SAFE MATERIAL HANDLING

Prevention, Legal Requirements, and Practical Controls for Ontario Workplaces

Material handling injuries are among the most common and preventable in Ontario workplaces. From lifting supply boxes in an office to moving construction materials on a job site, improper material handling causes chronic injury and acute trauma. Ontario law requires employers to assess, control, and minimize these risks.

Bullivant Health + Safety | bullivant.ca | 905-664-4943 | 158 S Service Road, Stoney Creek, ON
This resource is for general informational purposes only and does not constitute legal advice.

1. Overview & Statistics

• 1 in 3: Workplace injuries in Ontario involve material handling tasks
• 25 kg: Maximum recommended single-person lift under Ontario guidelines for occasional handling
• 85%: Of material handling injuries are preventable with proper controls and training

 

O. REG. 851, SECTION 45

No worker shall be required to lift, carry, or move any object, article or thing that is likely to endanger the health or safety of the worker. (Ontario Regulation 851 — Industrial Establishments)

2. Employer Obligations

HAZARD ASSESSMENT Assess all material handling tasks for risk — load weight, frequency, distance, posture, environment, and team handling requirements. MECHANICAL AIDS Provide appropriate mechanical handling equipment — pallet jacks, hand trucks, dollies, hoists, lift tables. Equipment must be maintained and workers trained. STORAGE DESIGN Frequently accessed loads at waist height. Heavy items at mid-level. Minimize reaching overhead or bending below knee height.

ELIMINATE OR SUBSTITUTE Can the task be redesigned? Can lighter materials be sourced? Can deliveries be placed closer to point of use? Elimination is always preferred. TEAM LIFTING PROCEDURES Establish procedures for loads requiring more than one person. Workers must know when team lifting is required and how to coordinate it. TRAINING Train all workers on safe lifting technique, risk factors, use of mechanical aids, and how to report concerns. Training must be documented.

 

3. Manual Handling Risk Factors

TASK & LOAD RISKS	ENVIRONMENTAL RISKS
Load weight above recommended limits for the frequency and posture Awkward or asymmetric loads with no handles or poor grip Lifting combined with twisting or bending at the waist Repetitive lifting with insufficient recovery time Carrying loads over long distances or up stairs	Narrow aisles or doorways that force awkward carrying postures Slippery or uneven floors creating instability during carries Poor lighting in storage or handling areas Time pressure that discourages use of mechanical aids Inadequate space to set loads down safely at destination

 

4. Safe Lifting Technique

1. Plan the lift — assess weight, check path, confirm destination is clear, determine if a mechanical aid or second person is needed.
2. Position close to the load — the further the load from your body, the greater the strain on your spine.
3. Use a stable base — feet shoulder-width apart, one foot slightly ahead of the other.
4. Bend at the hips and knees, not the waist — squat using leg muscles, keep your back in its natural curve.
5. Get a firm grip — use the full palm, not just fingertips. Wear gloves if needed.
6. Lift with your legs, keeping the load close to your body. Avoid jerking movements.
7. Never twist while lifting — move your feet to change direction, do not rotate your spine.
8. Set down with the same care — bend your knees and hips, lower the load under control.

 

TEAM LIFTING

One person must call the lift — "Ready? Lift." All workers must lift simultaneously. Have a plan for the carry and set-down before the lift begins. Uncoordinated team lifts cause more injuries than well-executed single-person lifts.

GENERAL INFORMATION NOTICE

This resource is for general informational purposes only. Contact the Ministry of Labour for regulatory guidance specific to your workplace.