Lift Smart: Five Manual Materials Handling Tips for Drivers

May 20, 2026

Manual materials handling is a part of the job for many drivers, and so are the risks that come with it. Sprains, strains, and back injuries are among the most common workplace injuries in trucking.

As we noted in a previous blog, 80% of driver injuries happen when the truck isn’t moving. Most of these injuries are preventable and these five tips are drawn from the CarriersEdge Manual Materials Handling course and give fleet managers practical coaching points to share with drivers.

Download a free driver tip sheet

Tip 1. Use a mechanical aid instead of lifting manually

The safest lift is the one that never happens. Carts, dollies, hand trucks, and pallet jacks exist for a reason, and drivers should be reaching for them whenever they are available.

Fleet managers can make sure drivers know what mechanical aids are available, where to find them, and how to operate them correctly. When that information is in place, using a cart becomes the easy choice rather than an afterthought.

Reducing manual lifting is not about avoiding effort. It is about protecting the people doing the work and keeping them healthy for the long term.

Tip 2. Plan before you pick anything up

A moment of planning before a lift can prevent an injury that sidelines a driver for weeks. Before moving any load, drivers should think through the full picture:

• Where does the load need to go?
• Is the destination clear and at a safe height?
• Is the path free of obstacles?
• Can the distance be reduced?
• Is there a cart that should be used instead?

These questions take seconds to build into a routine and can make a significant difference in injury rates across a fleet.

Tip 3. Keep loads in the green zone

The green zone is the safest position for carrying a load: close to the body, with arms bent and elbows near the sides, between shoulder and waist height. When a load stays in that zone, the risk of strain drops significantly. The farther a load is held away from the body, the greater the force placed on the back and shoulders.

Coach drivers to get the object into the green zone before bearing its full weight. If a load is on the floor, slide it close to the body before lifting, and lift with the legs, not the back. Get the load above knee height before beginning to carry, and once the load is moving, keep it close and keep it stable. The type of lift may vary depending on what is being moved, but the green zone principle applies across the board.

Tip 4. Protect your spine on every lift

Most back injuries in manual handling come down to the same root cause: poor form. Drivers who bend at the waist, twist while carrying, or rely on strength alone are taking on real risk every time they move freight.

Drivers should keep a neutral spine throughout every lift: back and hips straight, knees bent when picking up from the floor. When turning, the whole body should pivot or walk around rather than twisting at the waist.

Remind drivers that the goal is not to put their back into it. The goal is to use leg strength and proper mechanics to move the load without putting the spine under unnecessary stress. Posters in loading areas, brief pre-shift reminders, and regular coaching conversations all help keep neutral spine top of mind.

Tip 5. Know your limits before you lift

Not every load is what it appears to be, and not every driver is in the same condition from shift to shift. Both of these realities matter when it comes to safe materials handling.

Before attempting to move a load, drivers should check paperwork for weight information and physically test a load before committing to a full lift. Compromised handles, unstable stacking, or unexpected weight are all signs to stop and reassess. Options include repacking into smaller loads, asking for help, or using a mechanical aid.

Fatigue matters too. Drivers going straight from a long drive into physical work, or moving between warm and cold environments, are at higher risk of injury. Coach drivers to warm up before any handling task: lunges, trunk rotations, reaching overhead, and light walking all help get muscles ready. When fatigue sets in, a short break is far better than pushing through and getting hurt.

Prevention is the point

Manual handling injuries are preventable. Fleets that coach these habits consistently see fewer injuries, less time lost, and lower costs. Use the tools available, plan the move, keep loads close, protect the spine, and know the limits. Building those habits takes repetition, and that starts with fleet managers who make it a priority.

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Download a free driver tip sheet to share with your drivers.