What is the problem?

Manually lifting, carrying and installing timber beams can lead to sprains and strains. These tasks often involve:

  • Unloading beams from delivery trucks
  • Moving beams across site
  • Installing and securing beams

Timber beams are typically long, rigid and heavy, which makes them difficult to balance and manoeuvre. Their length and shape often mean they must be handled on one side of the body, increasing the strain on ligaments and muscles.

Beams come in various forms, including laminated veneer lumber (LVL), solid timber, and glued laminated timber (glulam). Sizes commonly range from 90 mm x 45 mm to 300 mm x 90 mm, with lengths ranging from 2.4 m to over 6 m. Depending on the material, thickness and size, individual beams can weigh around 10 kg to over 60 kg, making them hazardous when handled manually.

What is the risk?

If not properly controlled, handling beams can cause musculoskeletal injuries, including sprains and strains to the back, shoulders, neck, wrists and hands. Common risk factors include:

  • High forces due to the weight of beams when lifting, carrying or positioning
  • Awkward bending, twisting and reaching postures when manoeuvring or installing beams overhead, in tight spaces, and places where access is difficult
  • Sustained force when holding beams in place while fixing
  • Awkward wide grips due to beam size and shape

Injuries may happen suddenly or develop gradually after repeated or prolonged exposure to these tasks.

How to reduce the risk?

Site preparation – Planning ahead is key

  • Consider delivery access, beam size/ weight, and storage location to minimise double handling
  • Communicate early with the supplier about delivery timing and the availability of mechanical lifting aids
  • Store beams as close as reasonably practicable to the installation area to reduce carrying distances
  • Ensure the delivery truck can park close to the work area, with clear access for unloading and the use of mechanical aids
  • Check ground conditions and, if needed, provide ramps or continuous paths to ensure wheeled trolleys can be used safely
  • Consult with workers and subcontractors during planning to identify risks and agree on safe handling methods.

Use mechanical aids wherever possible

Crane, forklift, telehandler or other suitable plant - for unloading and positioning beams. Ensure suitable attachments are used.1395927

1395928

Beam trolleys or dollies – for transporting beams across site

1395930

  • Use heavy-duty equipment designed for long, rigid materials.
  • Consider the castor type which is suitable for the ground conditions.
  • Follow manufacturer recommendations for load limits, maintenance and directions of use.
  • Operate with two workers: one guiding from the front, one supporting from the rear

Mechanical lifters – for positioning beams overhead

1395931

  • Ensure equipment is well maintained, suitable for beam size and weight, and operated by trained workers

When manual handling of beams is still required, consider other ways that work could be organised to make the task easier, including:

  • Storing beams on bearers or stands to avoid lifting from ground level.
  • Minimising carry distances and allow short rest breaks for grip adjustment and recovery.
  • Rotating handling tasks between workers to reduce fatigue and prolonged exposure.
  • Breaking up manual handling tasks to avoid long periods of continuous lifting and carrying.
  • Using gloves that protect hands and improve grip to reduce strain and the risk of dropping materials.
  • Briefing workers on load characteristics and safe handling (e.g., team handling / two people lift) before starting the task.

*Some images in this factsheet are computer generated for illustrative purposes only. They may not accurately represent actual workplaces, equipment, or work practices.