Apr 14, 2025 • 7 min read
AusRehab's manual handling training with Future Form
See how AusRehab partnered with Future Form to deliver hands-on manual handling training that boosted safety and reduced injury risks on construction sites.
Written by: Stephen Zeng
At AusRehab, workplace safety is at the core of what we do. Recently, we had the privilege of delivering a comprehensive series of manual handling sessions to the team at Future Form, a leading formwork contracting firm operating across NSW, QLD, and the ACT.
Future Form has played a key role in building some of Australia’s most iconic projects, including Mirvac’s NINE development in Willoughby and the Western Sydney Airport. Their focus on precision and on-site safety aligns closely with our mission at AusRehab to support injury prevention and long-term wellbeing.
Over four engaging, practical sessions, we helped Future Form workers learn how to move smarter, not harder, on the job. In this blog, we’ll break down how the training was structured, what we covered, and why manual handling training is an essential part of long-term workplace safety.
What Is Manual Handling?
Manual handling refers to any activity that involves lifting, lowering, pushing, pulling, carrying, or otherwise moving a load by hand or physical force. It may seem straightforward, but the risks associated with poor technique or repetitive movements are significant.
In industries like construction, aged care, and warehousing, incorrect manual handling techniques can lead to:
- Musculoskeletal disorders (MSDs)
- Lower back pain
- Shoulder injuries
- Wrist and knee strain
- Fatigue and burnout
Understanding hazardous manual handling, such as lifting heavy or awkward loads, repetitive movements, or sustained force, is the first step toward preventing long-term health problems.
Why Manual Handling Training Matters
Too often, workers pick up bad habits on the job, such as rushing tasks, overloading, or using their backs instead of their legs to lift. These habits, over time, can result in chronic injuries or time off work.
That’s why manual handling training is so important. It goes beyond compliance. It’s a smart investment in your team’s health, safety, and long-term productivity.
At AusRehab, we created a manual handling course tailored to their construction environment, job roles, and high-risk tasks. This was a practical, physical, and engaging training session designed to make safety second nature.
Inside the Training: 4 Sessions, Real Impact
Each of the four sessions was led by Zara Khan, our highly experienced Exercise Physiologist and rehabilitation expert. She broke down safe manual handling techniques into clear, practical steps, using real-life scenarios and hands-on practice. Here’s how the presentation was structured:
Laying the Groundwork
We started each session with a short pop quiz covering basic facts, injury stats, and myths about manual handling. It was a great way to spark discussion and test pre-existing knowledge.
We then moved into the Four Core Principles of Manual Handling:
- Assess the environment
- Check the load
- Engage your core
- Use proper technique: focus on foot placement, grip, and posture
These principles are simple, and when applied correctly, they drastically reduce risk.
Safe Lifting and Carrying Techniques
The core of each session was dedicated to demonstrating safe lifting and carrying techniques, including:
- Lifting from floor to waist
- Overhead and team lifting
- Carrying tools, heavy items, and long objects
- Pushing and pulling loads safely
We walked through the difference between correct and incorrect movement patterns, and team members had the chance to practise and receive real-time feedback. This hands-on approach helped reinforce safer habits, especially for repetitive or physically demanding tasks.
Understanding Vibration and Manual Handling Risks
We then turned our focus to hazardous manual handling, particularly tasks that involve vibration from tools like drills, compactors, and jackhammers. While common, these tools can lead to:
- Grip fatigue
- Reduced circulation
- Long-term joint strain
- Hand-Arm Vibration Syndrome (HAVS)
We conducted a live demonstration to show how vibration impacts hand stability, grip, and endurance. We also covered prevention strategies to reduce risk and improve safety on the job.
This session opened a lot of eyes to risks that often go unnoticed but have lasting consequences if ignored.
Stretching for Injury Prevention
Finally, we introduced dynamic stretching, a simple and effective way to warm up the body and prevent strain.
These movements are quick, take less than 5 minutes, and can be done at the start of a shift, during breaks, or at the end of the day. Incorporating stretching into the daily routine can significantly reduce the likelihood of sprains and strains.
The Impact: Confidence, Engagement, and Safer Worksites
What stood out most was the engagement and enthusiasm of the Future Form team. Across all four sessions, their workers were curious, open, and eager to improve. From apprentices to seasoned workers, everyone took something valuable away.
We wrapped up each session with a Q&A, allowing team members to ask specific questions about their own work routines, lifting techniques, and injury history.
To wrap up each session, we issued every participant with a Certificate of Completion. This not only acknowledged their active engagement in the training, but also reinforced the importance of maintaining safe work practices over time.
These certificates serve as both a formal record of learning and a motivational tool, reminding workers that safety is a skill and one worth recognising.
Why Your Business Should Prioritise Manual Handling Training
According to icare NSW, some of the most common causes of workplace injuries are directly linked to manual handling. In fact, more than 145,000 workers were injured in NSW workplaces from 2012 to 2015. Among these, seven people died and over 1,300 were permanently injured, as reported by SafeWork Australia.
If you’re a business operating in construction, aged care, logistics, or manufacturing, your team is dealing with manual handling risks every day. Providing targeted, engaging manual handling training is one of the best ways to reduce injury, downtime, and insurance claims.
At AusRehab, we offer:
- Tailored manual handling courses
- On-site training options
- Certified instructors with real-world rehab experience
- Support for compliance and injury prevention
Whether you’re looking to upskill your staff, meet compliance, or reduce injury-related costs, we’ve got your back.
Let’s Build a Safer Workforce Together
Looking to get started with expert-led manual handling training?
Our programs are hands-on, evidence-based, and built with your team in mind. By investing in training, you’re taking real steps toward a safer, stronger, and more productive workforce.
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