Manual handling basics for couriers

Manual handling plays a steady part in courier work, even if most customers use forklifts or warehouse kit to unload larger pallets. You still tighten straps, move smaller items, shift boxes, adjust loads and work inside tight van spaces. Good habits protect your body and your business, especially if you’re new to the industry.

In this guide, we’ll cover manual handling basics for A to B deliveries and gives you practical steps you can use on every job.

What manual handling means in courier work

Manual handling covers any activity where you lift, lower, push, pull or move items by hand. In day-to-day courier work this usually means shorter movements rather than heavy lifting. But the risks still build up, especially over long days.

You’ll come across situations like:

• Adjusting pallets that aren’t sitting straight.
• Tightening or releasing load restraints and ratchet straps.
• Carrying boxes or loose items to or from the van.
• Using sack trucks for bulkier goods.
• Working inside the load area where space is tight.

Even when a forklift operator manages the pallet work, you still handle smaller pieces or shift things to make loads safe to travel. That’s all part of manual handling, and every movement matters.

Assess the load before you move it

A quick pause helps you move safely and reduces strain. Think about the load, your route and your footing before you lift or push anything.

Ask yourself:

• What does it weigh? Can one person carry it?
• Is the item stable? Does it tilt or move unexpectedly?
• Can you hold it securely without sharp edges catching you?
• Do you have a clear walking path from the van to the delivery point?

Check for uneven ground, slopes, wet surfaces or clutter around loading bays. These hazards cause more injuries than the load itself. You may also need to ask the customer to reposition a pallet if it sits badly. Most people accept this quickly, especially in warehouse settings where safety is a shared priority.

If you also deal with longer runs, such as international courier work, you’ll see more unfamiliar sites, so a quick assessment becomes even more useful.

Safe lifting technique for courier tasks

Good lifting doesn’t need to look textbook-perfect, but it needs to protect your back. You don’t need to move fast. You only need to move well.

Keep these habits in mind whenever you handle smaller items:

• Keep the item close to your body.
• Stand with your feet shoulder-width apart.
• Bend through your hips and knees.
• Lift smoothly and avoid twisting mid-movement.
• Place the item down with control.

You’ll use safe lifting whenever you move a bulky parcel, shift a box of parts or reposition goods in your van. These habits help even more on longer shifts where tired muscles make sloppy movements more likely.

Using equipment that supports safe movement

Handling equipment reduces strain and makes manual work easier.

Sack trucks, pallet trucks and basic van gear give you more control and protect your body over a long day.

Sack trucks

Sack trucks help you move compact, heavy goods that are awkward to lift by hand.

Use them on level ground and keep your hands clear of the wheels. A steady pull avoids sudden jerks that strain your shoulders. If you deliver heavier items during overnight courier jobs, sack trucks become even more helpful as muscles tire towards the end of a long shift.

Pallet trucks

Some couriers carry manual pallet trucks, especially when they deal with lighter warehouse goods.

Only use them on suitable surfaces and watch for slopes or broken concrete. Push rather than pull if you can. You get better control and your body works more naturally in front of the load.

Straps, ratchets and load bars

Securing pallets can strain your wrists, elbows and shoulders. Face the ratchet squarely, use two hands and avoid yanking. If a strap sits too high or too low, adjust your stance before tightening. Every movement adds up through a long day of handling tasks, so small changes help.

Common manual handling risks inside and around the vehicle

Your van creates its own set of hazards. The space is small, the roof can be low and the floor may get dusty or wet.

Inside the van

Most injuries inside the van happen due to:

• Overreaching into the load area.
• Crouching for long periods.
• Slipping on dusty or wet floors.
• Twisting while placing items.

Working with manual lifting in a small space demands patience. Move slowly and square up to the item instead of twisting your spine.

At the kerbside

Slopes, wet surfaces and uneven ground create ankle and knee risks. Watch out for kerbs, loose gravel or stacked pallets around industrial estates. These hazards become more common when you handle courier jobs in busy city areas or older industrial parks.

At customer sites

Warehouses and yards may have forklift traffic, pallet debris or noisy environments.

Keep a safe distance whenever a forklift operator moves a pallet. Never step under a raised load and avoid placing your hands anywhere near a moving pallet. The safer your distance, the fewer surprises you’ll deal with.

How to avoid the most common injuries in courier work

Couriers deal with repeated strain rather than single heavy lifts.

Over time, bad habits lead to back, shoulder, knee and wrist issues.

The biggest risks come from:

• Twisting while lifting boxes.
• Using too much force on ratchets.
• Moving unbalanced items.
• Poor footing on uneven surfaces.
• Sudden pulls instead of controlled movements.

A few small changes protect your long-term health.

If you carry smaller items often, consider personal protective equipment (PPE) like gloves that improve grip.

If your delivery work includes chilled and frozen transport, wear the right clothing so cold muscles stay warm and mobile.

If you offer bulk transport or waste transport that require a waste carrier licence, footwear with strong grip helps even more.

Good manual habits also support broader safety issues like tyre checks, which involve bending and reaching around wheels. Every movement you make during your working week benefits from safer patterns.

When not to handle the load

You don’t need to lift, shift or carry anything that feels unsafe. It’s fine to tell a customer the item needs two people or mechanical equipment.

Say no if:

• The load is too heavy for one person.
• The parcel or box has unstable contents.
• You can’t get a secure grip.
• The route is blocked or unsafe.

Clear communication helps you complete the delivery without risk. You still deliver professionally without injuring yourself. If you transport goods under ADR regulations, these rules become stricter and you may need to keep extra distance from hazardous items.

If a job goes beyond safe handling, it often comes with higher risk factors, and these risks link directly with your courier insurance costs. Many new drivers learn this the hard way, so it helps to take a cautious approach from the start.

Quick manual handling checklist for daily use

A simple list helps you build good habits through busy days.

• Check weight and shape before you lift.
• Clear your walking route.
• Use kit when you can.
• Keep items close to your body.
• Lift with both legs and avoid twisting.
• Place items down with control.
• Stop if something feels unsafe.

This checklist supports everyday tasks, whether you handle parcels, move parts or shift pallets used for manual load handling. It also supports your long-term wellbeing, especially when you focus on staying healthy as a courier.

Final thoughts: work smarter and protect your body

Good manual handling helps you work safely and confidently in every setting. You don’t need to move quickly. You only need to move well. These habits protect your body, reduce downtime and support steady work, whether you run local routes or take on international courier loads.

Safe habits also support your wider business. Many customers expect drivers to operate carefully, especially those who deal with courier insurance, public liability insurance or other compliance areas. When you move goods with care, you work more professionally and reduce the chance of damage or injury.

If you expand into specialist services like chilled transport, ADR or high-value courier jobs, your handling habits matter even more. And if you want to grow your income through additional courier work, the way you handle goods often shapes how customers see you.

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