Box Lifting Close

Keep the Load Close: What Does It Really Mean in Practice?

Safe lifting involves more than technique. Workplace design, load positioning and ergonomic solutions can help workers keep loads closer and reduce physical strain.

You’ve probably been told this before: Keep the load close while lifting.” This is one of the most important principles of safe lifting because the loads placed on the back increase substantially as a load is moved further away from the body.

But how do experienced manual handlers actually put this advice into practice? Is it really as simple as lifting from the closest spot on a box or tote?

Of course not.

Try picking up a box by lifting from its closest edge. If you grab the bottom edge of the box, it will tend to rotate out of your grasp. If you lift from the top edge, you may create very high gripping and wrist demands that are difficult to sustain, particularly when the task is repetitive.

So, what does keep the load close really mean in practice?

For experienced manual handlers, it is not simply about where they place their hands. It is about finding ways to position the load closer to the body before and during the lift, and there are several ways that the workplace can be designed to make this easier.

1. Step
If it is possible to step closer to the load, do this before lifting. This will sometimes mean taking a few extra steps, and it is understandable that workers may be reluctant to do so, particularly when handling light loads or performing highly repetitive tasks. However, the demands associated with walking and carrying are generally much lower than those created by lifting with a reach, so saving a few steps is unlikely to be worth the additional strain created by reaching for the load.

This is also an area where employers have an important role to play. Work areas should be arranged so that employees can get close to the loads they need to handle. Where possible, pallets should be spaced so that people can walk around them, and turntables or other positioning equipment can be provided where rotating a pallet would allow workers to bring the load into a better position.

The objective is not simply to tell workers to “get closer”; it is to design the workplace so that getting closer is actually possible.

2. Slide
If it is possible to slide the load closer to the body before lifting it, do this rather than reaching for it. A relatively small amount of horizontal movement can make a significant difference to effort required for the subsequent lift.

Employers can make this strategy easier by ensuring that loads will slide readily when they need to be repositioned. Depending on the application, waxed boxes, slip sheets, boxes with handles and smooth, non-nesting crates can all help workers move loads into a better position before lifting them.

This is a good example of how packaging and container design can influence manual handling demands. Rather than relying on workers to manage an awkward reach, consider whether the load itself can be made easier to reposition.

3. Hug
If the load can be held against the body while lifting and carrying, some of its weight can be transferred through the body rather than being supported entirely by the arms. Keeping the load close also reduces the horizontal distance between the load and the spine, which reduces the external moment placed on the back muscles.

There are some surprisingly practical considerations here. If a load is dirty, wet, rough or otherwise unpleasant to hold against the body, workers may naturally keep it away from themselves, even when doing so increases the physical demands of the task.

Employers can therefore help by keeping loads as clean, smooth and comfortable to grip and hold as reasonably possible. Providing suitable aprons or work uniforms can also allow employees to hold loads against their bodies without worrying about damaging their personal clothing.

Again, the point is not simply to tell workers to “hug the load.” The work should be designed so that holding the load close is a practical option.

4. Rake it or tilt it
If a worker must lift an object out of a container, look for ways to bring the object closer before asking them to lift it. For example, if the container can be tilted, the load may roll closer to the worker. If the container can open to allow the worker to reach or step into a better position, those features should be used. If a rake is available to pull items closer, use it.

There are many mechanical and ergonomic solutions that can reduce the need for forward reaching, including roller racks, tilt tables, custom walk-in racks, drop fronts, rakes, lifting straps and other assistive devices. Container design can also be modified so that heavy or awkward components are positioned in a way that minimises forward reach.

These solutions are particularly valuable because they address the source of the problem rather than asking the worker to compensate for poor positioning through lifting technique.

Lifting technique is only part of the solution

Lifting techniques are rarely the sole responsibility of workers. Employers have an obligation to do what they reasonably can to reduce the risk of back injury, and that includes looking at how the work, equipment, containers and materials are designed and arranged.

“Keep the load close” is good advice, but it should prompt a broader question: “What can we change so that workers don't have to reach for the load in the first place?

Can the worker step closer? Can the load slide closer? Can it be held comfortably against the body? Can the container tilt, open or otherwise bring the load within easier reach?

These are ergonomic and workplace-design questions and addressing them can often do more to reduce risk than simply providing workers with another list of lifting techniques.

Let an ergonomist help you explore practical ways to make your workplace safer and then let us train employees to use the lifting techniques that have been shown to be useful for the specific tasks, equipment and conditions in your industry.

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