UK / General HSE Article
Good manual handling control starts before the lift
Manual handling control is not just about telling people how to lift. It is about designing work so lifting, carrying, pushing and pulling are reduced or made safer.
Manual handling includes lifting, lowering, carrying, pushing, pulling, moving or supporting a load by hand or bodily force. Injuries can affect the back, shoulders, arms, wrists, knees and hands. Some happen suddenly, but many develop over time because the job is awkward, repetitive, badly arranged or done without the right handling aid.
Ask whether the load needs to be handled by hand
Before you tell someone how to lift, ask whether they need to lift it at all. A trolley, pallet truck, lift table, hoist, conveyor or change in delivery point may remove most of the risk. If the work can be redesigned so the person handles less weight, travels a shorter distance or avoids floor-level lifting, that is usually stronger than training alone.
- Avoid manual handling where reasonably practicable.
- Use mechanical aids and better layout before relying on strength.
- Move storage and delivery points closer to the work where possible.
Do not judge the risk by weight only
A lighter item can still cause injury if it is bulky, slippery, unstable, sharp, hot, handled above shoulder height or lifted repeatedly from the floor. A heavier load may be more manageable if it has good handles, is close to the body and is lifted with suitable equipment. Look at the whole task, not only the number on the load.
- Check the weight, shape, grip, stability and surface of the load.
- Look at lifting height, reach, twisting and carrying distance.
- Consider frequency and fatigue over the shift.
Use the task, individual, load and environment approach
A useful manual handling assessment looks at the task, the individual, the load and the environment. This helps you see why the job is difficult. The problem may be a poor route, uneven floor, awkward load, short staffing, poor storage height or a worker returning after injury.
- Task: frequency, posture, reach, twisting and distance.
- Individual: capability, training, health, pregnancy or return-to-work needs.
- Load and environment: grip, stability, route, space, lighting and floor condition.
Treat pushing and pulling as manual handling
Trolleys, cages, bins, pallet trucks and wheeled equipment can reduce lifting but still create injury risk. Poor wheels, damaged floors, heavy loads, tight turns, slopes and poor handle height can make pushing or pulling unsafe. Pushing is often better than pulling, but only if the route and equipment are suitable.
- Check wheels, handles, brakes and load stability.
- Keep routes clear, level and wide enough.
- Do not overload trolleys or block the worker’s view.
Use team lifting carefully
Team lifting can help with awkward loads, but it is not automatically safe. People may lift at different times, carry uneven weight, walk backwards, twist or lose communication. Team lifting should be planned like any other control.
- Agree who gives the command before lifting.
- Check both people can grip and move safely.
- Clear the route and decide where the load will be placed.
Teach lifting technique honestly
Good technique still matters once the task has been improved. Workers should plan the route, stand close to the load, keep the load close, avoid twisting, move smoothly and set the load down under control. But technique cannot fix a badly designed task. If the load is too bulky to hold close, or the area forces twisting, change the task.
- Keep the load close to the body where possible.
- Avoid twisting while carrying or placing the load.
- Report loads, routes or equipment that make safe handling unrealistic.
Manual handling risk factors
These are the areas that usually explain why a handling task is safe, difficult or unacceptable.
Task
How the load is moved, including lifting height, reach, twisting, frequency, carrying distance and pushing or pulling force.
Individual
The person’s capability, health, training, experience and any temporary restriction or additional need.
Load
The weight, shape, grip, stability, size, surface, sharp edges or temperature of the item being handled.
Environment
The route, floor, space, lighting, weather, stairs, ramps, housekeeping and storage arrangement.
Mechanical aid
Equipment used to reduce manual effort, such as a trolley, lift table, hoist, pallet truck or conveyor.
Before manual handling starts
- Can the handling be avoided?
- Can a handling aid be used?
- Is the load manageable and stable?
- Is the route clear and suitable?
- Is the storage height sensible?
- Is the worker trained and able to do the task?
Manual handling mistakes to avoid
- Relying only on lifting technique training
- Ignoring repetitive light handling
- Using damaged trolleys or poor routes
- Storing heavy items too low or too high
- Using team lifting instead of proper equipment
The aim of manual handling control
The aim is to make the task easier and safer, not to make people struggle more carefully. If the job can be redesigned so less force, reach, twisting or carrying is needed, that is usually the better control.