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Manual handling: stacking shelves

Reducing manual handling injuries when stacking shelves.

Contents

  1. Introduction
  2. What is manual handling?
  3. General problems and solutions
  4. Problems
  5. Solutions

1. Introduction

This pamphlet provides information on ways of reducing manual handling injuries when stacking shelves. It is important for people who work in shops, warehouses, libraries, sections managing files, hospitals or other workplaces where stacking shelves is a part of the job.

2. What is manual handling?

When stacking shelves, manual handling means lifting, lowering, pushing, pulling, carrying, moving or holding any item which has to be moved on to or removed from shelves. Shelf stacking may be associated with moving trolleys or unstacking pallets. These tasks are covered by other brochures in this series.

3. General problems and solutions

Manual handling hazards are covered by the general duty provisions in the Occupational Safety and Health Act. Specific requirements for hazard identification, risk assessment and control are established by Regulation 3.4 of the Occupational Safety and Health Regulations 1996.

The Code of practice for Manual tasks provides practical guidance on the identification, assessment and control of risks associated with manual handling at work.

It is important to consult with employees performing the tasks as they are likely to be aware of the risk of manual handling injuries which may be associated with their jobs.

Manual handling tasks likely to be a risk to workers' safety and health should be identified and assessed in detail to determine the nature and the extent of the problems.

Risk control means finding solutions to the problems.

The following general problems and suggested solutions are examples of how manual handling injuries may be reduced.

4. Problems

Strain injuries may occur when:

  • items are double handled;
  • items are stored above shoulder level;
  • items are lifted from below mid-thigh height;
  • items are too heavy when other risk factors, such as the number of times the items are moved or the distance moved, are taken into account;
  • the weight of items is unknown and they are heavier than expected for their size or shape;
  • excessive forward reaching is required when lifting or placing loads on and off shelves;
  • there is not enough space to handle items safely; and
  • the load is unstable or awkward to move.

5. Solutions

Here are some ideas that may be used to avoid strain injuries.

The examples provided may need to be used in combination with each other. Other risk control strategies, for example training, form part of any well thought out solution.

  1. eliminate double handling by keeping the amount of stock stored to a minimum so that items can be placed directly onto shelves for sale or use;
  2. organise storage so that heavy or high turnover stock is stored at waist height;
  3. limit the height of shelves to shoulder height;
  4. improve access by having rotating shelves;
  5. limit the depth of shelves;
  6. stack stock in their cartons rather than unloading individual containers onto shelves;
  7. ensure cartons are correctly labelled with their contents and weight;
  8. store large awkward items such as bicycles and wheelchairs at ground level;
  9. use step stools and steps to avoid over-reaching;
  10. ensure design of steps and stools is safe and appropriate;
  11. ensure sufficient space is allocated for handling when designing shelving work areas;
  12. use drawers instead of low shelves to eliminate bending and reaching; and
  13. use height adjustable trolleys for unloading and loading items.

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