Manual task solutions - Trolleys

The selected design should suit the load, environment, task and workers using the trolley, otherwise they may introduce new risks. 

Employees at a commercial laundry service were using a standard shopping trolley to transport laundry from a washing machine to a dryer. This increased the risk of back injuries to workers as they were repetitively twisting and bending to either pick up or place the laundry into the shopping trolley. The risk of injury was further increased as the trolleys were difficult to move and push, particularly when full, due to the small castors which frequently clogged with lint from the floor.  

The risk of injury could be reduced by providing more appropriately designed trolleys.

Design features which would have been more suitable included:

• height-adjustable or spring-loaded platforms;
• caged trolleys with a removable side;
• appropriately sized and number of castors to improve the manoeuvrability.

When selecting trolleys at your workplace and the systems to support the use of trolleys, the process should consider the trolley design features to match several aspects of the manual task, including the:

• task, organisation and work practices
• environment
• load
• worker characteristics  

The most effective risk controls allow workers to trial solutions before they are implemented. Where possible, trolleys should be trialled by the workers who will be using the equipment.  During this period workers should be consulted on the suitability of the trolley for the task. Consider obtaining information from the supplier or manufacturer and your industry association in order to establish if a trolley is suitable for the workplace.

The push/pull forces required to move a trolley must be kept within safe limits, in order to reduce the risk of strain injuries as well as the risk of slipping while trying to move and control a trolley. Prior to purchasing a trolley, consideration should be given to the environment and the loads being moved, since the push/pull forces required to move the trolley are influence by the weight of the loaded trolley; the floor surface and gradient; and the castor material and design. 

Consider where the trolley will be stored and how easy is will be for workers to retrieve the trolley when it is required (distance, obstructions such as doors or steps between storage and trolley use areas, etc.). Workers must be able to identify where the trolley is stored.

When selecting a trolley, consider the likely cost, frequency and method and type of maintenance. For example:

• Is the trolley used in outdoor or wet environments? Is there a risk of rust building up, risk of wear and tear from rough surfaces?
• Is the floor surface likely to have contaminants (for example lint, metal shavings or chemicals) which may affect the castor manoeuvrability?
• What maintenance or repair can be undertaken internally without requiring external assistance?
• Can parts such as castors, spring-loaded bases or frames be replaced or retro-fitted?
• How easy is it to find spare parts, modifications, and add-ons etc. (eg whether the supplier is local or parts need to be ordered)?

It is recommended that employers establish a maintenance routine to ensure the trolley is maintained, for example implementing an inspection routine, maintenance schedule and reporting system to ensure faults or damage are identified and repaired; and establishing contacts for external maintenance support.