Back to basics: Answers to your questions about manual material handling and MSDs

Musculoskeletal disorders (MSDs) linked to manual material handling take a huge toll on workers and businesses,” says Nathan Birtch, WSPS Specialized Consultant (Ergonomics). “Employers may not be aware of how much MSDs are costing them. It’s an area they cannot afford to ignore in terms of prevention activities.” 

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.

Nathan acknowledges that many workplaces find MSDs complicated to understand and address. He suggests focusing 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.

In the following Q&A, Nathan provides a ‘back to basics’ overview of manual material handling and MSDs – what the law says, how MDSs arise, what the risk factors are, what MSDs cost the employer, and how to find solutions. 

Manual material handling & MSDs: Q&A

1. 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,” notes Nathan.

2. 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,” explains Nathan. Soft tissue injuries can affect the muscles, tendons, ligaments, discs, cartilage and nerves, usually in the back, shoulders, hands and wrists.

3. What are the risk factors for developing MSDs during manual material handling?

“Risk factors include high force (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,” explains Nathan. “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.”

4. How do MSDs impact workers?

“MSDs usually develop over time, and can cause chronic pain, stiffness, and limited mobility, affecting daily activities, quality of life and overall well-being,” says Nathan. “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.”

5. What is the financial cost to employers from MSDs?

“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,” notes Nathan. “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.

6. 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,” states Nathan. 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,” says Nathan. 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,” says Nathan. “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,” suggests Nathan. 

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, says Nathan. “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,” says Nathan. 

PPE: Never ask workers to use back belts. “Back belts are problematic, and should be avoided,” says Nathan.  ”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.” 

7. 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. 

How WSPS can help

Connect with a WSPS consultant for help carrying out risk assessments and developing controls for materials handling tasks and equipment.

Training

• Safe Lifting & Manual Materials Handling (1/2 day, online instructor-led training)
• Safe Lifting & Manual Materials Handling - Supervisor (1 hour, online instructor-led training)
• Manual Materials Handling (1 hour, eCourse)

Free Webinars 

• MLITSD Material Handling Campaign: Update - Live, Nov. 26
• MLITSD Material Handling Campaign: The Essentials (pre-recorded)
• Material Handling in Manufacturing (pre-recorded)

Resources 

• MSD Risk Assessment 
• MSD Hazards Checklist 
• Business in Motion: Managing Material Handling Hazards
• MLITSD material handling inspections on now: be prepared
• MLITSD Material Handling Inspections - Frequently Asked Questions
• 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.