Do your staff regularly lift, carry, push, or pull loads as part of their work?
Quick check to see if manual handling regulations apply
Why manual handling matters
Manual handling is one of the most common causes of workplace injury in the UK. Every year, thousands of workers suffer musculoskeletal disorders (MSDs) — injuries to muscles, joints, tendons, ligaments, and nerves — often caused or made worse by work activities.
The human cost is significant: pain, reduced mobility, time off work, and in severe cases, permanent disability. The business cost is also substantial: absence, reduced productivity, staff turnover, compensation claims, and potential enforcement action.
Under the Manual Handling Operations Regulations 1992, employers must avoid hazardous manual handling operations so far as is reasonably practicable. Where avoidance is not possible, employers must assess the risk and put measures in place to reduce it to the lowest level reasonably practicable.
Most manual handling injuries develop gradually through repeated stress rather than a single incident. Back pain, shoulder problems, and repetitive strain injuries often result from poor technique, awkward postures, repetitive movements, or loads that exceed individual capability.
What counts as manual handling?
Manual handling means transporting or supporting a load by hand or bodily force. It includes:
- Lifting — raising a load from a lower to higher position
- Lowering — placing a load from a higher to lower position
- Carrying — transporting a load from one place to another while supporting it
- Pushing — moving a load away from the body
- Pulling — moving a load toward the body
- Moving — transferring a load from one position to another
It's not just about heavy weights. Risk also comes from:
- Repetitive handling of lighter loads
- Awkward postures (twisting, stooping, reaching)
- Carrying loads over distances
- Handling people (care work, healthcare)
- Sustained holding or gripping
There is no "safe weight limit" that applies universally. What is safe depends on the task, the individual, the load characteristics, and the environment. Assessment is essential.
Who is at risk?
Manual handling injuries can affect anyone, but some workers and sectors face higher risks:
| Sector | Typical Tasks | Common Injuries |
|---|---|---|
| Healthcare & Social Care | Lifting/moving patients, repositioning in bed, transfers | Back injuries, shoulder problems, hernias |
| Warehousing & Logistics | Lifting boxes, loading/unloading, sorting, packing | Back strain, repetitive strain injuries, crush injuries |
| Retail | Shelf stacking, stock handling, till operations, customer assistance | Back pain, shoulder strain, wrist injuries |
| Construction | Carrying materials, loading equipment, manual digging | Back injuries, joint problems, hernias |
| Manufacturing | Repetitive assembly, lifting components, packaging | Repetitive strain injuries, back pain, shoulder problems |
| Agriculture | Lifting feed/equipment, handling animals, harvesting | Back injuries, joint problems, strains |
| Hospitality | Carrying trays, moving furniture, handling laundry | Back strain, shoulder problems, slips/trips while carrying |
Risk varies within sectors depending on specific job roles and control measures in place.
The key legislation
Manual Handling Operations Regulations 1992
The principal UK law covering manual handling. It places duties on employers to:
- Avoid hazardous manual handling operations so far as is reasonably practicable
- Assess any hazardous manual handling operations that cannot be avoided
- Reduce the risk of injury from those operations to the lowest level reasonably practicable
- Review assessments when circumstances change
Employees also have duties to:
- Follow systems of work put in place for their safety
- Use equipment provided properly
- Cooperate with their employer on health and safety
- Report hazards and defects
Supporting legislation
- Health and Safety at Work Act 1974 — General duty to ensure health, safety and welfare of employees
- Management of Health and Safety at Work Regulations 1999 — Requires risk assessment and competent advice
- Provision and Use of Work Equipment Regulations 1998 — Covers mechanical handling equipment
- Lifting Operations and Lifting Equipment Regulations 1998 — Covers hoists and lifting equipment
The TILE assessment framework
TILE is a practical framework for assessing manual handling risks. Consider each element:
T — Task
What makes the task risky?
- Holding or manipulating loads at distance from the body
- Twisting, stooping, or reaching upward
- Large vertical movement (lifting from floor to shoulder height)
- Long carrying distances
- Repetitive handling (frequency and duration)
- Insufficient rest or recovery periods
- Work rate imposed by a process (e.g., production line)
- Precise positioning of the load required
Control measures: Can you eliminate the task? Use handling aids? Break the task into smaller steps? Reduce frequency? Improve work height?
I — Individual capability
Who is doing the task and what is their capability?
- Physical capability — strength, fitness, height, reach
- Health status — existing conditions, pregnancy, recent surgery
- Training and competence — do they know safe techniques?
- Age — younger workers and older workers may need special consideration
- Experience — new or temporary workers at higher risk
- Personal protective equipment — does it restrict movement?
Never make assumptions about capability based on gender, build, or appearance. Individual assessment is essential, and workers should be consulted about their own capability.
Control measures: Ensure adequate training. Match workers to tasks. Allow workers to report concerns. Provide team handling. Consider individual needs.
L — Load
What characteristics of the load create risk?
- Heavy — though there is no absolute safe weight
- Bulky or difficult to grasp — awkward shape, no handles
- Unstable or unpredictable — contents shift, uneven weight distribution
- Sharp, hot, or otherwise harmful — creates hazard beyond musculoskeletal risk
- Difficult to see over or around — obstructs view while moving
Control measures: Reduce load size/weight. Add handles or grips. Use containers. Split bulk loads. Label load weight and contents. Improve packaging.
E — Environment
What environmental factors increase risk?
- Space constraints — restricted headroom, narrow passages
- Uneven, slippery, or unstable floors — increases risk of slips/trips
- Steps, slopes, or level changes — increase effort and risk
- Poor lighting — can't see hazards or where to place load
- Temperature extremes — heat or cold affects capability
- Poor weather (outdoor work) — wind, rain, ice
- Vibration or movement (vehicles, machinery)
Control measures: Improve workplace layout. Ensure good housekeeping. Provide adequate lighting. Control temperature. Clear routes. Use anti-slip flooring. Maintain floors and access routes.
TILE in practice: warehouse example
Before Assessment
- •Staff lifting 20kg boxes from floor to shoulder-height shelves (Task)
- •No training provided, staff use their own technique (Individual)
- •Boxes have no handles, contents shift inside (Load)
- •Narrow aisles, poor lighting in some areas (Environment)
- •Result: 3 back injury reports in 6 months
After Assessment & Controls
Recommended- •Installed lift table at waist height, reduced lift distance (Task)
- •Mandatory manual handling training for all staff (Individual)
- •Changed to boxes with handholds, max 15kg (Load)
- •Widened aisles, improved lighting, anti-slip flooring (Environment)
- •Result: Zero manual handling injuries in 12 months
Bottom line: Systematic assessment using TILE identifies specific hazards and points to practical controls that reduce risk.
Hierarchy of controls for manual handling
Apply controls in this order of priority:
1. Eliminate the task
Can you avoid the manual handling operation entirely?
- Redesign the process to eliminate the need
- Change the product or material to remove handling
- Automate the operation
Examples: Order smaller quantities that don't require manual breaking down. Use bulk systems that eliminate individual handling. Relocate work to avoid transport.
2. Mechanise or automate
If you can't eliminate the task, can you use equipment to do it?
- Hoists, lifts, and cranes for vertical movement
- Conveyors and chutes for horizontal/downward movement
- Trolleys, pallet trucks, and forklifts for transport
- Vacuum lifters and powered grabs for awkward loads
- Patient hoists in care settings
Examples: Use a sack truck for moving boxes. Install a conveyor for repetitive movement. Provide adjustable height trolleys.
Equipment is only effective if it's suitable, well-maintained, and staff are trained to use it. Providing a trolley doesn't help if staff don't know how to use it safely or if it's always broken.
3. Improve the task
If some manual handling remains, how can you make it safer?
- Reduce load weight/size — split into smaller quantities
- Improve load design — add handles, improve grip, reduce bulk
- Adjust work heights — avoid floor level or overhead
- Reduce carrying distance — relocate storage closer to use
- Reduce frequency — batch deliveries, reduce repetition
- Allow rest breaks — prevent fatigue
- Use team handling for heavier/awkward loads
- Provide handling aids — boards, straps, grips
4. Provide information and training
Essential at all levels, but not sufficient on its own:
- Safe lifting technique — bend knees, keep load close, avoid twisting
- When to ask for help or use equipment
- Specific risks in their role
- How to use handling aids properly
- How to report problems or concerns
Training should be practical, job-specific, and reinforced regularly. New starters, those changing roles, and those returning after injury need particular attention.
Manual handling assessment requirements
When assessment is required
You must assess manual handling operations that present a risk of injury. This includes:
- Regular operations that are part of the job
- Occasional operations if they present significant risk
- One-off tasks if they are high risk (e.g., moving heavy equipment)
Assessment should be done before work starts, or as soon as the need becomes apparent.
Who can do assessments
Assessments should be carried out by someone who is:
- Competent — has the knowledge, training, and experience
- Familiar with the work being assessed
- Able to identify hazards and evaluate risk
For straightforward situations, a trained supervisor or manager may be competent. For complex operations (e.g., patient handling in hospitals, heavy engineering), specialist advice may be needed.
What assessments must cover
Use the TILE framework to systematically consider:
- The tasks involved and their characteristics
- The loads being handled
- The working environment
- Individual capability of those doing the work
Record:
- What the manual handling operation involves
- The risks identified
- Any existing control measures
- Additional controls needed to reduce risk
- Who is responsible for implementing controls
- Review date
There is no legal requirement for the assessment to be in a particular format. However, recording it in writing is essential evidence that you have complied with the law and is required if you have 5 or more employees.
When to review assessments
Review your manual handling assessments:
- At least annually (good practice)
- After an injury or near miss related to manual handling
- When the task changes — new equipment, different materials, changed process
- When the workforce changes — if capabilities of workers change
- When the environment changes — premises move, layout changes
Training requirements
Training is a legal requirement under the Manual Handling Operations Regulations. Employers must provide employees with:
General training content
- Basic anatomy — understanding the spine and how injuries occur
- Individual risk factors — when to take particular care
- Safe handling techniques — how to lift, carry, push, pull safely
- Use of handling aids — how and when to use equipment provided
- Importance of good posture and avoiding awkward positions
- Recognising risks — spotting hazardous situations
- Reporting problems — defective equipment, new hazards
Job-specific training
Training must be tailored to the specific manual handling tasks workers perform. For example:
- Care workers — moving and handling people, use of hoists, risk assessment for individuals
- Warehouse staff — safe use of pallet trucks, stacking techniques, team lifting
- Retail staff — shelf stacking, customer assistance, unpacking deliveries
- Delivery drivers — loading/unloading, use of tail lifts, handling on customer premises
Frequency and refreshers
- New starters — before they begin manual handling tasks
- Existing staff — when tasks or risks change
- Refreshers — at least every 2-3 years (more frequently in high-risk roles)
- After injury — if someone has been off with a manual handling injury
Training alone is not sufficient. It must be combined with risk assessment, appropriate equipment, and safe systems of work. Training cannot make an unsafe task safe — it helps workers carry out reasonably safe tasks correctly.
Manual handling in specific sectors
Care homes and healthcare
Moving and handling people presents unique challenges:
- Loads are heavy and unpredictable — people move, resist, or cannot assist
- Dignity and comfort must be balanced with safety
- Equipment must be available — hoists, slide sheets, handling belts
- Individual care plans required for each person needing assistance
- Staff capability varies — injuries affect ability to assist
Key controls: Comprehensive risk assessments for each resident/patient. Adequate equipment and training in its use. Two-person handling protocols. Regular review of care plans.
Learn more: Manual handling in care settings →
Warehousing and logistics
High-risk environment due to:
- Volume of handling — repetitive tasks throughout shift
- Variety of loads — different sizes, weights, shapes
- Time pressure — targets and deadlines
- Powered equipment — forklifts, pallet trucks require training
Key controls: Mechanical handling aids. Good warehouse design. Weight labelling. Team handling protocols. Adequate breaks. Training and supervision.
Learn more: Warehouse safety →
Retail
Often overlooked, but manual handling injuries are common:
- Shelf stacking — repetitive reaching, awkward heights
- Stock handling — unpacking deliveries, moving stock
- Customer service — helping customers load cars
- Till operations — repetitive scanning, bagging
Key controls: Step stools for high shelves. Trolleys for stock movement. Limits on individual load weight. Team handling for heavy items. Training in safe techniques.
Learn more: Retail sector guidance →
Manufacturing
Risks vary by operation but often include:
- Repetitive tasks — assembly line work, packing
- Heavy components — machine parts, raw materials
- Awkward postures — working in confined spaces
- Sustained grip — holding tools, supporting work pieces
Key controls: Ergonomic workstation design. Job rotation to vary tasks. Height-adjustable work surfaces. Mechanical aids. Adequate rest breaks.
Learn more: Manufacturing safety →
Common questions
There is no specific maximum weight limit in UK law. The Manual Handling Operations Regulations require assessment of risk — what is safe depends on the individual, the task, the load characteristics, and the environment. The HSE provides guideline figures (e.g., 25kg for men, 16kg for women at waist height in ideal conditions) but these are guides only, not legal limits. Many tasks involving lower weights still present risk if they involve awkward postures, repetition, or poor environment.
Yes, if the occasional lifting presents a risk of injury. The regulations don't only apply to frequent manual handling. Even occasional tasks need assessment, and if risk is identified, training is part of reducing that risk. However, the training can be proportionate — occasional, low-risk handling may only need basic instruction rather than comprehensive training.
No. Relying on training alone, without assessing and controlling risks, does not comply with the regulations. The priority is to avoid or reduce the manual handling requirement, not just teach people to handle unsafely designed tasks 'properly'. Training is important but comes after you have eliminated or reduced risk through task design, equipment, and workplace improvements.
Pregnant workers are at increased risk from manual handling due to postural changes, shift in centre of gravity, and effects on ligaments. You must review risk assessments for pregnant workers and adjust or remove manual handling tasks as necessary. Similarly, workers with existing back problems, recent surgery, or other health conditions may need individual assessment and adjustments. Workers should be encouraged to inform you of relevant health issues.
If you have 5 or more employees, you must record the significant findings of your risk assessments. Even with fewer than 5 employees, written records are strongly advisable as evidence of compliance. Records should include: what the task involves, risks identified, who is at risk, control measures in place, and review date.
Employees have the right to stop work if they believe there is serious and imminent danger. If manual handling appears unsafe, they should report concerns to their supervisor. Employers must not penalise workers for raising safety concerns. Good practice is to have a system for workers to report manual handling problems and to respond promptly to concerns raised.
You must provide suitable equipment AND ensure it's used. This means: training staff in how to use it, supervising to check it's being used, maintaining it so it works properly, investigating why staff might avoid using it (is it actually suitable and practical?), and having clear policies that equipment must be used. Disciplinary action may be appropriate for persistent refusal, but first check that the equipment is genuinely fit for purpose.
There is no fixed legal requirement, but good practice is to refresh training every 2-3 years. More frequent refreshers may be needed in high-risk environments or if incidents occur. Training should also be refreshed when tasks change, new equipment is introduced, or an employee returns to work after a manual handling injury.
The HSE or local authorities can issue improvement notices requiring you to address failings. Serious breaches can lead to prosecution, with fines that can be substantial (especially in higher courts). If an employee suffers injury due to inadequate controls, you may face civil claims for compensation. Injuries are also reportable under RIDDOR if they result in over 7 days off work.
Real-world examples
Logistics company fined £600,000 after repeated back injuries
A delivery and logistics company was prosecuted after HSE investigation following multiple reports of back injuries among warehouse staff over an 18-month period.
- ✗No manual handling risk assessments carried out despite clear risks
- ✗Employees regularly lifting parcels over 25kg from floor level
- ✗No height-adjustable equipment provided for sorting
- ✗No formal manual handling training provided to staff
- ✗Previous injury reports not investigated or acted upon
- ✗Management aware of risks but failed to implement controls
The company was fined £600,000 plus £75,000 costs. The court noted that injuries were foreseeable and preventable. The company was required to implement a full manual handling programme across all sites.
Ignoring manual handling risks, even in 'routine' operations, can have serious consequences. Repeat injuries are a clear sign that controls are inadequate. HSE takes enforcement action even without a serious injury if systematic failings are identified.
Source: Based on HSE prosecution records
Care home reduces handling injuries by 80% through equipment investment
A 60-bed care home had a poor record of staff back injuries and high turnover. Management decided to invest in manual handling improvements.
Over the following 2 years: staff back injury reports dropped by 80%, staff sick leave reduced by 35%, staff turnover improved significantly, resident feedback improved (dignity and comfort), avoided several potential compensation claims.
Investment in proper equipment and training pays for itself through reduced injuries, improved staff retention, and better quality of care. A 'no-lift' policy is achievable in care settings with the right equipment and approach.
Source: Based on care sector case studies
Related sectors and content
Manual handling requirements apply across industries. See sector-specific guidance:
Care Homes
Moving and handling residents, equipment requirements, and individual care planning.
Healthcare
Patient handling in hospitals, clinics, and community settings.
Retail
Stock handling, shelf stacking, and customer assistance without injury.
Warehousing & Logistics
High-volume handling, mechanical aids, and preventing repetitive strain.
Manufacturing
Repetitive tasks, heavy components, and ergonomic workplace design.
Construction
Handling materials on site, team lifting, and site-specific risks.
Related content
Complete TILE Assessment Guide
Step-by-step guide to conducting manual handling assessments using the TILE framework.
Manual Handling Training Requirements
What training must you provide, how often, and what it should cover.
Safe Lifting Techniques
Practical guidance on proper lifting, carrying, pushing, and pulling techniques.
Moving and Handling People
Specific guidance for care and healthcare settings handling patients and residents.
Get expert help
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Disclaimer: This guidance is for general information only and does not constitute legal advice. Manual handling regulations apply differently depending on your specific circumstances. For complex operations or if you are unsure about your legal duties, you should seek professional advice from a competent health and safety advisor.