General manual handling risk assessment

A manual handling risk assessment should break down the real lifting, lowering, carrying, pushing or pulling operation and who performs it. Load weight, grip and stability interact with posture, reach, repetition, route, pace and individual capability; there is no universal safe weight. The Manual Handling Operations Regulations 1992 establish a hierarchy: avoid hazardous handling where reasonably practicable, assess what cannot be avoided and reduce the risk. Observe the task rather than relying only on a description, and speak with workers who know where it becomes difficult. Redesign storage height, delivery size or workflow before defaulting to lifting technique training. Where aids are selected, make sure they fit the route, are maintained and do not introduce new pushing or trapping hazards.

In short

A risk assessment identifies what could cause harm in your work, who could be harmed and how, and what you do to control the risk. Every employer must make a suitable and sufficient assessment; with five or more employees the significant findings must be recorded.

What it must include

  • ✓The hazards in the activity or workplace
  • ✓Who might be harmed and how
  • ✓Existing controls and further action needed
  • ✓Risk rating (e.g. 5x5 likelihood x severity)
  • ✓Who does what by when
  • ✓Review date and when to review sooner
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1

The assessment

Activities involvedOptional

Tick any work being done, such as electrical work or painting, to add its hazards. For building work, a RAMS also gives you the method statement.

2

Your details

3

The activity

4

Emergency arrangements

Leave blank and the document reminds you to confirm them on site.

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Questions

Is 25 kg a legal lifting limit?

No. Guideline figures are filters, not limits, and an assessment must consider all task, load, environment and individual factors.

Should pushing and pulling be assessed?

Yes. Starting force, slope, floor condition, handle height, visibility and stopping all affect the risk.

When must an assessment be redone?

Review after injury, task or equipment changes, new information, worker concerns, or evidence that controls are ineffective.

Guides

Sources

Page updated 2026-10-04.

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