How to Do a Manual Handling Risk Assessment

Manual handling risk assessment is a legal requirement under the Manual Handling Operations Regulations 1992. A proper assessment identifies hazards, evaluates risks, and determines what control measures are needed to protect workers from injury.

What is a manual handling risk assessment?

A manual handling risk assessment is a systematic examination of tasks involving lifting, lowering, pushing, pulling, or carrying to identify what could cause injury and determine what measures are needed to control the risks.

Purpose of assessment

Risk assessments serve multiple purposes:

Legal compliance:

• Required by Manual Handling Operations Regulations 1992
• Demonstrates you've identified hazards and evaluated risks
• Shows you've considered control measures
• Evidence of meeting legal duties

Injury prevention:

• Identifies hazards before injuries occur
• Prioritizes risks requiring urgent attention
• Determines appropriate control measures
• Provides basis for implementing improvements

Organizational benefits:

• Reduces injuries and associated costs
• Improves productivity (less fatigue and discomfort)
• Supports better workplace design
• Informs equipment and purchasing decisions
• Guides training priorities

Worker engagement:

• Involves workers in identifying risks and solutions
• Demonstrates employer commitment to safety
• Provides information workers need to work safely
• Creates dialogue about manual handling concerns

When assessment is required

You must assess manual handling operations that involve "a risk of injury."

This means:

Obviously high-risk tasks:

• Lifting heavy loads (approaching or exceeding guideline weights)
• Very frequent or sustained manual handling
• Awkward postures (bending, twisting, reaching overhead)
• Long carrying distances
• Handling unstable or difficult-to-grip loads

Less obvious risks:

• Light loads handled very frequently
• Occasional but strenuous handling
• Handling in confined spaces
• Handling by vulnerable workers
• Pushing or pulling requiring significant force

When in doubt: If there's any possibility of injury, assess it. The cost of assessment is minimal compared to the cost of injury.

The TILE assessment framework

TILE is the most widely used framework for manual handling risk assessment in the UK. It provides a structured approach to examining all relevant risk factors.

Overview of TILE

TILE stands for:

• Task - What does the activity involve?
• Individual - Who performs it and are they capable?
• Load - What is being handled?
• Environment - Where is the work being done?

Why this framework works:

• Systematic - ensures all factors considered
• Comprehensive - covers all major risk categories
• Memorable - easy for assessors to remember
• Flexible - applies to any manual handling task
• Recognized - widely accepted by HSE and industry

The assessment examines how these factors interact:

• No single factor determines risk
• Combinations create higher risk than individual factors
• Same task can be low risk in one situation, high in another
• Must consider all four elements together

T - Task factors

The task is what workers actually do - the movements, postures, and actions involved.

Key questions about the task:

What movements are required?

• Lifting from what height? (Floor level is highest risk)
• Lifting to what height? (Overhead is high risk)
• How far is the load carried?
• What postures are needed? (Bending, twisting, reaching)
• Is the task static or does it require movement?

How often is it performed?

• Many times per hour, shift, day?
• Continuous or intermittent?
• Any recovery time between handling?
• Seasonal variations in frequency?

What makes the task difficult?

• Awkward starting or ending positions
• Need for precision in placement
• Confined spaces restricting movement
• Obstacles in the path
• Time pressure or pacing
• Unpredictable movements required

High-risk task indicators:

• Handling loads while seated or in confined space
• Twisting the trunk or sideways bending
• Reaching upwards or bending down
• Large vertical movement (floor to height or vice versa)
• Long carrying distances (more than 10 meters)
• Repetitive handling (more than 30 times per hour)
• Insufficient rest or recovery
• Fast-paced or timed work
• Holding or manipulating loads at distance from body

I - Individual factors

Individual capability varies enormously. What's safe for one person may be too much for another.

Key questions about individuals:

Who performs this task?

• Range of workers (permanent, temporary, contractors)
• Age range and experience levels
• Physical size and build variations
• Gender considerations (guideline weights differ)

Physical capability:

• Strength and fitness levels
• Any existing health conditions or injuries
• Previous back or musculoskeletal problems
• Restrictions from occupational health

Special considerations:

• Pregnant workers (changing center of gravity, ligament laxity)
• Young workers (inexperienced, still developing)
• Older workers (reduced strength and recovery)
• Workers with disabilities or long-term conditions
• Those returning from injury or illness

Experience and training:

• How experienced with this task?
• Have they been trained in safe techniques?
• Do they understand the risks?
• Can they recognize when help is needed?

Individual risk indicators:

• History of musculoskeletal problems
• Pregnancy (especially second and third trimester)
• Recent injury or surgery
• Reduced strength or mobility
• Inexperience with the task
• Lack of training
• Not understanding risks

L - Load factors

The characteristics of what's being handled significantly affect risk.

Key questions about loads:

Weight:

• How much does it weigh? (Actual, not estimated)
• Is weight clearly marked?
• Does weight vary? (Partially filled containers)
• How does it compare to guideline weights?

HSE guideline weights reminder:

• Men: 25kg at knuckle height (ideal conditions)
• Women: 16kg at knuckle height (ideal conditions)
• Reduce by half if at arm's length
• Reduce further if frequent or conditions not ideal
• These are guides, not absolute limits

Size and shape:

• How large or bulky is it?
• Can it be held close to the body?
• Does size prevent good posture?
• Awkward or irregular shape?
• Can it be gripped securely?

Stability and grip:

• Is the load stable or does it shift?
• Is there a secure grip point?
• Are there handles or handholds?
• Smooth or slippery surfaces?
• Does the load move unpredictably?

Other characteristics:

• Is it hot or cold to touch?
• Sharp edges or projections?
• Hazardous contents (spills, leaks)?
• Center of gravity off-center?
• Difficult to see over or around?

High-risk load indicators:

• Exceeds guideline weights
• Bulky or difficult to grasp
• Unstable or unbalanced
• Contents shift during handling
• Awkward shape prevents close carry
• No handles or grip points
• Slippery or difficult to hold
• Obscures vision when carried
• Hot, cold, sharp, or otherwise hazardous

E - Environment factors

Where the work is done affects risk as much as what's being done.

Key questions about environment:

Space and layout:

• Adequate space to adopt good posture?
• Room to position feet properly?
• Can loads be accessed easily?
• Are storage heights appropriate?
• Clear routes for carrying?

Floors and surfaces:

• Level and stable?
• Slip-resistant?
• Any steps, slopes, or uneven areas?
• Holes, grates, or trip hazards?
• Suitable for wheeled equipment?

Lighting:

• Adequate lighting to see clearly?
• Shadows or glare affecting vision?
• Can workers see where they're going?
• Can they see loads and grip points clearly?

Temperature and conditions:

• Extreme heat or cold?
• High humidity?
• Adequate ventilation?
• Weather exposure (outdoor work)?
• Effect on capability and fatigue?

Access and constraints:

• Doorways wide enough?
• Need to negotiate stairs or slopes?
• Barriers or obstacles in routes?
• Confined spaces?
• Access restrictions?

High-risk environmental factors:

• Confined spaces preventing proper positioning
• Uneven, slippery, or unstable floors
• Steps, slopes, or level changes
• Poor lighting
• Extreme temperatures
• Cluttered or obstructed routes
• Inadequate space for safe postures
• Storage requiring reaching high or low

Step-by-step assessment process

Follow this systematic process to conduct thorough manual handling risk assessments.

Step 1: Identify all manual handling tasks

Create a comprehensive list:

• Walk through your entire workplace
• Observe all activities
• Talk to workers about what they handle
• Include obvious tasks and occasional handling
• Consider all shifts and seasonal variations
• Don't forget maintenance, cleaning, and ancillary tasks

For each task, note:

• Brief description of what's being handled
• Where it occurs
• Who does it
• How often
• Approximate weights and frequency

Don't overlook:

• Infrequent but strenuous tasks
• Set-up and clean-down activities
• Emergency or breakdown situations
• Tasks done by contractors or visitors
• Handling in ancillary areas (stores, offices)

Step 2: Prioritize tasks for detailed assessment

If you have many tasks, prioritize based on:

• Frequency and number of people exposed
• Severity of potential injury
• Weights approaching or exceeding guidelines
• Known problems (injuries, complaints, near misses)
• New or changed tasks
• Concerns raised by workers

Assess urgently:

• Tasks that have caused injuries
• Very frequent heavy lifting
• Awkward postures with significant loads
• Vulnerable workers doing manual handling
• Tasks workers have raised concerns about

Step 3: Observe tasks being performed

Don't assess from a desk - observe actual work:

• Watch the task being performed by different workers
• At different times of day (fatigue effects)
• Under various conditions (busy periods, normal operations)
• Complete cycles, not just snapshots

What to look for:

• Actual postures and movements (not just what should happen)
• Variations between workers
• Shortcuts or workarounds
• Difficulties workers encounter
• Near misses or loss of control
• Environmental constraints

Talk to workers:

• What makes this task difficult?
• What causes discomfort or fatigue?
• Have they had near misses or close calls?
• What would make it easier or safer?
• Do they use equipment properly? If not, why not?

Step 4: Apply the TILE framework

For each task, systematically examine:

Task factors:

• Document movements, postures, distances
• Note frequency and duration
• Identify awkward aspects
• Consider whether task could be eliminated or redesigned

Individual factors:

• Who does this work?
• Are they capable of doing it safely?
• Any vulnerabilities requiring individual assessment?
• Is training adequate?

Load factors:

• Actual weights (measure, don't guess)
• Size, shape, stability
• Grip and handling characteristics
• Compare to guideline weights

Environment factors:

• Space, layout, access
• Floor conditions and surfaces
• Lighting and temperature
• Constraints and obstacles

Step 5: Evaluate the risk level

Consider likelihood and severity:

Likelihood: How likely is injury?

• High: Injuries have occurred or near misses frequent
• Medium: Could reasonably cause injury
• Low: Unlikely to cause injury

Severity: How serious could injury be?

• High: Major injury (fracture, serious back injury, hospitalization)
• Medium: Injury requiring medical attention (moderate back strain, time off work)
• Low: Minor discomfort, unlikely to require medical attention

Overall risk: Combine likelihood and severity. High likelihood + high severity = critical priority. Low likelihood + low severity = lower priority (but still assess controls).

Risk factors that increase likelihood or severity:

• Multiple adverse factors combining
• Vulnerable individuals performing task
• High frequency or sustained exposure
• Previous injuries or near misses
• Poor compliance with procedures

Step 6: Identify and evaluate existing controls

What's already in place?

• Equipment provided (trolleys, hoists, lifting aids)
• Procedures and safe systems of work
• Training and information
• Environmental controls (layouts, storage heights)
• Supervision and monitoring

Are existing controls adequate?

• Are they being used consistently?
• Are they effective in controlling risk?
• Are they maintained and available?
• Do workers know how to use them?
• Do they address the actual risks?

Gaps in control:

• What additional measures are needed?
• What's preventing existing controls from being effective?
• What would reduce risk further?

Step 7: Determine additional controls needed

Apply the hierarchy of control:

1. Elimination:

• Can the manual handling be eliminated entirely?
• Automation, redesign, process changes?

2. Engineering controls:

• Mechanical aids (hoists, trolleys, lifting equipment)
• Height-adjustable equipment
• Improved layouts reducing distances or improving access
• Load reduction (smaller containers, lower weights)

3. Administrative controls:

• Rotation to vary tasks and allow recovery
• Reduced frequency
• Team lifting for certain tasks
• Procedures for safe handling

4. Information and training:

• Training in safe techniques
• Information about weights and risks
• Instruction on equipment use
• When to ask for help

Prioritize controls based on:

• Effectiveness in reducing risk
• Feasibility and cost
• Time to implement
• Worker acceptance

Step 8: Record the assessment

Your record should include:

Task details:

• What task is being assessed
• Where and when it occurs
• Who performs it

TILE findings:

• Key risks identified in each category
• How factors combine to create risk
• Overall risk level

Existing controls:

• What's currently in place
• Whether they're adequate

Additional controls needed:

• What improvements are required
• Priority (urgent/short-term/long-term)
• Responsibility for implementation
• Target completion dates

Assessment details:

• Who conducted assessment and when
• Workers involved or consulted
• When review is due

Template structure: Many organizations use forms or templates. Ensure they cover all necessary elements and allow adequate detail.

Step 9: Implement controls

Assessment without action is worthless:

• Create action plan from assessment findings
• Assign responsibilities clearly
• Set realistic timescales
• Prioritize high-risk tasks
• Allocate resources (budget, time, people)

Monitor implementation:

• Track progress against action plan
• Remove barriers to implementation
• Follow up on overdue actions
• Ensure controls are working as intended

Communicate:

• Tell workers what's being done and why
• Explain new equipment or procedures
• Provide training on changes
• Encourage feedback on effectiveness

Step 10: Review and monitor

Ongoing monitoring:

• Observe whether controls are being used
• Check equipment is maintained and available
• Monitor injury and near miss data
• Gather worker feedback
• Supervise and correct poor practice

Formal review triggers:

• After any manual handling injury
• When tasks, equipment, or layout changes
• When new workers start or workers' circumstances change
• If controls aren't working
• At least annually for high-risk tasks

Common assessment mistakes

Understanding common errors helps you avoid them.

Mistake 1: Generic template assessments

The problem: Copying generic templates without adapting to your workplace. Result: Assessment doesn't reflect actual tasks and misses critical risks.

The solution: Use templates as starting points but customize based on observation of your specific tasks, workers, loads, and environment.

Mistake 2: Desk-based assessment

The problem: Conducting assessment at a desk without observing tasks or talking to workers. Result: Misses what actually happens vs. what should happen.

The solution: Observe tasks being performed. Talk to workers who do the work. Base assessment on reality, not assumptions.

Mistake 3: Focusing only on weight

The problem: Considering only whether loads exceed guideline weights, ignoring task, individual, and environmental factors.

The solution: Apply full TILE framework. Even light loads can be high risk depending on other factors.

Mistake 4: Not involving workers

The problem: Assessment done by managers without input from those who do the work. Result: Misses practical difficulties and real risks.

The solution: Involve workers throughout. They know what causes problems, what's difficult, and what would help.

Mistake 5: Assessing but not implementing

The problem: Completing assessments but not implementing controls identified. Assessment becomes paper exercise with no actual improvement.

The solution: Assessment must lead to action. Create action plans, assign responsibilities, monitor implementation.

Mistake 6: One-time assessment

The problem: Assessing once then not reviewing for years. Result: Assessment becomes outdated as tasks, workers, and workplace change.

The solution: Review regularly and after changes. Assessment is ongoing, not one-off.

Mistake 7: Treating training as sufficient control

The problem: Identifying high-risk tasks but only implementing training, not eliminating or controlling hazards.

The solution: Follow hierarchy: eliminate if possible, use engineering controls, then train on residual risks. Training alone is insufficient for genuinely hazardous tasks.

Recording and documenting assessments

Proper documentation is essential for compliance and ongoing management.

What records must show

If you have 5 or more employees: You must record significant findings.

If you have fewer than 5: Recording isn't legally required but is strongly recommended.

Your records should demonstrate:

• You've identified hazardous manual handling tasks
• You've assessed risks systematically
• You've determined what controls are needed
• You've implemented appropriate measures
• You review assessments appropriately

Effective documentation

Good assessment records:

• Clear description of task assessed
• Systematic examination of TILE factors
• Risk level determined
• Existing controls evaluated
• Additional controls identified with timescales
• Assigned responsibilities
• Review date set

Avoid:

• Overly complicated forms that discourage completion
• Forms that don't allow adequate detail
• Checklists with yes/no boxes but no explanation
• Records that don't lead to clear actions

Balance: Enough detail to be meaningful and useful, but not so complex that it becomes burdensome.

Storage and accessibility

Who needs access?

• Managers and supervisors
• Workers performing the tasks
• Health and safety representatives
• HSE inspectors (on request)
• Those conducting reviews or audits

How long to keep:

• Keep current assessments for as long as task continues
• Retain for at least 3 years after task stops
• Archive superseded assessments (demonstrate evolving approach)
• Consider longer retention where appropriate

Reviewing and updating assessments

Assessments must be living documents, not static records.

When reviews are required

Mandatory review triggers:

After incidents:

• Any manual handling injury
• Near misses involving manual handling
• Dangerous occurrences
• Must understand what went wrong and prevent recurrence

When significant changes occur:

• New tasks or changed procedures
• Different equipment or loads
• Workplace layout changes
• New workers or changes to workforce
• Pregnant workers or workers returning from injury

Regular intervals:

• At least annually for most tasks
• More frequently for high-risk activities
• When injury rates are concerning
• As part of routine health and safety review

What to review

Check whether:

• The task description still accurate?
• TILE factors remain the same or have changed?
• Risk level still appropriate?
• Existing controls still in place and effective?
• Additional controls implemented as planned?
• New risks emerged?
• Worker feedback suggests problems?

Update:

• Any changed TILE factors
• New controls implemented
• Risk level if changed
• Review date
• Any new actions required

Involving workers in reviews

Workers can provide crucial information:

• Are controls working in practice?
• What makes tasks difficult?
• What's changed since last assessment?
• Near misses or close calls?
• Ideas for improvements?

Methods for involvement:

• Regular safety discussions
• Specific consultation during review
• Suggestion schemes
• Safety representative involvement
• Anonymous feedback mechanisms

Frequently asked questions

Next steps

To ensure effective manual handling risk assessment in your workplace:

1. Identify all manual handling tasks - Walk through your workplace, observe all activities, talk to workers. Create comprehensive list.

2. Prioritize for assessment - Start with high-risk, frequent, or problematic tasks. Work through all hazardous handling systematically.

3. Conduct TILE assessments - Observe tasks, involve workers, systematically examine Task, Individual, Load, and Environment factors.

4. Determine and implement controls - Follow hierarchy (eliminate, then engineering controls, then admin controls and training). Create action plan.

5. Record findings - Document tasks assessed, risks identified, controls needed, and implementation plans. Make records accessible and useful.

6. Implement controls - Ensure measures identified are actually implemented. Monitor progress, remove barriers, allocate resources.

7. Review regularly - After incidents, when tasks change, and at least annually. Keep assessments current and relevant.

8. Monitor effectiveness - Check controls are working, gather feedback, observe technique, review injury data. Continuously improve.

Related articles:

• What is manual handling?
• Manual Handling Operations Regulations explained
• Back injury prevention at work

Useful tools:

• Manual Handling Risk Calculator
• TILE Assessment Tool