Manual handling remains a significant workplace health and safety issue in the UK, with 511,000 workers affected by work-related musculoskeletal disorders in 2024/25. There is an assumption that manual handling risks are simply due to lifting heavy objects, but in reality, they can also involve carrying, pushing, pulling and other repetitive tasks.
In this guide, we will explain where manual handling risks are highest, when employers need to assess them, how the assessment works and what practical steps can be taken to reduce the risk.
What is manual handling?
Manual handling is the moving, lifting, lowering, pushing, pulling, carrying, holding or supporting of a load using bodily force. That load could be an object, a person, or even an animal, so it can include lifting boxes, moving furniture, pushing a trolley, pulling equipment or assisting a patient or resident.
Manual handling risks can arise from both individual tasks and repeated handling throughout a working day. Poor handling can contribute to musculoskeletal injuries such as back strain and muscle sprains.
Which industries and jobs have the highest manual handling risks?
Manual handling risks are particularly relevant in industries where employees regularly move materials, equipment, stock or people.
|
Industry
|
Why the risk is high
|
| Construction |
Heavy lifting, carrying materials, awkward postures, repetitive handling. |
| Transportation & Storage (Warehousing and Logistics) |
Loading/unloading vehicles, moving pallets, picking orders, repetitive lifting. |
| Administrative & Support Services |
Cleaning, waste collection, facilities management and labour supply work involving frequent manual handling. |
| Human Health & Social Care |
Moving and handling patients, transferring people, pushing beds and wheelchairs. |
| Manufacturing |
Repetitive lifting, assembly work, machine loading and handling raw materials. |
| Wholesale & Retail |
Stock replenishment, unloading deliveries, moving cages and shelves. |
Why manual handling assessments matter
Poor manual handling can contribute to musculoskeletal disorders affecting different parts of the body. According to the HSE, 43% of cases affect the back and 41% affect the upper limbs and neck, whilst 15% affect the lower limbs.
There are also business consequences to consider. Injuries can contribute to sickness absence, reduced productivity and disruption. Employers need to do more than simply teach employees how to lift, as they have a responsibility to identify hazards and then control or reduce workplace risks.
When should you carry out a manual handling assessment?
A manual handling assessment should be carried out where hazardous manual handling cannot reasonably be avoided.
This might be necessary if a new manual handling task is introduced or if the workplace, equipment or process changes. It will also be required when heavy, bulky, unstable or awkward loads are introduced, or if the work becomes repetitive or involves prolonged handling.
Assessments should also take place following an accident, injury or near miss, or if an employee reports pain or discomfort. They may also be needed when there are changes to the workforce that could affect the risk. An assessment should be reviewed when the existing assessment may no longer reflect the actual task.
How to carry out a manual handling assessment
The Manual Handling Operations Regulations set out the Avoid-Assess-Reduce approach. This means employers must first consider whether hazardous manual handling can be avoided altogether, and if it cannot, then the task needs to be assessed.
They are then responsible for reducing the remaining risk as far as reasonably practicable.
The assessment needs to consider four key TILE factors:
Task
Employers need to consider how the task is actually performed by looking at lifting frequency, repetition, posture, reaching and twisting. For example, there may be repeated twisting while lifting from one position to another, which increases the risk.
Individual
It is important to look at whether the person carrying out the task has the capability and appropriate training required, as well as any relevant health considerations. The assessment needs to consider the person doing the work and not just the object that is being moved.
Load
It is necessary to assess the weight, size, shape, stability and gripping of the load in question and consider whether it is difficult to hold or likely to shift during movement. For example, a large load with no secure grip may present a greater risk than its weight alone suggests.
Environment
The area in which the handling takes place needs to be checked. The assessment should consider lighting, available space, flooring, obstacles and whether surfaces are uneven, wet or slippery. A restricted space may force an employee into an awkward posture while lifting.
Equipment should be considered where relevant, including whether a trolley, hoist or other mechanical aid could remove or reduce the need for manual handling.
Safe manual handling best practice
Assessment and control measures should come before relying on lifting technique alone. When a load is being moved or lifted, it should be assessed before any attempts to move it.
The route should be planned and cleared, and the employee needs to adopt a stable stance before lifting. They should keep the load close to the body where possible and avoid twisting while carrying or lifting.
They should move smoothly, avoid sudden movements and maintain visibility to ensure they can see where they are going. They also need to use handles where they provide a secure grip and stop if the load is too heavy, unstable or otherwise unsafe to move.
Mechanical aids such as trolleys, sack trucks, pallet trucks and hoists are effective ways of reducing manual handling where appropriate.
Pushing and pulling
When pushing or pulling a load, it is important to check the route and equipment before starting, keep control of the load and avoid sudden movements.
Any assessment should consider whether a mechanical aid could reduce the physical effort required. It is important to remember that pushing and pulling are also forms of manual handling and therefore need to be assessed where they present a risk.
Need help with manual handling assessments?
Watson & Watson are able to support employers with manual handling assessments and wider health and safety requirements. An assessment can help to identify hazards, determine the appropriate control measures and establish where employees may need further information, instruction or training.
Get in touch with Watson & Watson now about your manual handling assessments, manual handling training and health and safety consultancy.
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