FOR HOME BUILDING WORKERS

MANUAL MATERIAL

HANDLING INJURIES

A BASIC GUIDE FOR PREVENTING

SIMPLE SOLUTIONS
2 • SIMPLE SOLUTIONS for Home Building Workers

SIMPLE SOLUTIONS

TABLE OF CONTENTS

DISCLAIMER

This document is in the public domain and may be freely copied or reprinted. Mention 

of any company or product does not constitute endorsement by the National Institute 

for Occupational Safety and Health (NIOSH). In addition, citations to websites external 

to NIOSH do not constitute NIOSH endorsement of the sponsoring organizations or 

their programs or products. Furthermore, NIOSH is not responsible for the content of 

these web sites.

INTRODUCTION 3

1. Soft tissue injuries 4

2. Costs of injury 5

3. Material handling 6

4. Store and place materials 8

5. Lifting and carrying 10

6. Moving materials 12

7. Raising and lowering 14

8. Raise exterior walls 16

9. Raise roof trusses 18

10. Position and hold materials 20

11. Repetitive handling 22

12. Strengthen and lengthen 24

13. Summary 26

14. Worker protection 28

15. Construction safety resources 30

ACKNOWLEDGEMENTS

Jason Cato (Design); Mary Ann Zapalac (Illustrations); National Council of Compensation 

Insurance (unpublished injury cost data, p. 5); Revised NIOSH Lifting Equation (weight 

limit recommendation, p. 16); Jennifer Hess, DC, PhD (pp. 24-25). Special thanks to the 

residential building subcontractors and workers whose participation in focus groups 

shaped this booklet.
SIMPLE SOLUTIONS for Home Building Workers • 3

INTRODUCTION

SIMPLE SOLUTIONS

Home building is physically demanding work and manual material 

handling may be the most difficult part of the job. Manual material 

handling includes all of the tasks that require you to lift, lower, push, 

pull, hold or carry materials. 

These activities increase the risk of painful strains and 

sprains and more serious soft tissue injuries. 

Soft tissues of the body include muscles, tendons, ligaments, discs, 

cartilage and nerves. Soft tissue injuries cause workers pain, suffering 

and lost income. They can also restrict non-work activity, like sports 

and hobbies. Builders’ and employers’ costs include loss of productivity 

and high workers’ compensation insurance premiums. 

This booklet provides basic information about readily available work 

practices and equipment that can help both new and experienced 

workers, contractors and builders prevent serious manual material 

handling injuries. 
4 • SIMPLE SOLUTIONS for Home Building Workers

SOFT TISSUE INJURIES

SOFT TISSUE INJURIES

 Are common with manual 

material handling

 Occur suddenly or develop 

over time

 Affect the low back, 

shoulders, neck, elbows, arms, 

hands, wrists, hips, legs, knees, 

ankles and feet

 Cause everyday discomfort, 

pain and may lead to disability

 Can take months or years to 

repair—if they ever do

 Interferes with work and 

non-work activities

Soft tissue injuries are 

different than broken bones, 

bruises, or punctures. They 

are injuries of the muscles, 

discs, tendons, ligaments, 

cartilage and nerves.

ROTATOR CUFF TEAR

HIP-LOW BACK STRAIN

HERNIATED DISC
SIMPLE SOLUTIONS for Home Building Workers • 5

COSTS TO WORKERS

COSTS TO EMPLOYERS

COSTS TO SOCIETY

 Discomfort, pain & loss of 

income

 Restricted activities, like 

sports and hobbies

 Possible health care expenses

 Loss of productivity

 Increased workers’ 

compensation premiums

 Medical expenses for 

uninsured workers

 Social Security disability 

payments

Workers’ compensation 

costs for an average losttime injury for a shoulder 

are $20,000 and for a 

back $25,000.

COSTS OF INJURY
6 • SIMPLE SOLUTIONS for Home Building Workers

Stress on the body and risk of injury increase when you: 

STRESS ON THE BODY

MATERIAL HANDLING

 Lift, carry, or hold heavy, unbalanced materials, especially 

 far from the body.

 Use jerking or fast movements to lift or place materials.

 Bend and twist your back when picking up materials.
SIMPLE SOLUTIONS for Home Building Workers • 7

Stress on the body and risk of injury also increase when you: 

STRESS ON THE BODY

MATERIAL HANDLING

 Hold materials overhead or away from the body for 

long periods.

 Repeatedly lift, hold, and place heavy materials.

 Hold materials away from the body.
8 • SIMPLE SOLUTIONS for Home Building Workers

Material storing problems commonly include:

 Not planning where materials should be staged before they are delivered.

 Staging materials far from where they will be used results in unnecessary 

handling.

 Storing materials too low to the ground or in confined areas makes 

handling more difficult. ‘Waist’ or ‘belt’ height is best.

Poorly placed materials increase material handling and the risk of 

injury and decrease productivity.

PROBLEMS

STORE & PLACE MATERIALS
SIMPLE SOLUTIONS for Home Building Workers • 9

Better material storage and placement includes:

SOLUTIONS

STORE & PLACE MATERIALS

 Plan in advance where materials will be stored when they are delivered.

 Stage materials close to where they will be used and where they will 

not be in other’s way.

 Store materials off the ground and between knee and chest height. 

Leave walking space between materials.

Placing materials near the work area decreases material handling and 

injury risk and increases productivity.
10 • SIMPLE SOLUTIONS for Home Building Workers

Avoid bending down to lift long boards of lumber. Pad your shoulder 

to cushion the weight of the board. Lift only one end of the board 

before standing and walk to the middle of the board. Rest the board 

on your shoulder and raise the board.

LUMBER

LIFTING & CARRYING
SIMPLE SOLUTIONS for Home Building Workers • 11

It’s easier to lift sheet goods off a raised pile. But when they are closer to the 

ground, use your legs to lift, not your back. Get as close as possible to the 

sheet. Raise the sheet and then tilt it so you can get a firm hold in the center. 

Then let the sheet become level and raise it to a comfortable position.

SHEET MATERIALS

LIFTING & CARRYING
12 • SIMPLE SOLUTIONS for Home Building Workers

Using simple tools and equipment can reduce the strain on the body 

when carrying heavy materials. 

HAND TOOLS

MOVING MATERIALS

Handles made with pipe and straps for 

2 people to carry heavy lumber.

One-person & 2-person panel carriers 

reduce bending and make carrying easier.

Drywall dolly keeps materials off ground 

& moves sheet materials on floors.

Adjustable panel dolly supports heavy 

weights on pneumatic tires. 
SIMPLE SOLUTIONS for Home Building Workers • 13

Builders/contractors can provide powered equipment to move 

the heavier materials. Using powered equipment reduces stress 

on the body & increases worker productivity.

Suppliers can unload materials using truck 

mounted cranes or fork trucks.

Skid steer loaders can move materials 

around on difficult building sites.

HANDLING EQUIPMENT

MOVING MATERIALS

Work site fork trucks can quickly move 

materials to where they will be used. 

Move materials with walk-behind load- ers, power-wagons and other compact 

equipment.
14 • SIMPLE SOLUTIONS for Home Building Workers

Raising and lowering heavy materials increases the risk of soft 

tissue injuries of the back, shoulder and neck. Struck-by injuries 

and falls from heights can increase when heavy loads are handled 

between levels.

PROBLEMS

RAISING & LOWERING

OSHA requires that one hand grasp a ladder at all times, and it 

prohibits holding materials while climbing up and down a ladder.
SIMPLE SOLUTIONS for Home Building Workers • 15

Prevent injuries by handling smaller weights for less time. Use 

mechanical lifting equipment to eliminate unnecessary manual 

material handling.

SOLUTIONS

RAISING & LOWERING
16 • SIMPLE SOLUTIONS for Home Building Workers

PROBLEMS

RAISE EXTERIOR WALLS

Exterior walls 12 ft. and longer weigh more than 250 lbs. Lifting walls 

by hand increases the risk of muscle strains and other injuries. Never 

lift more than 50 lbs. without getting help. Use enough people so no 

one lifts more than 50 lbs.

Lift with legs, not with your back. Work together, not against 

each other. Use wall stops and bracing to steady the wall.
SIMPLE SOLUTIONS for Home Building Workers • 17

SOLUTIONS

RAISE EXTERIOR WALLS

Manual and powered wall jacks can be used to raise heavy exterior 

walls. Smaller crews can easily raise heavy walls using the jacks, which 

can be purchased or rented.
18 • SIMPLE SOLUTIONS for Home Building Workers

PROBLEMS

RAISE ROOF TRUSSES

Trusses shorter than 20 feet can be raised by hand. Use 

enough people so no one lifts more than 50 lbs. Raise trusses 

with cranes or other equipment when possible. Balance 

trusses between the ropes to prevent roll.

Place & secure boards to use as a truss ‘slide.’ Raise trusses 

with rope attached to peak. Avoid bending truss.
SIMPLE SOLUTIONS for Home Building Workers • 19

SOLUTIONS

RAISE ROOF TRUSSES

Raise roof trusses more than 20 feet long using a crane 

or other equipment. Comply with OSHA fall protection 

and crane safety regulations, and always follow the truss 

manufacturer’s recommendations.
20 • SIMPLE SOLUTIONS for Home Building Workers

Manually holding and placing heavy steel I-beams and wood 

or laminated beams increases workers’ risk of strains and 

sprains, falls, broken bones, and crushed fingers.

PROBLEMS & SOLUTIONS

POSITION & HOLD MATERIALS

Placing a steel I-beam by hand across foundation wall 

can result in a disabling injury or death.

Place steel I-beam using skid steer with tele-boom, 

crane or other powered equipment.
SIMPLE SOLUTIONS for Home Building Workers • 21

Manually holding and positioning sheet materials overhead, 

like drywall, can strain the neck, back, shoulder and arm 

muscles. Use tools like T-braces or mechanical lifts to hold 

sheets against the ceiling. 

PROBLEMS & SOLUTIONS

POSITION & HOLD MATERIALS

Handling drywall overhead fatigues the muscles 

and can lead to neck and shoulder injuries.

Simple tools like the T-brace and panel lift 

reduce fatigue and stress on the body.
22 • SIMPLE SOLUTIONS for Home Building Workers

Repeatedly handling heavy blocks and other materials puts extra 

stress on your body. The weight of the materials and awkward body 

positions – like frequent bending, reaching, and twisting – increase 

your chance of a muscle or joint injury. 

PROBLEMS

REPETITIVE HANDLING
SIMPLE SOLUTIONS for Home Building Workers • 23

Change the way you do the work to reduce injury risks. Place 

materials close to where they are needed. Set up the work to reduce 

bending and twisting. Keep materials close to your body. 

Take short breaks to give muscles and joints needed rest-time.

SOLUTIONS

REPETITIVE HANDLING

Increase height of blocks to reduce bending & twisting.

Use two-level veneer or mason scaffold for higher walls.
24 • SIMPLE SOLUTIONS for Home Building Workers

MUSCLE EXERCISES

STRENGTHEN & LENGTHEN

Stand upright with arms relaxed. Step forward 

slowly with one foot. Do not move knee past 

your ankle. Keep trunk erect. Return to standing. 

Continue for 1 min. Switch legs & repeat.

Slowly make large circles forward and 

backward with each arm while marching in 

place. Continue for 1 min.

Stand upright with arms relaxed. Take a large 

step to the left then return to standing. Repeat 

by stepping to right. Continue for 1 min. 

Stand upright with arms relaxed. Take 5 sidesteps to the right. Take 5 side-steps to the left. 

Repeat 5 times.

Improve core strength and muscle 

tone with these exercises before work 

or during breaks. Exercise slowly, 

don’t bounce!
SIMPLE SOLUTIONS for Home Building Workers • 25

MUSCLE EXERCISES

STRENGTHEN & LENGTHEN

Hold bar (or pretend to) behind neck, arms 

bent at elbows 90°. Gently pull bar backward 

away from head until you feel stretch in the 

front of shoulders. Hold 12 seconds, relax. 

Perform 5 times. 

Stand straight, lock stomach muscles by 

pulling rib cage and pelvis together as 

shown. Try to mildly tighten stomach 

muscles (10%) when lifting objects. Hold 

12 sec, perform 10 times.

Place hands on hips as pictured. Slowly bend 

backwards, keeping knees straight. Do not extend 

your head. Hold 12 sec, perform 5 times. 

Stand straight, extend one leg 

backward, contracting buttock 

muscles. Keep trunk upright. Hold 10 

sec, perform 3 times, each side.

If you have an existing muscle, joint 

or disc injury, or experience pain 

with exercise, consult your doctor before doing exercises. 
26 • SIMPLE SOLUTIONS for Home Building Workers

MANUAL MATERIAL HANDLING can cause 

strains & sprains and more serious injuries to your 

body. These injuries often result in pain, time away 

from work and lost wages. Even less serious injuries 

can keep you from enjoying non-work activities, like 

sports and hobbies.

You can reduce your chance of serious injury by using safe work 

practices and following the recommendations below:

Staging materials far from where they will be used and close to 

the ground increases injury risks.

 Plan ahead to save time and effort.

 Decide in advance where YOU want the materials placed when 

they’re delivered.

 Keep materials off the ground to reduce stressful bending and lifting.

Bending and twisting your body when lifting heavy materials 

increases the risk of muscle and other soft tissue injuries.

 Don’t lift and carry more than 50 lbs. alone. Get help from coworkers.

 Bend your knees and push up with your legs.

 Hold materials close to your body.

 Lift heavier lumber at one end – not the center – and walk to the 

center to lift it. 

 Use tools and equipment to transport heavy materials when possible.

PREVENTING INJURIES

SUMMARY
SIMPLE SOLUTIONS for Home Building Workers • 27

Raising and lowering heavy materials to different work levels 

increases the risk of soft tissue and other serious injuries.

 Lift, hold, and carry materials close to your body.

 Use supports and equipment to hold materials overhead.

 Use platforms for raising materials to different work heights.

 NEVER carry materials in your hands on ladders.

 NEVER lift or position heavy materials standing on a ladder. 

 Use mechanical equipment to raise and lower heavier materials.

 Use fall protection as required when working at heights and raising or 

lowering materials. 

Holding unsupported materials above the shoulders fatigues the 

shoulders and neck and can result in serious injury.

 Use tools and equipment to support materials.

 NEVER support heavy materials on your head.

 Take short breaks to give muscles and joints time to ‘recover’ from 

the strain.

 Use tools & equipment to support heavy loads and reduce your strain.

Repeatedly lifting and positioning heavy materials – like concrete 

blocks – increases the physical stress on the same muscles and soft 

tissues.

 Use boards or scaffolds to keep blocks, mortar, and other materials 

around knee high.

 Don’t twist the body when lifting or placing materials.

PREVENTING INJURIES

SUMMARY
28 • SIMPLE SOLUTIONS for Home Building Workers

RIGHTS & RESPONSIBILITIES

WORKER PROTECTION

Employers must insure their employees have a workplace 

free of recognized job hazards that can cause serious injury 

or death. Federal and State Occupational Safety and Health 

Administrations (OSHA) enforce job safety and health 

regulations to protect workers.

WORKERS’ SAFETY & HEALTH RIGHTS INCLUDE:

 Taking action alone or with co-workers to protect your safety and health.

 Contacting OSHA to request a safety inspection of your job site.

EMPLOYERS’ SAFETY RESPONSIBILITIES INCLUDE: 

 Informing employees about job hazards through training and 

other means.

 Training employees in a language and vocabulary they can understand.

 Providing certain types of personal protective equipment (PPE), including 

fall protection.

If you live in one of the States (or Puerto Rico) shown below, you can get 

your State OSHA contact info by calling Federal OSHA (1–800–321–6742) or 

visiting http://www.osha.gov/dcsp/osp/index.html. 

Alaska, Arizona, California, Hawaii, Indiana, Iowa, Kentucky, Maryland, Michigan, 

Minnesota, Nevada, New Mexico, North Carolina, Oregon, South Carolina, 

Tennessee, Utah, Vermont, Virginia, Washington, Wyoming, and Puerto Rico.

If you live in other States or US Territories, contact Federal OSHA at: (Tel) 

1–800–321–6742 or find the contact information for the nearest Federal OSHA 

Regional or Area office by visiting http://www.osha.gov/html/RAmap.html
SIMPLE SOLUTIONS for Home Building Workers • 29

WORKER PROTECTION

RIGHTS & RESPONSIBILITIES

WORKERS’ COMPENSATION INSURANCE

 Employers must have Workers’ Compensation insurance to pay 

employees’ injury-related medical costs and other benefits in every 

state except Texas. Without Workers’ Compensation benefits workers 

may not receive the medical care or other benefits they deserve. 

 For info regarding individual State Workers’ Compensation programs, 

visit http://www.dol.gov/owcp/dfec/regs/compliance/wc.htm

FEDERAL AND STATE WAGE LAWS

 Federal and State laws require that employers pay employees a 

minimum wage for the regular hours they work. If you work more 

than 8 hours per day or 40 hours per week, you may be eligible for a 

higher wage for the extra hours you work. For info regarding Federal 

wage and overtime pay requirements, call 1–866–487–2365 or visit 

http://www.dol.gov/whd/.

 For info regarding individual State wage and overtime pay 

requirements, visit http://www.dol.gov/whd/contacts/state_of.htm

Employers sometimes classify workers as “independent 

contractors”, rather than as employees. Employees have 

legal rights to minimum wage, overtime pay, Workers’ 

Compensation, job site safety and health and filing OSHA 

complaints. “Independent contractors” do not have these 

protections.

For more information call 866–487–9243 or visit

http://www.dol.gov/whd/workers/misclassification/
30 • SIMPLE SOLUTIONS for Home Building Workers

CONSTRUCTION SAFETY

RESOURCES

For more information about preventing work related injuries and illnesses, you 

can check out the information provided by the following organizations: 

OSHA’S RESIDENTIAL CONSTRUCTION REGULATIONS

Description of Occupational Safety & Health Administration (OSHA) safety & 

health regulations. 

http://www.osha.gov/SLTC/residential/index.html

NIOSH CONSTRUCTION INFORMATION 

Free information about safety and health hazards in the construction industry. 

http://www.cdc.gov/niosh/construction/

CENTER FOR CONSTRUCTION RESEARCH & TRAINING

Source for information about controlling and eliminatingconstruction safety and 

health hazards and training. 

http://www.cpwrconstructionsolutions.org/

WASHINGTON STATE RESIDENTIAL CONSTRUCTION 

SAFETY INFORMATION

http://www.lni.wa.gov/safety/topics/atoz/topic.asp?KWID=252

NATIONAL ASSOCIATION OF HOME BUILDERS

Safety & health information from home builders’ trade association.

http://www.nahb.org/page.aspx/category/sectionID=616

CALIFORNIA FRAMING CONTRACTORS ASSOCIATION

Source for safety information. 

http://www.californiaframingcontractors.org/

INTERFAITH WORKER JUSTICE

Affiliated Worker Centers provide safety & health training in English and Spanish 

and assist workers with other employment problems, like “wage theft”. 

http://www.iwj.org/network/workers-centers
SIMPLE SOLUTIONS for Home Building Workers • 31

RESOURCES

CONSTRUCTION SAFETY

Lifting and carrying more than 50 lbs. increases your risk of low back injury. Use 

the list below to help keep the weight you handle to around 50 lbs.

4 10 ft. 2"x4" 51 lbs.

3 12 ft. 2"x4" 46 lbs.

2 10 ft. 2"x6" 40 lbs.

2 12 ft. 2"x6" 48 lbs.

2 10 ft. 2"x8" 53 lbs.

1 10 ft. 2"x10" 66 lbs.

1 10 ft. 2"x12" 41 lbs.

2 10 ft. 4"x4" 60 lbs.

2 3/8 in. 4'x8' 68 / 77 lbs. 

1 1/2 in. 4'x8' 45 / 54 lbs.

1 5/8 in. 4'x8' 58 / 67 lbs.

1 3/4 in. 4'x8' 68 / 80 lbs.

1 7/16 in. 4'x8' 96 lbs. 

1 6"x8"x16" 22 / 34 lbs. 

1 8"x8"x16" 27 / 44 lbs.

1 12"x8"x16" 35 / 55 lbs.

LUMBER PIECES (KILN DRIED)

SHEETS— PLYWOOD / OSB

SHEETS — CEMENTITIOUS BACKBOARD

CONCRETE BLOCKS — LIGHT WT. / NORMAL WT.

1 10 ft. 1 3/4"x9 1/4" 47 lbs.

1 10 ft. 1 3/4"x11 7/8" 61 lbs.

1 10 ft. 1 3/4"x14" 71 lbs.

LVL (LAMINATED VENEER LUMBER) PIECES
Delivering on the Nation’s promise:

safety and health at work for all people

through research and prevention.

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occupational safety and health topics, contact NIOSH:

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DHHS (NIOSH) Publication No. 2013–111

SAFER • HEALTHIER • PEOPLETM

DEPARTMENT OF HEALTH AND HUMAN SERVICES

Centers for Disease Control and Prevention

National Institute for Occupational Safety and Health