Manual handling is the movement of loads through lifting, lowering, pushing, pulling, carrying or moving. Present in almost every type of workplace, manual handling often forms an essential part of the day-to-day running of businesses, particularly where the movements of goods such as stock within a warehouse or equipment within a construction site as just two common examples are concerned.
Regardless of the type of business you may own, if manual handling is required by your employees, then the proper procedures need to be in place to remove the chances of injury. An added benefit of efficient manual handling is that your operations can be made to be more efficient too.
Here is an overview of what to consider with manual handling, including what training is required and how to avoid injury. Plus, how material rather than manual handling could reduce the strain on your employees and on your business as a whole.
Manual Handling Meaning – A Clear Definition
Manual handling refers to any activity that requires a person to use bodily force to lift, lower, carry, push, pull, hold or restrain a load. The term “load” encompasses physical objects such as boxes, equipment and materials, but also includes people and animals in certain working contexts.
In UK health and safety law, manual handling is governed by the Manual Handling Operations Regulations 1992, which place a duty on employers to avoid hazardous manual handling tasks where reasonably practicable, assess the risk of tasks that cannot be avoided, and reduce the risk of injury as far as possible.
Injuries arising from manual handling are among the most common causes of workplace absence in the UK, with musculoskeletal disorders affecting the back, shoulders and upper limbs being particularly prevalent. Proper training, ergonomic workplace design and the use of mechanical aids are the primary means of controlling manual handling risk.
Manual Handling Examples
Whether an employee is lifting a large parcel in an office or heavy goods on a building site, manual handling comes in many forms and cannot be completely avoided. However, every time a load is manually handled, it leads to the chances of that employee facing injury through trapping, crushing or cuts, in addition to the obvious risk of musculoskeletal injuries.
Injury through manual handling is more likely when any of the following applies:
- Awkward postures
- Poor lifting techniques
- Failing to route plan
So, it’s perhaps no surprise that when it comes to manual handling training, these three aspects are key when it comes to the correct lifting and repositioning of goods through manual rather than mechanical means.
Manual Handling Training
First and foremost, no member of staff should be tasked with manual handling unless they have completed health and safety training to reduce the risk of injury. This includes within non-typical settings such as offices or retail work. If the employee has any condition which makes them more susceptible to injury through manual handling, then they should not be tasked with any such jobs.
For any member of staff who will be required to undertake manual handling, then they will need to undergo training relating to how to lift correctly, along with knowing what is a safe load to be lifted manually.
Furthermore, the Manual Handling Operations Regulations 1992 states that hazardous manual handling operations should be avoided as is reasonably practical and that the risk of injury in circumstances where manual handling is unavoidable must be reduced.
Some key aspects to note in relation to these statements include:
- Employees must learn common injuries associated with manual handling, along with the ‘see-saw’ effect in relation to balancing a load correctly.
- How to avoid manual handling wherever possible, including the legal limit for loads.
- How to carry out a manual handling risk assessment based on the load and environment.
- Learning control strategies to reduce the risk of injury where avoidance of manual handling is not possible.
To reiterate, it is essential that all employees tasked with manual handling undergo training and gain certification in the practice, before any kind of manual handling is attempted. The appointed trainer must hold the correct certification to be able to train others in manual handling, which is why many employers seek out official courses.
On the contrary, if an employee does attempt manual handling where no training has been given and serious injury occurs, the employer may be liable for legal action.
When Is Manual Handling No Longer A Safe Option?
Under UK law, there is no single weight limit that automatically makes manual handling unsafe. Instead, the Manual Handling Operations Regulations 1992 require a risk assessment based on four key factors, commonly remembered as TILE:
- Task – does it involve twisting, stooping, long carrying distances, or repetitive movement?
- Individual – is the person pregnant, returning from injury, or physically unsuited to the task?
- Load – is it heavy, bulky, unstable, difficult to grip, or with sharp edges?
- Environment – are there space constraints, uneven floors, poor lighting, or extreme temperatures?
The Health and Safety Executive (HSE) does publish guideline figures as a starting point. For example, a fit adult male lifting from waist height has a guideline weight of 25kg, reducing significantly for low or high lifts, twisting, or frequent repetition. For women, the guideline figures are lower.
Manual handling becomes unsafe when the risk assessment identifies that the risk of injury cannot be adequately controlled, at which point the employer must introduce mechanical aids, team lifting, or redesign the task entirely.
What Are The Alternatives To Manual Handling?
Where manual handling cannot be avoided entirely, employers are required to reduce the risk of injury by introducing mechanical aids or redesigning the task. Common alternatives include:
- Pallet trucks and pump trucks – used to move heavy or bulky loads across flat surfaces without lifting
- Forklifts and powered industrial trucks – suitable for moving heavy loads across warehouses or loading areas
- Conveyor systems – eliminate repeated lifting by moving goods along a fixed route
- Hoists and cranes – used where loads must be raised or lowered vertically, particularly in construction and manufacturing
- Sack trucks and trolleys – allow a single person to move loads that would otherwise require team lifting
- Vacuum lifters and suction devices – commonly used for flat, smooth loads such as glass or sheet materials
- Team lifting – where mechanical aids are not practicable, coordinated two-person lifts can reduce individual strain
The HSE advises that mechanical solutions should always be the first consideration, with team lifting treated as a last resort rather than a routine substitute for proper equipment.
Metreel Material Handling Equipment UK
As noted, manual handling should be avoided whenever possible. One such way to achieve this aim is by using material handling equipment, which will lift, lower and reposition loads without the need for manual handling.
Metreel is a leading manufacturer of material handling in the UK, and we are on hand to ensure your workplace operations become safer and more efficient.
Based in Derbyshire, we operate not just across the East Midlands but on a global scale. So, if you are in search of the perfect material handling solutions for your business, or if you have any questions about workplace safety in general, you’re in the right place.
You can also download our free brochure to discover more about our product specifications by visiting our product brochure page. If you’re ready to place an order or have any questions, please give us a call on 0115 932 7010 or email us at [email protected].