manual handling

What is Manual Handling?

Manual handling involves lifting, lowering, pushing, pulling, or carrying loads. Learn about the regulations, risks, and how to protect your team from musculoskeletal disorders.

This guide includes a free downloadable checklist.

Get the checklist

Manual handling is one of the most common causes of workplace injury in the UK. It's responsible for over a third of all workplace injuries, with musculoskeletal disorders (MSDs) costing businesses millions in lost time and compensation claims every year.

Does your workplace involve manual handling?

Let's identify what applies to you.

What is manual handling?

Manual handling is any activity that requires a person to use force to:

  • Lift — raising an object from a lower to a higher position
  • Lower — moving an object from a higher to a lower position
  • Push — moving an object away from the body
  • Pull — moving an object towards the body
  • Carry — transporting an object from one place to another
  • Move — changing the position or location of an object

This includes handling people (such as in healthcare or care settings), as well as objects and loads.

Key Point

Manual handling isn't just about heavy lifting. Pushing a trolley, moving boxes, or even handling small awkward items repeatedly can all cause serious injury if not done properly.

Why manual handling matters

Musculoskeletal disorders (MSDs) are the biggest cause of workplace injury in the UK:

  • Over 470,000 workers suffer from work-related MSDs each year
  • 6.6 million working days are lost annually due to manual handling injuries
  • Back, shoulder, and neck problems account for the majority of these injuries
  • Long-term impact — many manual handling injuries lead to chronic pain and disability

The human cost is significant, but there's also a substantial financial burden:

  • Lost productivity
  • Sick pay and replacement staff costs
  • Compensation claims
  • Enforcement action and fines
  • Reputational damage
Warning:

Manual handling injuries don't just happen suddenly. Many develop gradually over time through repeated strain, poor posture, and cumulative damage. By the time someone reports pain, the damage may already be significant.

Manual Handling Operations Regulations 1992

The Manual Handling Operations Regulations 1992 (MHOR) set out your legal duties as an employer. The regulations apply to virtually all workplaces where manual handling takes place.

The hierarchy of control

The regulations require you to follow a three-step hierarchy:

  1. Avoid hazardous manual handling where reasonably practicable
  2. Assess any hazardous manual handling that can't be avoided
  3. Reduce the risk of injury to the lowest level reasonably practicable

Let's break down what each step means in practice.

Step 1: Avoid manual handling

The best way to prevent manual handling injuries is to eliminate manual handling altogether.

Can you:

  • Automate the process? (Conveyors, automated guided vehicles, robotic systems)
  • Redesign the work? (Change the layout, process, or storage to eliminate the need)
  • Use mechanical aids? (Hoists, trolleys, pallet trucks, lifting equipment)
Success Story

Warehouse reduces injuries by 80% with mechanical aids

The Situation

A distribution warehouse was experiencing high rates of back injuries from workers repeatedly lifting boxes weighing 15-20kg from floor level to shelving.

What Went Right
  • ✓Installed adjustable height pallet trucks
  • ✓Reorganised storage so heavy items stayed between knee and shoulder height
  • ✓Used scissor lift tables for loading and unloading
  • ✓Provided slide sheets and roller conveyors for moving heavy items
  • ✓Trained staff on using equipment properly
Outcome

Back injury rates dropped by 80% within six months. Staff reported less fatigue, and productivity actually improved because workers weren't slowed down by pain and discomfort.

Key Lesson

Mechanical aids don't have to be expensive or complicated. Even simple equipment like height-adjustable trolleys can make a huge difference to injury rates.

Step 2: Assess the risks

For any manual handling you can't avoid, you must carry out a suitable and sufficient risk assessment. This means systematically examining:

  • What tasks involve manual handling
  • Who is doing them
  • What the risks are
  • Whether your current controls are adequate
  • What more you need to do
Note:

If your manual handling activities are fairly uniform and straightforward, you can assess them by type or category rather than individually. But if you have varied, complex, or high-risk activities, each one needs its own assessment.

Step 3: Reduce the risk

Where you can't eliminate manual handling, you must reduce the risk to the lowest level reasonably practicable. This means implementing appropriate control measures based on your assessment.

TILE assessment framework

TILE is a structured framework for assessing manual handling risks. It helps you systematically identify hazards and evaluate the level of risk.

T — Task

What does the activity involve? Look for:

High-risk task factors:

  • Holding or manipulating loads at a distance from the body
  • Twisting the trunk or turning while handling
  • Reaching upwards or stooping down
  • Excessive lifting or lowering distances
  • Excessive carrying distances
  • Repetitive handling
  • Insufficient rest or recovery time
  • Fast-paced work
  • Unpredictable movement of loads

I — Individual

Who is doing the work? Consider:

Individual capability factors:

  • Physical capability (strength, fitness, age)
  • Existing health conditions or injuries
  • Pregnancy
  • Experience and training
  • Size and build (can they reach? do they have to overextend?)
  • Personal protective equipment requirements (does PPE restrict movement?)
Key Point

Don't assume everyone has the same capability. What's manageable for one person might be too much for another. Individual risk assessments may be needed for pregnant workers, those returning from injury, or anyone with health conditions affecting their capability.

L — Load

What is being handled? Look at:

Load characteristics:

  • Weight (obviously, but not the only factor)
  • Size and shape (bulky, awkward, difficult to grasp)
  • Stability (does the load shift or move unpredictably?)
  • Sharp edges or hazardous surfaces
  • Temperature (hot or cold)
  • Centre of gravity (does it sit unevenly?)

Guideline weights:

The HSE provides guideline weights for safe lifting. These are guidelines, not absolute limits — the actual safe weight depends on all the TILE factors.

HSE Guideline Weights for Lifting

Men

  • •Shoulder height: 10kg
  • •Elbow height: 20kg
  • •Knuckle height: 25kg
  • •Mid-lower leg: 20kg
  • •At arm's length (full reach): reduce by half
  • •Frequent lifting: reduce further

Women

  • •Shoulder height: 7kg
  • •Elbow height: 13kg
  • •Knuckle height: 16kg
  • •Mid-lower leg: 13kg
  • •At arm's length (full reach): reduce by half
  • •Frequent lifting: reduce further

Bottom line: These are guidelines for infrequent lifting in ideal conditions. If conditions are less than ideal, or lifting is repetitive, reduce these weights further. If loads exceed these guidelines, you must assess whether the task can be made safer.

E — Environment

Where is the work being done? Consider:

Environmental factors:

  • Space constraints (enough room to adopt good posture?)
  • Floor surfaces (level, stable, slip-resistant?)
  • Lighting (can workers see clearly?)
  • Temperature and humidity (extreme heat or cold affects capability)
  • Weather conditions (for outdoor work)
  • Steps, slopes, or uneven surfaces
  • Obstructions or trip hazards
  • Adequate ventilation

Risk factors for injury

Certain factors significantly increase the risk of manual handling injury:

High-risk activities

  • Repetitive handling — doing the same movement many times
  • Sustained awkward postures — bending, twisting, reaching for extended periods
  • Heavy loads — anything exceeding guideline weights
  • Forceful exertions — pushing, pulling, or lifting requiring significant effort
  • Vibration — combining manual handling with whole-body or hand-arm vibration

Vulnerable workers

Some workers are at higher risk:

  • Young workers — less experience, still developing physically
  • Older workers — reduced strength, flexibility, and recovery
  • Pregnant workers — changing centre of gravity, ligament laxity
  • Workers with disabilities — may have reduced capability
  • Those returning from injury — may not be fully recovered
Warning:

You cannot discriminate against someone because they're at higher risk, but you must make appropriate adjustments to protect them. This might mean modifying tasks, providing additional equipment, or adjusting duties temporarily.

Good lifting technique

While the right approach is to eliminate or reduce manual handling, when lifting is unavoidable, proper technique is essential.

The safe lifting technique

  1. Plan the lift

    • Where is the load going?
    • Is the route clear?
    • Do you need help?
    • Do you need equipment?

  2. Position your feet

    • Stand with feet hip-width apart
    • One foot slightly forward for balance
    • Face the direction you'll be moving

  3. Adopt a stable posture

    • Bend your knees, not your back
    • Keep your back straight (natural S-curve, not rounded)
    • Slight inward curve in the lower back

  4. Get a firm grip

    • Use the whole hand, not just fingers
    • Test the weight before lifting fully
    • Ensure you can hold it securely

  5. Lift smoothly

    • Keep the load close to your body
    • Lift with your legs, not your back
    • Don't jerk or twist
    • Look ahead, not down

  6. Move your feet

    • Don't twist your back to turn
    • Move your feet to change direction
    • Take small steps if carrying

  7. Put down carefully

    • Lower with control
    • Bend your knees
    • Place, don't drop
Key Point

"Keep your back straight" doesn't mean "keep your back vertical." Your back should maintain its natural S-curve while you bend from the hips and knees. Rounding or arching your back is what causes injury.

When two-person lifting is needed

If a load is too heavy, bulky, or awkward for one person, use team lifting:

  • Agree on the plan before starting
  • Designate one person to coordinate (count "1, 2, 3, lift")
  • Both should adopt good posture
  • Lift and move in unison
  • Make sure both can see where they're going

Training requirements

The Manual Handling Operations Regulations require you to provide information and training to employees who perform manual handling tasks.

What training must cover

Theoretical knowledge:

  • Risks associated with manual handling
  • How injuries occur
  • The importance of good technique
  • How to recognise hazardous tasks
  • When to ask for help or use equipment

Practical skills:

  • Safe lifting and carrying techniques
  • How to use mechanical aids and equipment
  • How to plan and prepare for manual handling tasks
  • Adjusting technique for different loads and situations

Job-specific information:

  • Specific risks in your workplace
  • Control measures in place
  • Where to find equipment
  • Who to report problems to

Manual Handling Training Schedule

At induction
Initial manual handling training

Before employees start work involving manual handling

Ongoing
On-the-job coaching

Regular observation and feedback on technique

When changes occur
Update training

When new equipment, processes, or risks are introduced

Annually
Refresher training

Review good practice and address any bad habits

After injury
Incident review

Understand what went wrong and prevent recurrence

Who needs training?

Anyone who does manual handling work needs training. This includes:

  • Regular staff performing routine manual handling
  • Occasional workers who may need to lift or move things
  • Temporary workers and agency staff
  • Managers and supervisors (so they can identify risks and coach good practice)
Tip:

Training isn't a one-off event. Manual handling injuries often result from poor habits that develop over time. Regular refreshers, toolbox talks, and on-the-job coaching help maintain good practice.

Common manual handling injuries

Manual handling can cause a range of musculoskeletal disorders:

Back injuries

The most common manual handling injuries:

  • Lumbar strain — damage to muscles, ligaments, or discs in the lower back
  • Slipped disc — when the cushioning disc between vertebrae ruptures or bulges
  • Chronic back pain — long-term pain from repeated strain

Warning signs: Sharp pain, stiffness, difficulty bending, pain radiating down the leg

Shoulder and neck injuries

Often from reaching, lifting overhead, or carrying:

  • Rotator cuff injuries — damage to the shoulder muscles and tendons
  • Frozen shoulder — stiffness and pain limiting movement
  • Neck strain — tension and pain in neck muscles

Warning signs: Pain when reaching, weakness, reduced range of motion

Upper limb disorders

From repetitive movements or forceful exertions:

  • Tendonitis — inflammation of tendons
  • Carpal tunnel syndrome — compression of nerves in the wrist
  • Epicondylitis (tennis elbow) — pain in the elbow from repetitive wrist movements

Warning signs: Pain, tingling, numbness, loss of grip strength

Hernias

From excessive strain or poor lifting technique:

  • Inguinal hernia — weakness in the abdominal wall

Warning signs: Bulge in groin or abdomen, discomfort when lifting or straining

Warning:

If someone reports pain or discomfort from manual handling, don't ignore it. Early intervention — modifying tasks, seeking medical advice, adjusting work patterns — can prevent minor problems becoming serious injuries.

Mechanical aids and alternatives

The right equipment can eliminate or significantly reduce manual handling risks.

Common mechanical aids

Lifting equipment:

  • Hoists (mobile, overhead, gantry)
  • Lifting trolleys
  • Scissor lift tables
  • Vacuum lifters
  • Jib cranes

Moving equipment:

  • Pallet trucks (manual or powered)
  • Sack trucks and hand trolleys
  • Platform trolleys
  • Roller conveyors
  • Slide sheets (for moving people in care settings)

Storage and access:

  • Adjustable height workbenches
  • Mobile shelving
  • Step platforms (for safe access to height)
  • Gravity feed racks

Choosing the right equipment

Consider:

  • What manual handling it will eliminate — the greatest benefit comes from targeting the highest risks first
  • Ease of use — if equipment is awkward or slow, workers may avoid using it
  • Maintenance — equipment must be kept in good working order
  • Training — users need to know how to operate it safely
  • Space — do you have room for it?
  • Cost vs. benefit — weigh the investment against injury costs

Manual vs. Mechanical Handling

Manual Handling

  • •Higher injury risk
  • •Physical strain and fatigue
  • •Slower over time as workers tire
  • •Limited by human capability
  • •No equipment costs
  • •Flexible and adaptable

Mechanical Aids

Recommended
  • •Much lower injury risk
  • •Less physical strain
  • •Consistent speed and efficiency
  • •Can handle heavier/bulkier loads
  • •Initial investment required
  • •Requires space and maintenance

Bottom line: Mechanical aids nearly always deliver better outcomes — fewer injuries, less fatigue, and often improved productivity. The initial cost is quickly offset by reduced injury rates and improved efficiency.

Frequently asked questions

There's no legal maximum weight, but the HSE publishes guideline weights: 25kg for men and 16kg for women at knuckle height in ideal conditions. These are guidelines, not limits. If conditions are less than ideal, or lifting is repetitive, safe weights are much lower. The real test is whether the task poses a risk of injury — not just whether it exceeds a weight limit.

There's no such thing as a legal 'manual handling certificate.' What the regulations require is that you provide adequate information, instruction, and training. Some training providers issue certificates of attendance, which can be useful records, but they don't in themselves demonstrate competence. What matters is that workers understand the risks and know how to handle loads safely in your workplace.

There's no fixed legal requirement, but good practice is to provide refresher training annually, or more frequently if injury rates are high or bad habits are developing. Training should also be updated whenever you introduce new equipment, processes, or tasks.

You can require employees to follow safe working practices, use equipment provided, and attend training. However, if someone reports that a task is causing them pain or that they're not capable of doing it safely, you must take that seriously and make adjustments. Forcing someone to continue a task they can't do safely could lead to injury and liability.

Employees have a duty to follow health and safety procedures and use equipment provided. If someone refuses, find out why — is the equipment awkward, broken, or poorly understood? Provide coaching and emphasise that equipment is there to protect them. If refusal continues despite training and support, it becomes a disciplinary matter.

Yes. If employees are manual handling as part of their work, even at home, you have duties under the regulations. This might include moving equipment, handling deliveries, or setting up workstations. You should assess the risks and provide appropriate information, training, and equipment.

Take it seriously. Record the report, encourage them to seek medical advice if appropriate, and review the task to identify what's causing the problem. Make adjustments — reduce weights, provide equipment, change work patterns, or reassign tasks temporarily. Don't wait for a serious injury to develop.

Pregnancy significantly affects capability — changing centre of gravity, ligament laxity, and reduced stamina. You must conduct an individual risk assessment and adjust tasks to protect both mother and baby. This usually means eliminating or significantly reducing manual handling during pregnancy, especially in later stages.

Next steps

If you have manual handling activities in your workplace, your next steps are:

  1. Identify all manual handling tasks — walk through your workplace and note every activity involving lifting, carrying, pushing, or pulling.

  2. Assess the risks — use the TILE framework to systematically evaluate each task.

  3. Implement controls — eliminate where possible, use mechanical aids, improve techniques, and provide training.

  4. Review regularly — after injuries, when processes change, or at least annually.

Need help assessing manual handling risks? A qualified health and safety consultant can visit your workplace, identify risks you might have missed, and recommend practical, cost-effective solutions.

Speak to a professional

Related articles:

Useful tools: