Back to basics: Answers to your manual material handling and MSD questions
Musculoskeletal disorders (MSDs) linked to manual material handling (e.g. tasks like lifting, lowering, pushing, pulling, holding or carrying materials from one place to another) take a huge toll on worker well-being and business success. It’s a health and safety issue employers cannot afford to ignore.
Manual material handling is a top priority of the Ministry of Labour, Immigration, Training and Skills Development (MLITSD) too. For the second year in a row, they’re conducting a campaign to raise awareness, increase compliance and drive injury rates down. Inspections of workplaces began in April 2024 and continue until March 31, 2025.
Many workplaces find MSDs complicated to understand and address. But they don’t have to be. It’s important to focus on simple, inexpensive solutions that have a big impact. And making use of the many resources at your disposal to develop a better understanding of the issues.
Use this Q&A as your foundation to improving your manual material handling practices and prevent MSDs among your workers.
- What is an MSD? How do MSDs impact workers?
MSDs is a broad term that describes a variety of injuries and conditions affecting the muscles, tendons, ligaments, bones and nerves. MSDs usually develop over time, and can cause chronic pain, stiffness, and limited mobility, affecting daily activities, quality of life and overall well-being. They also contribute to stress, anxiety, depression, and other mental health issues. MSDs can sometimes lead to permanent disability and the inability of the worker to return to their pre-injury job.
- How does manual material handling lead to MSDs?
Manual material handling involves lifting, lowering, pushing, pulling, holding or carrying materials from one place to another. These activities can result in MSDs, including painful strains and sprains, and other soft tissue injuries. Soft tissue injuries can affect the muscles, tendons, ligaments, discs, cartilage and nerves, usually in the back, shoulders, hands and wrists.
- What is an employer’s duty under the Occupational Health and Safety Act (OHSA) when it comes to MSDs?
- Section 45 of Regulation 851 – Industrial Establishments says that materials must be lifted, carried or moved in a way that does not endanger the safety of any worker.
- Section 25 requires employers to take every reasonable precaution to protect workers. Section 25 is often referenced by an MLITSD inspector when manual material handling concerns exist and are not adequately controlled.
- What are the risk factors for developing MSDs during manual material handling?
Risk factors include high force (i.e. the physical effort required to lift, lower, push, pull, carry or move objects), poor or awkward postures, frequency of task, bending and twisting, improper or heavy lifting, and poor workplace design. Having just one of these risk factors is not usually a concern, but when several are present in combination (i.e. reaching away from the body to access heavy items twice per minute), the risk increases significantly.
- What is the financial cost of MSDs for employers?
MSDs are one of the largest contributors to lost time claim costs, with sprains and strains alone accounting for 38% of total WSIB [Workplace Safety & Insurance Board] claims in 2023. That amounts to a staggering direct cost of $115,600,641. Direct costs include WSIB costs, prescriptions/medical fees, loss of wages, etc. Indirect costs, such as replacing, hiring and training new workers and impacting employee morale, company reputation and retention, are 2 to 7 times the direct cost.
- How can I reduce the risks of workers developing MSDs as a result of manual material handling?
First and foremost, workplaces need to strive to design tasks and equipment and organize the work in a way that meets the capabilities of workers, rather than the other way around. This means including ergonomics in the discussion as early on as possible during the design phase, as this is the most effective way to control risks and reduce injuries and costs.
But there are steps you can take to reduce risks in addition to addressing design elements. He suggests putting together a team that includes workers and other relevant workplace parties (i.e. engineers, maintenance, etc.) and using the Hierarchy of Controls to reduce hazards.
The hierarchy of controls ranks controls from the most effective to the least effective and includes in descending order: elimination/substitution, engineering, administrative/awareness, and personal protective equipment (PPE).
Here are some examples of how your workplace can reduce MSDs using these controls.
Eliminate/substitute: If you can eliminate the need for manual material handling, do it. For example, can you use a conveyor or robot instead? Or is there unnecessary handling occurring (i.e. moving an object more than once).
You can also reduce the weight and size of loads that must be physically moved. For example, break up a heavy load into separate, more manageable loads.
Engineering: This could even be as simple as implementing a cart to transport items instead of carrying or stacking pallets to reduce bending.
Administrative/Awareness:
- Include job rotation in workers’ daily schedules. By rotating from a task with high physical demands, such as order picking, to one with lower demands, like driving a forklift, workers’ muscles have time to rest and recover and MSD injuries can be reduced. The job rotation should involve using different muscle groups at a regular frequency throughout the day, ideally every 1-2 hours. It should be coordinated and monitored by the supervisor to ensure it is adhered to.
- Establish safe work practices and train employees to use proper lifting techniques. These include:
- Lifting with proper posture and body mechanics
- Using assistive devices or tools
- Breaking down heavy or large loads into smaller, manageable parts
To be effective, training should always include a practical element carried out on the floor.
PPE: Never ask workers to use back belts. Back belts are problematic, and should be avoided. They are ineffective at preventing injury and can actually increase intra-abdominal pressure and cardiovascular stress. They also create a false sense of security, which may lead workers to handle materials beyond their physical capabilities.
- Where can I find resources?
WSPS offers many resources to help you reduce MSDs during manual material handling, including an assessment tool that can assist in identifying high-risk areas, and tools to help train workers. Our consultants are also on hand to do a no-cost walk-through of your workplace and provide recommendations.
Additional Resources
Connect with a WSPS consultant for help carrying out risk assessments and developing controls for materials handling tasks and equipment.
Resources
- MLITSD Material Handling Campaign: The Essentials (pre-recorded webinar; jointly delivered by the MLITSD and WSPS)
- MLITSD Material Handling Inspections - Frequently Asked Questions
- MLITSD material handling inspections on now: be prepared (article)
- MSD Risk Assessment
- MSD Hazards Checklist
- Business in Motion: Managing Material Handling Hazards
- Hand Pallet Trucks and Pump Trucks Job Aid
- Safe Lifting / Preventing musculoskeletal disorders or MSDs
- MSD Prevention Guideline for Ontario (CRE-MSD)
- Why PPE should be your last choice when it comes to workplace hazards (article)
- Small Biz Bytes: Hazard Control Hierarchy (video)
The information in this article is accurate as of its publication date.
Have health and safety questions? Please contact Denise Lam, WSPS Account Manager, Small Business at Denise.Lam@wsps.ca.
About Workplace Safety & Prevention Services (WSPS)
Workplace Safety & Prevention Services (WSPS) is a not-for-profit organization committed to protecting Ontario workers and businesses. A proud partner in Ontario’s occupational health and safety system and a trusted safety advisor since 1917, WSPS has a rich history of making Ontario workplaces safer. WSPS serves the manufacturing, agricultural and service sectors. WSPS offers unparalleled health and safety expertise, consulting, training and resources for businesses of any size. For more information visit WSPS.ca.
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This article was prepared by Workplace Safety & Prevention Services (WSPS). At WSPS we are committed to helping businesses understand their risks and legal obligations to stay in compliance and build safer workplaces. If you would like permission to republish or use information in this article, please contact Jessica Bowes, Content Development Lead at jessica.bowes@wsps.ca.
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