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The hidden costs of manual load transport

Status: 16.07.2025

The invisible costs manual load transport

At first glance, manually transporting loads such as boxes, packages, or materials appears to be cost-effective: no equipment is required, only manpower.

However, behind every manual handling operation lies a network of costs that are rarely considered but have a huge impact on operating results and employees.

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1. Physical strain and health consequences

Key points of this chapter

  • Heavy physical strain often leads to back problems and impairs the ability to work.
  • Musculoskeletal disorders are a common cause of absenteeism and incur high costs.

What many companies underestimate: Regularly lifting, pulling, or carrying heavy loads can have a significant impact on health. The back—one of the most sensitive areas of the human body—is particularly affected. Muscle tension, disc problems, and chronic back pain are typical consequences that not only affect employees' quality of life but also their ability to work.

Absenteeism due to musculoskeletal disorders is one of the most common causes of sick leave in Germany. These absences not only cause direct costs through continued wage payments and the need for replacements, but also indirect losses through lower productivity and longer throughput times.

2. Hidden productivity losses and operational risks

Key points of this chapter

  • Manual load handling leads to fatigue, slower work, and a higher error rate.
  • Frequent breaks and sick leave cause noticeable losses in productivity.
  • Increased risk of accidents on stairs, ramps, and due to carelessness can lead to high costs and downtime.

People who move heavy objects manually often work more slowly, tire more quickly, and are more prone to errors. These factors add up over the course of a working day and lead to significant losses in productivity—especially when employees take longer breaks or call in sick more often due to overexertion.

Added to this is the increased risk of accidents. One wrong step on the stairs, a moment of inattention when lifting – and it's already happened. Accidents at work caused by manual load transport can not only lead to serious injuries, but also to expensive recourse claims, long downtimes and, in the worst case, permanent incapacity to work.

Typical risks at a glance:

  • Higher risk of injury when transporting goods on stairs or ramps
  • High error rate due to fatigue or overload
  • Time lost due to inefficient transport routes
The picture shows an employee of a craftsman's business using a CargoMaster stair climber to transport a large, heavy roll of material up or down an external staircase. He is operating the stair climber alone and does not need any assistance to transport the heavy load.

3. Psychological and social costs

Key points of this chapter

  • High physical stress can lead to frustration, demotivation, and a sense of injustice within the team.
  • Poor well-being reduces identification with the company and increases staff turnover and dissatisfaction.

What is often overlooked is that high physical strain also affects team morale. Those who regularly have to perform heavy work feel that this is unfair in the long run—especially if their colleagues are not required to do so or if technical aids are lacking. This can lead to frustration, demotivation, and, in the worst case, to employees mentally checking out.

The poorer the physical well-being, the greater the decline in identification with the company. In the long term, this has an impact on staff turnover, the working atmosphere, and the willingness to go above and beyond the minimum requirements.

4. Overall economic overview

A slipped disc or similar work-related health problem not only affects the person concerned, but also has far-reaching financial consequences for the company. A lack of aids or ergonomic support can result in high direct and indirect costs – from treatment costs and lost working hours to productivity losses, staff turnover, and increased insurance costs. The following overview shows examples of cost factors that should be taken into account in the company:

Cost factor

Type

Impact (example)

Treatment / absence

Direct

€1,200 per day of absence due to back problems

Loss of productivity

Indirect

8% drop in performance in midsummer

Material damage

Indirect

2% return rate – rework and replacements

Staff turnover

Indirect

5% employee turnover per year

Accident costs / insurance

Direct/Indirect

€5,000–10,000 expenditure for arbitration

*The figures and information provided are based on our own research and are for guidance only. We do not have access to official sources or complete data sets.

The picture shows an employee of a craftsman's business using a CargoMaster stair climber to transport a large, heavy roll of material up or down an external staircase. He is operating the stair climber alone and does not need any assistance to transport the heavy load.

2. Hidden productivity losses and operational risks

Our CargoMaster series electric stair climbers reduce physical strain when transporting heavy loads up and down stairs – e.g. on construction sites, in public buildings, or in the field. This not only reduces the risk of injury, but also protects the long-term health of employees.

Models such as the CargoMaster C120, the CC system, the powerful A350, and the C400 meet all the requirements for a transportable stair climber – replacing dangerous lifting with safe technology.

5. Conclusion: Smart investing saves money in the long term

Key points of this chapter

  • Manual load transport causes high hidden costs due to physical and emotional strain, absences, and accidents.
  • Investing in ergonomic aids and better work organization increases productivity, reduces absenteeism, and promotes employee satisfaction.

The invisible costs of manual load transport quickly add up—physical strain, lost working hours, declining performance, accidents, and emotional stress all contribute to significant economic disadvantages. A holistic view shows that investments in transport aids such as CargoMaster's electric stair climbers, ergonomic training, and organizational work design pay off through reduced absenteeism, increased productivity, and higher employee satisfaction – measurable in the long term in significantly better results.

The CargoMaster models – with load capacities from 120 kg to 400 kg – offer the right solution for almost any stair transport challenge. Whether transporting heavy household appliances, boilers, vending machines, or sensitive technology, the devices relieve employees physically and mentally while increasing work safety.

After all, it is not just machines or technology that ensure a company's success – it is healthy, motivated people who work efficiently and enjoy their work.

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Der CargoMaster C120

CargoMaster

C120

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up to 120 kg
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Der CargoMaster CC-SYSTEM

CargoMaster

CC-SYSTEM

LOADS

up to 200 kg
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Der CargoMaster CC-SYSTEM LI-ION

CargoMaster

CC-SYSTEM LI-ION

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up to 200 kg
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Der CargoMaster A350

CargoMaster

A350

LOADS

up to 350 kg
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Der CargoMaster C400

CargoMaster

C400

LOADS

up to 400 kg
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