7 Manual handling statistics you should know

Manual handling

Manual handling processes are used in most industries, from manufacturing to retail. The movement of heavy loads, whether that’s lifting, positioning, or pushing/pulling loads, can all contribute to injuries, especially when done incorrectly or where the right equipment is not used.

Download our checklist

Thank you for your request to download the MasterMover 'Manual Handling Checklist'.

We'll also send you an email shortly with your download link included for safe keeping.

If you do not receive the email, please let us know at salesteamuk@mastermover.com.

 

Download Now

Request a consultation

Thank you for submitting your consultation request.

A member of the team will be in touch shortly.

manual-handling-injuries
roll-cage-mover-manual-handling.jpg

1) 543,000 workers suffering from work-related musculoskeletal disorder

Musculoskeletal disorders (MSDs) typically impact the back, shoulders, upper limbs and neck. Injuries can be caused by a range of activities, from lifting to manually manipulating heavy-wheeled loads. MSDs are often caused by repetitive tasks or processes which result in overexertion and fatigue.
Source: HSE, 2025

2) 7.1 million working days are lost due to work-related musculoskeletal disorders

Musculoskeletal disorders remain one of the largest single causes of lost working time in UK workplaces, with each affected worker losing an average of around 14 working days over the year. 

Lost working days have obvious impacts on efficiency and output for businesses and so reducing the risk of MSDs and manual handling operations within the workplace should be a priority.
Source: HSE, 2025.

3) Manual handling accounts for 17% of all workplace injuries

 Handling, lifting and carrying is the second most common cause of non-fatal workplace injury in the UK, behind only slips, trips and falls on the same level. This proportion has held steady across the 2023/24 and 2024/25 reporting years. 

With the Health and Safety Executive reporting that 17% of all workplace injuries are caused by manual handling tasks, the case for assessing and reducing the risk is clear.

Organisations must prioritise assessing their manual handling processes to understand what tasks present a high risk of manual handling accidents or injuries.
Source: HSE, 2025.

Greystar Before New 2

4) 43% of MSD cases affect the back (the single largest category)

Back conditions remain the most common MSD outcome, ahead of upper limb and neck disorders (41%) and lower limb disorders (around 15%). Back-related conditions also account for a disproportionate 41% of MSD-related working days lost, reflecting their severity and tendency to recur.

MasterMover field cases support this. Awkward pushing, pulling, and steering of heavy loads often cause back strain; this strain gets worse when workers are expected to handle loads on slopes
Source: HSE, 2025.

5) Manual handling accounts for 17% of all non-fatal workplace injuries

Handling, lifting, and carrying is the second most common cause of non-fatal workplace injury in the UK, behind only slips, trips and falls on the same level. This proportion has held steady across the 2023/24 and 2024/25 reporting years.

Handling aids such as MasterMover electric tugs are a simple solution that eliminates manual handling from heavy wheeled load-moving processes.

Source: HSE, 2025.

6) Estimated £22.9 billion annual cost of workplace injuries & ill-health

Back conditions remain the most common MSD outcome, ahead of upper limb and neck disorders (41%) and lower limb disorders (around 15%).

Back-related conditions also account for a disproportionate 41% of MSD-related working days lost, reflecting their severity and tendency to recur.

Source: HSE, 2025.

www.mastermover.comhubfsmanual-handling-injuries

7) Compensation for manual handling back injuries can exceed £190k

Where an employer is found liable for a manual handling injury — commonly through a breach of MHOR risk assessment duties — compensation for the most severe back injuries can run into six figures. This isn't an HSE figure; it reflects the Judicial College Guidelines, the reference tables UK courts use to value personal injury claims, and actual awards vary by case.

At MasterMover, we've seen firsthand how proactive investment in tools and equipment such as electric tugs successfully works as a preventative approach, rather than reacting once an injury has already happened and facing additonal compensation costs.

Source: Cited via UK Law, referencing the Judicial College Guidelines, 18th edition (2026).

How many injuries happen at work by poor lifting and moving?

Approximately 21% of workplace injuries can be directly attributed to manual handling activities such as lifting, carrying, or moving objects. These injuries occur when employees are not properly trained or equipped to handle heavy loads, resulting in strains, sprains, or other musculoskeletal issues. Poor lifting techniques and inadequate ergonomic practices often contribute to these incidents. It is crucial for employers to prioritise safe manual handling practices and provide thorough training to prevent manual handling injuries and promote a healthy work environment.

 

Reduce the risk of manual handling injuries

While manual handling incidents are common, the majority of injuries are preventable. Businesses must prioritise health and safety risk assessments and implement manual handling training to ensure workers use safe manual handling techniques.

Appropriate tools and equipment, such as MasterMover electric tugs, should be used to reduce the risk of injury in manual handling operations where tasks exceed individual capability or are repetitive.

Download your manual handling injury checklist

Quickly assess high risk tasks and identify next steps in reducing the risk of manual handling injuries with our manual handling checklist.