The Employer’s Guide to Manual Handling and Repetitive Strain Injury Prevention

Manual handling tasks and repetitive strain injuries (RSIs) are two of the most common causes of workplace injuries – and compensation claims. For employers, addressing these hazards isn’t just about meeting compliance obligations; it's about protecting your workforce and reducing lost productivity and insurance costs.

This guide breaks down how employers can approach training, risk assessments, and control strategies to reduce manual handling injuries and RSIs.

Why Manual Handling & RSI Prevention Matters

• High Incidence of Injuries
  Poor manual handling techniques or prolonged repetitive movements can lead to musculoskeletal disorders, lower back pain, carpal tunnel syndrome, and more – often resulting in time off work or permanent injury.
• Legal Responsibility
  Employers are legally required to assess and manage health and safety risks. Ignoring manual handling and RSI risks may lead to penalties, insurance claims, or litigation.
• Financial Impact
  Direct costs (claims, compensation, medical expenses) and indirect costs (absenteeism, lower morale, decreased productivity) can be substantial if injuries are not prevented.

Step 1: Conduct a Manual Handling & RSI Risk Assessment

Start by identifying tasks that may pose risks. Key areas to assess include:

• Lifting, pushing, or carrying loads
• Prolonged use of keyboards, mice, tools, or equipment
• Static postures or repetitive motions
• Inadequate workstation design or layout

Risk Assessment Checklist:

• What task is being done?
• Who is doing it and how often?
• What tools or aids are being used?
• Are workers trained to use safe techniques?
• Are there any reported discomforts or past injuries?

Step 2: Implement Control Strategies

Once risks are identified, use the hierarchy of controls to reduce them:

• Eliminate the Hazard
  Can the task be automated, delegated, or removed?
• Substitute with Safer Alternatives
  Use lighter materials, adjustable equipment, or more ergonomic tools.
• Engineering Controls
  Install lifting aids (trolleys, hoists)
  Reconfigure workstations for better posture
  Use anti-fatigue mats, adjustable chairs, or sit-stand desks
• Administrative Controls
  Rotate tasks to avoid repetitive strain
  Set mandatory break schedules
  Limit duration of high-risk activities
• Personal Protective Equipment (PPE)
  PPE should always be the last resort and must be used correctly.

Step 3: Provide Practical Training

Your training program should be hands-on, specific to job roles, and regularly updated. What to Include in Training:

• Safe lifting techniques (e.g., bend knees, not back)
• Recognizing early signs of RSI
• Proper workstation setup and posture
• Correct use of manual handling equipment
• Reporting hazards or discomfort early

Training Delivery Tips:

• Combine theory with practical demonstrations
• Use role-based scenarios
• Re-train annually or after changes in task/process

Step 4: Encourage Early Reporting and Monitoring

• Encourage employees to report discomfort, fatigue, or unsafe tasks early.
• Create a culture where reporting is supported and followed by action.
• Monitor absence trends, injury reports, and near-misses.

Step 5: Review and Update Policies Regularly

Workplaces evolve, and so should your safety strategies.

• Reassess manual handling risks when new tasks, equipment, or layouts are introduced.
• Keep training materials, signage, and manuals up to date.

Manual handling and RSI prevention is not a one-time effort—it’s an ongoing responsibility that involves clear risk assessments, control strategies, effective training, and a culture of reporting and review. Employers who prioritize this not only reduce injury claims but also create a healthier, more productive workforce.