Manual lifting is one of the most common tasks performed on board ships – from moving stores and spare parts to handling tools, drums, and provisions. Yet, it remains one of the leading causes of crew injuries, especially in the constantly moving environment of a vessel. Knowing how to lift safely is an essential part of seamanship and personal safety.
Сhallenges of manual handling at sea
On land, a stable surface and predictable surroundings make lifting operations relatively straightforward. At sea, however, conditions are dynamic. Rolling and pitching can suddenly change a seafarer’s balance, confined spaces may limit movement, and deck surfaces can be slippery or obstructed. Even a small lapse in concentration can lead to a back strain, slip, or crush injury.
Injuries related to manual handling are among the most frequent onboard incidents on both merchant and fishing vessels. The most common injuries are to the back, shoulders, and knees. Improper lifting, repetitive movements, awkward postures, and unstable loads are common contributing factors. When these are combined with ship movement or poor weather, the risk increases sharply.
Common causes of injury:
- Improper lifting technique. For example, lifting with the back instead of the legs – many seafarers instinctively bend at the waist when lifting, placing excessive stress on the lower spine.
- Overestimating personal strength. Attempting to lift or carry more than one can handle – especially without help or lifting equipment – can result in acute muscle or joint injuries.
- Poor planning. Moving loads without assessing the route or obstacles can lead to sudden slips or crush incidents.
- Ignoring ergonomics. Repetitive lifting in awkward postures can cause long-term musculoskeletal disorders (MSDs).
- Complacency. Routine daily tasks often create a false sense of safety, causing crew to skip toolbox talks or lift without proper coordination.
Key principles of safe manual lifting
Avoid manual handling whenever possible
The safest lift is the one that doesn’t require manual effort. Whenever feasible, use mechanical aids such as cranes, chain blocks, hoists, or trolleys. If mechanical lifting is not possible, break heavy loads into smaller parts or redesign the task to minimize handling.
Assess the risk before lifting
Every manual handling task should begin with a quick risk assessment and a pre-task safety briefing. Consider:
- The weight, size, and shape of the load (and whether it’s stable or difficult to grip).
- The route to be taken – check for obstructions, wet decks, or narrow spaces.
- The working environment – temperature, lighting, ship motion, and nearby hazards.
- The crew’s physical condition – avoid assigning heavy lifts to unfit or fatigued crew.
- The weather – postpone non-urgent manual work in heavy seas or strong winds.
Plan the lift carefully
Before starting, decide:
- Where the load will be placed.
- Who will be involved and what equipment is available.
- How to communicate during the lift.
- Whether rest points are needed for long or high lifts (for example, from deck to shoulder level).
Good planning also includes checking that PPE is appropriate for the conditions – gloves for grip, safety shoes for support, and weather-appropriate clothing that doesn’t restrict movement.
Work as a team when necessary
Some loads require more than one person. In team lifts:
- One person should coordinate and give clear commands.
- Lift and lower together on agreed signals.
- Keep movements synchronized and communication constant.
Keep the work area safe
Ensure the deck or platform is clean, dry, and free from obstructions. Avoid performing lifts near open hatches, moving machinery, or in areas where the ship’s motion is most pronounced.
Use the “stop and think” approach
Before each lift, pause for a moment. Ask yourself:
- Is there a safer way to do this?
- Do I have the right equipment and enough people?
- Is the weather or ship movement making it unsafe right now?
If anything feels unsafe, stop the operation and reassess. Reporting near misses and potential hazards helps improve safety culture across the crew.
Use good handling technique
When lifting manually:
- Stand close to the load with feet shoulder-width apart, one slightly forward.
- Bend your knees, not your back. Let your leg muscles do the work.
- Keep the load close to your waist, with the heaviest side toward your body.
- Grip firmly using both hands; if possible, hug the load rather than holding it by the edges.
- Lift smoothly without jerking. Avoid sudden or twisting movements.
- Keep your head up and look ahead, not down.
- Move your feet to turn – never twist your torso.
- Lower the load carefully, bending your knees again and adjusting position only after the load is stable.
Common mistakes to avoid
- Lifting with a rounded or twisted back.
- Trying to lift an object too heavy for one person.
- Failing to check the deck surface or surrounding area.
- Ignoring fatigue or back pain.
- Lifting while the vessel is rolling heavily.
Safety culture on board
Safe manual handling should be part of the vessel’s safety culture. Regular toolbox talks and onboard training help crew members maintain awareness and good habits. Reporting unsafe conditions or lifting-related near misses contributes to improving procedures for everyone.
Key takeaways include:
- Always use mechanical aids where possible.
- Conduct risk assessments and toolbox talks before any manual handling job.
- Ensure effective communication between all crew members.
- Encourage crew to recognize their own physical limits.
- Maintain supervision during complex or team operations.
- Share lessons learned across the fleet to prevent similar incidents.
Long-term health considerations
Improper lifting doesn’t just cause immediate injuries. Repeated strain can lead to chronic back pain, herniated discs, and other musculoskeletal problems. These may develop gradually and affect a seafarer’s ability to work. Maintaining fitness, stretching regularly, and staying hydrated are important preventive measures.
Poor physical health – such as high blood pressure or dehydration – can also increase the risk of injury by reducing alertness and physical capacity during lifting operations.
Manual handling will always be part of life at sea, but it should never be taken lightly. A moment of inattention or a poorly planned lift can have lasting consequences. The key is to plan, communicate, and lift smart – using the right technique, teamwork, and equipment whenever possible.
Every seafarer has a responsibility to protect their health and the safety of others. A few extra seconds spent planning can prevent months of pain and ensure you stay fit for duty throughout your career at sea.
