Lifting Aids Toolbox Talk: Using Hoists, Lift Tables and Trolleys

The safest lift is the one your body doesn't have to do. Hoists, lift tables, vacuum lifters and trolleys exist for exactly that, but they only protect people who use them. This lifting aids toolbox talk is for anyone who handles loads, and for supervisors who decide which equipment the crew has. The crew will leave knowing what's available, how to check it and why it's worth the extra minute.

Why do lifting aids matter?

HSE's guidance puts equipment ahead of technique. Its manual handling brief guide says employers should first avoid hazardous handling, including through mechanical aids such as conveyors, chutes, pallet trucks and hoists. It also warns that training alone can't overcome a lack of mechanical aids.

HSE's leaflet Making the best use of lifting and handling aids gives practical examples. In one, workers hand-feeding 25 kg sacks into a mixer had back pain. Switching to big bags handled by lift truck removed the manual handling and cut loading time from an hour to 15 minutes.

CCOHS adds the basic rules for using aids:

• check whether an aid is available before lifting,
• select the right equipment for the task,
• don't operate equipment you aren't trained on,
• inspect it before use for faults such as loose wheels or damaged platforms.

Talking points for your lifting aids toolbox talk

• Know what we've got. Name the aids on this site and where they live: trolleys, pallet trucks, lift tables, hoists, vacuum lifters, bin tilters. An aid nobody can find isn't an aid.
• Match the aid to the load. A sack truck suits stacked boxes, a lift table suits work you need at bench height, a hoist suits heavy vertical lifts. Using the wrong one creates new risks.
• Trained means trained. Only use equipment you've been shown how to use. Powered lift trucks need formal training; ask if you're unsure about anything else.
• Check before every use. Look at wheels, brakes, slings, hooks, controls and safe working load labels. If something's wrong, tag it out and report it.
• The extra minute is worth it. Skipping the hoist "just this once" is how many back injuries happen. Plan the aid into the job time.
• Never stand under a suspended load. CCOHS warns never to position yourself or others under a suspended load.
• Suggest new aids. If a task still relies on muscle, say so. Many aids are cheap compared with an injury.

Example to share with the crew

For example, imagine a site that bought a vacuum lifter for 20 kg drums, but it's parked at the far end of the bay and takes a minute to set up. On busy days people just lift the drums by hand, and the lifter gathers dust.

Moving the lifter next to the drum station and adding it to the task instructions makes the safe way the easy way. Within a week, nobody hand-lifts drums. Aids get used when they're close, working and expected.

Lifting aids checklist

• Every regular heavy or frequent lift has been checked for a suitable aid
• Aids are stored where the task happens, not across the site
• Workers using each aid have been trained on it
• Pre-use checks are done and faults are tagged out and reported
• Safe working load labels are visible and respected
• Nobody works or walks under suspended loads
• Workers know how to suggest a new aid for a manual task

Questions to ask the crew

1. Which lift here would be easier with an aid we don't have yet?
2. Which of our aids is used least, and what gets in the way of using it?
3. When did you last find a fault on a trolley, hoist or table, and what happened?

To show the difference an aid makes, score a manual lift in the NIOSH lifting calculator. For storage and picking areas, the warehouse ergonomics guide has more ideas.

How to close the talk

Close this lifting aids toolbox talk with one message: if an aid exists for the job, use it, check it first and report faults straight away. Tell your supervisor or use the site's hazard report if an aid is missing, broken or in the wrong place. There are more safety topics for toolbox talks in the library.