavy load, using their back rather than their legs.

Also, a lack of clear weight and handling details on packages can exacerbate issues. An example could be that an employee attempts to lift a load but soon realizes it is too heavy, dropping it on their foot, causing metatarsal fractures.

 

Understanding Manual Handling Injuries in the Workplace

Once you understand potential injuries and common risks, there is other important information to understand.

Who's Accountable? Labor Laws and Regulations

Workplace safety is a shared responsibility that involves everyone - employers, employees, clients and even visitors. Each individual who enters a workplace has a part to play in ensuring their safety and the safety of others.

However, from a legal perspective, the level of responsibility varies. The main share of the responsibility falls on the employer, whilst employees also have a legal obligation towards health and safety. 

Also, injuries can be very expensive. According to Libery Mutual, disabling workplace injuries cost businesses more than $59 billion (£44 billion) per year. 

Learn more about lifting regulations for the USA and how they are enforced. 

Consider Weight Limits 

One way to prevent manual handling injuries is to establish weight limits. If a load is over a certain weight, then a worker needs assistance from another person, or they should use equipment to lift it. 

But each person is different. Their individual fitness level can affect how much they can safely lift without overexerting themselves. 

Are you aware of the maximum weight limits people can lift at work? Explore weight limits and ergonomic factors.

Assess Risk

Employers should conduct a risk assessment, evaluating all the risks their employees are exposed to. Preventative and protective measures must be put in place, such as ensuring that each worker has received the necessary health and safety information and training. Sometimes, additional measures might be taken. For example, preventing dangerous situations from occurring and providing training.

Here are certain actions to take while conducting a risk assessment:

1. Identify the possible hazards
2. Assess the risks arising from the hazards (for example, estimate the probability and severity of the consequences and decide whether the risk can be tolerated)
3. Plan actions to eliminate or reduce risks
4. Document the risk assessment

Discover how to conduct a risk assessment.

 

Steps to Improve Safety & Prevent Injuries 

Even though risk assessments are conducted, they merely identify the risk instead of alleviating it. The next step is to take action. 

Redesign Processes 

It’s important to design a system, so people aren’t put in a situation where there is a high risk of injuries. People shouldn’t lift items that are too heavy for them or lift items for a long time with no break. 

Redesigning the layout can make lifting safer. Work areas can be moved, so loads are transported shorter distances. Also, loads can be placed at waist or chest height to reduce bending over or lifting above shoulder height. 

Little changes can have a huge impact on safety. Explore safe lifting techniques and how to design a safer workplace.

Add Lift Assists

How can you prevent injuries from happening? One solution is removing manual handling from your process. 

Implement semi-automation or automation for material handling, so workers don’t physically lift the weight of a load. The right tool, such as a vacuum lifter, can enhance safety, productivity, and work retention. 

Understand how to prevent work-related injuries. 

 

Conclusion

Understanding these common types of manual handling injuries and implementing preventive measures can significantly reduce the risk of workplace injuries, ensuring a safer and more productive environment for your workforce.

Want to minimize injuries whilst bolstering business performance? Read our guide: "The Complete guide to improving efficiency within warehousing logistics".

If you're ready to start exploring solutions, contact TAWI. We'll be happy to discuss your lifting needs.