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Manual Handling

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Manual Handling

SECTION GUIDE

What is Manual Handling?

Manual handling means using physical effort to move, lift, lower, push, pull, carry, or support a load. A “load” can be anything which is to be pushed, pulled, lifted or carried.

Manual handling does not only refer to heavy lifting.

In practice, manual handling includes:

  • Lifting a box of files in an office.
  • Moving stock in a warehouse.
  • Pushing a trolley in retail or healthcare.
  • Carrying building materials on a construction site.
  • Transferring patients in a care home.

It is one of the most common causes of workplace injury in the UK. Poor technique, lack of training, or unsafe loads can result in strains, sprains, back pain, or long-term musculoskeletal disorders (MSDs).

What does Manual Handling mean?

From an HR and H&S perspective, manual handling is about risk management and compliance with the Manual Handling Operations Regulations 1992 (MHOR).

Employers have three main duties:

  1. Avoid hazardous manual handling wherever reasonably practicable.
  2. Assess unavoidable tasks to identify risks of injury.
  3. Reduce risks by introducing safer systems, equipment, and training.

There is no absolute maximum weight in UK law. Guidance indicates that loads should be easy to grasp, held close to the body, and handled in ideal conditions (heat, light, standards of housekeeping). Risks increase sharply when twisting, reaching, working at height, or handling awkwardly shaped objects.

  • Why does Manual Handling matter for your business?

    Manual handling matters because it affects employee health, legal compliance, productivity, and costs.

    If ignored, risks include:

    • Injury claims – employees suffering back or shoulder injuries may claim compensation, leading to tribunal cases or insurance payouts.
    • HSE enforcement – employers can face improvement notices, fines, or prosecution if they fail to control manual handling risks.
    • Lost productivity – musculoskeletal injuries are one of the leading causes of long-term absence in the UK, costing businesses millions each year.
    • Reputational damage – poor safety standards affect staff morale, retention, and employer brand.

    On the positive side, organisations that manage manual handling well benefit from:

    • Lower absence levels and higher productivity.
    • Improved employee wellbeing and engagement.
    • Reduced insurance premiums and legal risk.
    • Enhanced reputation as a responsible employer.

    For SMEs, the impact can be even greater, as the absence of just one or two employees can disrupt operations significantly.

  • Manual Handling – best practices and guidelines

    To manage manual handling effectively, employers should take a systematic approach.

    Carry Out Risk Assessments

    • Identify all tasks involving lifting, pushing, pulling, or carrying.
    • Consider the load (weight, size, shape, stability), the task (distance, posture, frequency), the working environment (space, floors, lighting), and the individual’s capability.
    • Record and review assessments regularly.

    Introduce Equipment & Aids

    • Use trolleys, pallet trucks, hoists, sack barrows, conveyor belts and other aids.
    • Encourage staff to ask for help with heavy or awkward loads.

    Provide Training

    • Train staff in recognised manual lifting techniques (bending knees, feet apart, chin up, keeping back straight, avoiding twisting).
    • Reinforce training with posters, videos, and refreshers.
    • Ensure managers and supervisors set a good example.

    Redesign the Workplace

    • Store heavier items at waist height to reduce bending and stretching.
    • Ensure workspaces are tidy, with clear walkways.
    • Reduce the need to carry items over long distances by improving layout.

    Develop Policies & Culture

    •  Include manual handling in health and safety policies.
    • Encourage employees to report risks and near misses.
    • Make manual handling part of induction and ongoing H&S training.

Your Questions Answered

FAQs on Manual Handling

  • How often should manual handling risk assessments be reviewed?Reveal

    Following changes in work processes, equipment, or staffing changes. It is a good idea to review as part of a routine management process. For this reason, annual reviews would be considered good practice.

  • Does manual handling apply in offices as well as manual jobs?Reveal

    Yes. Even in offices, staff may move boxes, furniture, or equipment. All workplaces should risk assess manual handling.

  • What are the risks of poor manual handling?Reveal

    Back pain, slipped discs, hernias, sprains, long-term musculoskeletal disorders (MSDs), and chronic absence.

  • Who is responsible for safe manual handling?Reveal

    The employer has overall responsibility. Managers must enforce safe practices, and employees must follow training and report risks.

  • Do I legally need to provide manual handling training?Reveal

    Yes. Under Manual Handling Operations Regulations 1992 (MHOR), employers must ensure employees are trained in safe practices. Training is vital for compliance and prevention.

  • What’s the maximum manual handling weight an employee can lift in the UK?Reveal

    There is no fixed legal maximum. Manual handling assessments should be carried out considering the task, load, individual capability and surrounding environment.

Where to find out more A collection of hand-picked useful resources in relation to Manual Handling from impact HR and beyond

Need support with Manual Handling training?

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