Part 4.2: WHS Hazardous Manual Tasks

Regulatory citation: Model Work Health and Safety Regulations, Part 4.2 (Regulations 60–61)

What Are the Hazardous Manual Tasks Regulations?

Part 4.2 of the model Work Health and Safety Regulations requires PCBUs to manage the risk of musculoskeletal disorders (MSDs) associated with hazardous manual tasks. A hazardous manual task is a task that requires a person to lift, lower, push, pull, carry or otherwise move, hold or restrain any person, animal or thing, and that involves one or more risk factors such as repetitive or sustained force, high or sudden force, repetitive movement, sustained or awkward posture, or exposure to vibration.

Why These Regulations Matter

Body stressing injuries, such as back, shoulder and neck injuries, are among the most common and costly work-related injuries. Many develop gradually through repeated strain rather than a single event, so they need to be managed proactively.

Core Obligations

1. Manage the Risk of MSDs (Regulation 60)

PCBUs must manage risks to health and safety relating to musculoskeletal disorders associated with hazardous manual tasks, using the standard risk management process and the hierarchy of controls.

2. Consider All Relevant Factors

In determining control measures, PCBUs must consider all relevant matters that may contribute to an MSD, including:

• Postures, movements, forces and vibration relating to the task
• The duration and frequency of the task
• Workplace environmental conditions that may affect the task or the worker
• The design of the work area
• The layout of the workplace
• The systems of work used
• The nature, size, weight or number of persons, animals or things involved

3. Designer and Supplier Duties (Regulation 61)

Designers, manufacturers, importers and suppliers of plant and structures must ensure, so far as is reasonably practicable, that their products are designed to eliminate or minimize the need for hazardous manual tasks, and must provide information about safe use.

Common Compliance Approaches

Task Risk Assessments

Observe tasks, talk to workers and review injury data to identify which risk factors are present and how severe they are.

Redesign the Work

Eliminate or reduce lifting by using mechanical aids such as hoists, trolleys, conveyors and vacuum lifters, and redesign workstations so work is done at waist height within easy reach.

Reduce Load and Frequency

Ask suppliers for smaller or lighter packaging, break up repetitive tasks and introduce job rotation and rest breaks.

Train in Context

Training on safe techniques should support, not replace, higher-order controls, and should be specific to the actual tasks workers perform.

Example: Hazardous Manual Tasks in Practice

A beverage distributor has repeated shoulder and back injuries among workers loading 20 kg cartons onto high shelves. After consulting workers, the business installs a powered lift table, lowers the highest storage level, asks its supplier to switch to 12-can packs and introduces rotation between picking and loading roles. Injury reports and worker feedback are reviewed three months later to confirm the controls are working.

Note: This summary is based on the model WHS laws published by Safe Work Australia. Most states and territories have adopted them with minor variations, while Victoria has its own OHS laws. Always check the legislation and codes of practice that apply in your jurisdiction.

Frequently Asked Questions

Is there a maximum weight workers can lift under WHS law?

No. The model WHS Regulations don't set a single maximum weight because risk depends on many factors, including posture, frequency, duration, grip and the working environment. A lighter load lifted repeatedly in an awkward posture can be more hazardous than a heavier load lifted occasionally at waist height.

What is a musculoskeletal disorder?

A musculoskeletal disorder is an injury to, or disease of, the musculoskeletal system, such as sprains and strains, back injuries, joint and bone injuries, nerve injuries and soft tissue injuries. MSDs can result from a single event or gradual wear and tear from repeated or sustained tasks.

Is manual handling training enough to comply?

No. Training is an administrative control and is less effective on its own. PCBUs should first eliminate or redesign hazardous tasks using mechanical aids, better layout and changes to loads, then use training to support those controls.