MAN/Specific Tasks/TBT-MAN-011

Handling Pipes and Ducting

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Handling Pipes and Ducting

Toolbox Talk Record

Ref: TBT-MAN-011  |  Issue: 1  |  Date: March 2026
PresenterProject
LocationDate

What?

  • Pipes and ducting come in a wide range of sizes, materials, and weights from lightweight plastic to heavy steel.
  • Long pipe sections are awkward to carry, creating risk of striking others and losing balance.
  • Pipe bundles stored on site can roll, shift, and collapse if not properly chocked and restrained.
  • Lowering pipes into trenches manually is a common cause of back injuries and crushed hands.
  • Mechanical aids including mini cranes, vacuum lifters, and pipe hooks reduce manual handling injuries.
  • The Manual Handling Operations Regulations 1992 require employers to avoid or reduce risky manual handling.
  • Pipe ends and cut edges can be sharp, causing cuts and lacerations during handling without gloves.
  • Team lifting of long pipes requires coordination and communication to prevent uneven loading on individuals.
  • Large-diameter pipes stored upright must be secured against toppling with chains or restraint systems.
  • Cold weather makes metal pipes harder to grip and increases the risk of hand injuries during handling.

Why?

Back injuriesManual handling of heavy pipes is one of the most common causes of musculoskeletal injuries in construction.
Crush and strikePipes rolling from stacks, swinging during lifting, or falling from trenches cause crush injuries and broken bones.
Legal dutyThe Manual Handling Operations Regulations 1992 require mechanical aids where manual handling risk cannot be avoided.
Do Don't
  • Use mechanical lifting aids for pipe sections that exceed safe manual limits.
  • Chock and restrain pipe stacks to prevent rolling and collapse on site.
  • Wear cut-resistant gloves when handling pipes with sharp ends or edges.
  • Coordinate team lifts with clear communication and matched lifting actions.
  • Lower pipes into trenches using slings, pipe hooks, or excavator assistance.
  • Secure upright pipes against toppling with chains, straps, or A-frame supports.
  • Plan pipe storage areas on flat ground away from traffic routes and edges.
  • Assess the weight and length of each pipe before deciding the handling method.
  • Use pipe rollers or trolleys to move heavy sections across the site.
  • Brief the team on the handling method and signals before moving each pipe.
  • DON'T manually lift pipes that exceed the safe capacity for your team size.
  • DON'T leave pipe stacks unchocked on sloping ground or near excavation edges.
  • DON'T handle cut pipe ends with bare hands; sharp edges cause deep lacerations.
  • DON'T lower pipes into trenches by dropping or sliding them down the sides.
  • DON'T carry long pipes alone through congested areas where you could strike others.
  • DON'T store pipes where they could roll into traffic routes or work areas.
  • DON'T stand in the path of a pipe being swung, lifted, or lowered.
  • DON'T rush team lifts; uncoordinated efforts cause uneven loading and injuries.
  • DON'T stack pipes higher than two layers without secure separation between rows.
  • DON'T drag pipes across the ground as this damages coatings and joint surfaces.

See also: Manual Handling Awareness | Team Lifting and Mechanical Aids
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