Manual Handling SWMS — Warehousing

Manual handling injuries are the number one injury type in Australian warehousing, accounting for more workers compensation claims than any other mechanism. Picking, packing, palletising, and depalletising operations expose workers to repetitive lifting, awkward postures, sustained force application, and vibration from powered hand tools. The binding of the Hazardous Manual Tasks Code of Practice under Section 26A from July 2026 makes this the single most impactful regulatory change for warehousing businesses because every warehouse operation involves hazardous manual tasks. This SWMS template covers manual handling across all warehouse functions with controls mapped to the binding code.

Legal Requirements

regulation

WHS Regulation 2025 Part 4.2 — Hazardous Manual Tasks

hrcw category

Hazardous manual tasks (repetitive, forceful, sustained, awkward postures)

code of practice

Hazardous Manual Tasks (binding July 2026 under Section 26A)

section 26a binding

Yes — Manual Tasks code binding July 2026. Non-compliance is admissible as evidence of breach.

Hazards

Hazard	Consequence	Likelihood
Repetitive lifting during order picking from floor-level and above-shoulder locations	Chronic back injuries, shoulder injuries, disc herniation	Likely
Awkward postures during packing and wrapping at non-adjustable workstations	Musculoskeletal disorders, repetitive strain injuries	Likely
Sustained force during manual palletising of heavy products	Acute back strain, shoulder injuries, hernias	Likely
Crush injuries from shifting loads during manual depalletising	Hand and foot crush injuries, fractures	Possible
Whole-body vibration from riding powered pallet jacks for extended periods	Lower back pain, spinal degeneration	Possible

Controls (Hierarchy of Controls)

Provide mechanical lifting aids including pallet lifters, vacuum lifters, and scissor-lift tables for loads exceeding 16 kg

Design pick faces to position high-frequency items between knuckle and shoulder height to eliminate bending and reaching

Implement job rotation schedules that alternate between high-risk and low-risk manual handling tasks

Install adjustable-height packing benches to accommodate different worker heights and reduce awkward postures

Use powered pallet wrappers to eliminate manual stretch wrapping of pallets

Conduct hazardous manual task risk assessments for every significant lifting, pushing, and pulling task

Provide manual handling training covering correct technique, mechanical aid use, and load limit awareness

Recent Prosecutions

Warehouse manual handling injuries — Victoria$180,000

Multiple workers at a distribution centre developed chronic back injuries from repetitive heavy lifting during order picking. The employer had not conducted hazardous manual task assessments, provided mechanical aids, or implemented job rotation despite injury reports over two years.

2024 — WorkSafe Victoria Prosecution Database

What Your SWMS Must Include

✓Hazardous manual task register listing every significant lifting, pushing, and pulling task with risk rating

✓Mechanical aid register and availability map showing location of lifting aids in the warehouse

✓Job rotation schedule alternating between high-risk and low-risk tasks across each shift

✓Pick face design specifications positioning high-frequency items at optimal heights

✓Manual handling training requirements including frequency, content, and competency assessment

Need a compliant Manual Handling SWMS?

Our WHS consultants develop manual handling SWMS with hazardous task assessments, mechanical aid specifications, and job rotation schedules that reduce injury rates.