Manual Handling Risk Assessment: Protect Your Workers from Injury

Manual handling is one of the most common causes of workplace injury in the UK. Over 8.9 million working days are lost each year due to musculoskeletal disorders, many caused by poor manual handling practices.

What Is Manual Handling?

Manual handling means transporting or supporting a load by hand or bodily force. This includes:

• Lifting and carrying
• Pushing and pulling
• Moving loads by hand
• Team handling

Legal Requirements

The Manual Handling Operations Regulations 1992 require employers to:

1. Avoid hazardous manual handling where possible
2. Assess the risk of injury from any hazardous handling
3. Reduce the risk of injury to the lowest level reasonably practicable

When Is an Assessment Required?

You need a manual handling risk assessment when employees must:

• Lift loads heavier than 25kg (men) or 16kg (women) repetitively
• Carry loads over distances
• Push or pull heavy objects
• Handle loads in awkward positions
• Work in poor conditions (lighting, space, floor surfaces)

The TILE Assessment Method

Use the TILE framework to assess manual handling risks:

T - Task

Consider the nature of the task:

• Does it involve twisting or stooping?
• Is there excessive reaching?
• Are there repetitive movements?
• Is the work rate too high?
• Does it require sustained effort?

I - Individual

Assess the person doing the work:

• Age and fitness level
• Physical capability and limitations
• Training received
• Previous injuries or conditions
• Pregnant workers or new mothers

L - Load

Evaluate what's being moved:

• Weight of the load
• Size and shape
• Is it awkward or unstable?
• Are there sharp edges or hot surfaces?
• Is the load difficult to grip?
• Is the weight evenly distributed?

E - Environment

Check the surroundings:

• Floor conditions (slippery, uneven)
• Space constraints
• Lighting levels
• Temperature and ventilation
• Obstacles in the way
• Stairs or level changes

Weight Guidelines

The HSE provides guideline weights for lifting:

| Position | Men | Women | |----------|-----|-------| | Arms close to body, waist height | 25kg | 16kg | | Arms extended from body | 5kg | 3kg | | Below knee height | 15kg | 10kg | | Above shoulder height | 10kg | 7kg |

These are guidelines, not limits. Actual safe weights depend on the TILE factors.

Control Measures

Eliminate the Hazard

• Use mechanical aids (trolleys, hoists, forklifts)
• Have goods delivered directly to point of use
• Order smaller packages
• Use contractors for heavy work

Reduce the Risk

• Use team lifting for heavy items
• Reduce distance of lifts
• Improve workplace layout
• Provide handles or grips on loads
• Split loads into smaller units

Engineering Controls

• Install conveyors or rollers
• Use adjustable height workbenches
• Provide sack trucks and pallet trucks
• Install hoists for patient handling

Administrative Controls

• Rotate workers between tasks
• Provide adequate rest breaks
• Set weight limits for manual handling
• Plan delivery schedules to avoid peak times

Personal Protective Equipment

• Safety footwear with good grip
• Gloves for grip and protection
• Back supports (note: not a substitute for proper technique)

Training Requirements

All employees who carry out manual handling should receive training covering:

1. Manual handling hazards and risks
2. Safe lifting techniques (kinetic lifting)
3. Use of equipment and aids
4. Reporting procedures for problems
5. Individual capabilities and limitations

Safe Lifting Technique

1. Plan the lift - where are you going?
2. Position feet shoulder-width apart
3. Bend knees, keep back straight
4. Get a firm grip on the load
5. Lift smoothly using leg muscles
6. Keep the load close to your body
7. Avoid twisting - turn with your feet
8. Set down by reversing the process

Common Injuries

Manual handling injuries include:

• Back injuries (slipped discs, muscle strain)
• Neck and shoulder injuries
• Repetitive strain injury (RSI)
• Hernias
• Cuts and bruises from loads
• Fractures from dropped items

These injuries often develop over time from repeated poor practice, not just single incidents.

Documentation

Your manual handling risk assessment should record:

• The tasks assessed
• Who is at risk
• The TILE factors identified
• Current control measures
• Additional actions needed
• Review date

Review and Monitoring

Review your assessment:

• Annually
• When work processes change
• After an injury or near-miss
• When new equipment is introduced
• When employees report problems

Summary

Manual handling injuries are preventable. By following the TILE assessment method and implementing appropriate controls, you can protect your workers and reduce lost time.

Next Steps

• Create a manual handling risk assessment
• Read about working at height risks
• Learn the 5 steps to risk assessment