NUMERICAL GUIDELINES FOR MANUAL HANDLING ASSESSMENTS

Introduction - the need for assessment

1. The Management of Health and Safety at Work Regulations 1992 requires employers to make a suitable and sufficient assessment of the risks to the health and safety of the employees while at work. Where this general assessment indicates the possibility of risks to employees from the manual handling of loads the requirements of the Manual Handling Operations Regulations 1992 (The Regulations)need to be considered.
2. The Regulations set out a hierarchy of measures for safety during manual handling:
   1. avoid hazardous manual handling operations so far as is reasonably practicable;
   2. make suitable and sufficient assessment of any hazardous manual handling operations that cannot be avoided; and
   3. reduce the risk of injury from those operations so far as is reasonably practicable.

   Purpose of the guidelines

3. The Manual Handling Operations Regulations set no specific requirements such as weight limits. Instead, assessment based on a range of relevant factors listed in Schedule 1 to the Regulations is used to determine the risk injury and point the way to remedial action. However a full assessment of every manual handling operation is not necessary and the following numerical guidelines provide an initial filter which can help to identify those manual handling operations deserving more detailed examination. The guidelines set out an approximate boundary within which operations are unlikely to create a risk of injury sufficient to warrant more detailed assessment. This should enable assessment work to be concentrated where it is most needed.
4. There is no threshold below which manual handling operations may be regarded as 'safe'. Even operations lying within the boundary mapped out by the guidelines should be avoided or made less demanding wherever it is reasonably practicable to do so.

   Individual capability

5. There is a wide range of individual physical capability, even among those fit and healthy enough to be at work. For the working population the guideline figures will give reasonable protection to nearly all men and between one half and two thirds of women. To provide the same degree of protection to nearly all working women the guideline figures should be reduced by about one third. 'Nearly all' in this context means about 95%.
6. It is important to understand that the guideline figures are not limits. They may be exceeded where a more detailed assessment shows that it is appropriate to do so. However, even for a minority of fit, well-trained individuals working under favourable conditions any operations which would exceed the guideline figures by more than a factor of about two should come under very close scrutiny.

   Guidelines for lifting and lowering

7. Basic guideline figures for manual handling operations involving lifting and lowering are set out in Figure 1. They assume that the load is readily grasped with both hands and that the operation takes place in reasonable working conditions with the handler in a stable body position.
8. The guideline figures take into consideration the vertical and horizontal position of the hands as they move the load during the handling operation, as well as the height and reach of the individual handler. It will be apparent that the capability to lift or lower is reduced significantly, if, for example, the load is held at arm's length or the hands pass above shoulder height.
9. If the hands enter more than one of the box zones during the operation the smallest weight figure should be used. The transition from one box zone to another is not abrupt; an intermediate figure may be chosen where the hands are close to a boundary. Where lifting or lowering with the hands beyond the box zones is unavoidable a more detailed assessment should be made.

   Twisting

10. The basic guideline figures for lifting and lowering should be reduced if the handler twists to the side during the operation. As a rough guide the figures should be reduced by about 10% where the handler twists through 45° and by about 20% where the handler twists through 90°. Frequent lifting and lowering
11. The basic guideline figures for lifting and lowering are for relatively infrequent operations - up to approximately 30 operations per hour - where the pace of work is not forced, adequate pauses for rest or recovery are possible and the load is not supported for any length of time. They should be reduced if the operation is repeated more frequently. As a rough guide the figures should be reduced by 30% where the operation is repeated once or twice per minute, by 50% where the operation is repeated around five to eight times per minute, and by 80% where the operation is repeated more than about 12 times per minute.

    Guidelines for carrying

12. Basic guideline figures for manual handling operations involving carrying are similar to those given for lifting and lowering, though carrying will not normally be carried out with the hands below knuckle height.
13. It is also assumed that the load is held against the body and is carried no further than about 10 m without resting. If the load is carried over a longer distance without resting the guideline figures may need to be reduced.
14. Where the load can be carried securely on the shoulder without first having to be lifted (as for example when unloading sacks from a lorry) a more detailed assessment may show that it is acceptable to exceed the guideline figure.

    Guidelines for pushing and pulling

15. The following guideline figures are for manual handling operations involving pushing and pulling, whether the load is slid, rolled or supported on wheels. The guideline figure for starting or stopping the load is a force of about 25 kg (i.e. about 250 Newtons). The guideline figure for keeping the load in motion is a force of about 10 kg (i.e. about 100 Newtons).
16. It is assumed that the force is applied with the hands between knuckle and shoulder height; if this is not possible the guideline figures may need to be reduced. No specific limit is intended as to the distance over which the load is pushed or pulled provided there are adequate opportunities for rest or recovery.

    Guidelines for handling while seated

17. The basic guideline figure for handling operations carried out while seated is given in Figure 4 and applies only when the hands are within the box zone indicated. If handling beyond the box zone is unavoidable or, for example, there is significant twisting to the side a more detailed assessment should be made.

REMEMBER - the guideline figures should not be regarded as precise recommendations. They should be applied with caution. Where doubt remains, a more detailed assessment should be made.

Manual Handling of Loads

ASSESSMENT CHECKLIST

* circle as appropriate

SECTION A - Preliminary:

 

Q1	Do the operations involve a significant risk of injury? If 'Yes' go to Q2. If 'No' the assessment need go no further. If in doubt answer 'Yes'. You may find the guidelines in Appendix 1 helpful.	Yes/No*
Q2	Can the operations be avoided/mechanised/automated at reasonable cost? If 'No' go to Q3. If 'Yes' proceed and then check that the result is satisfactory.	Yes/No*
Q3	Are the operations clearly within the guidelines in Appendix 1? If 'No' go to Section B. If 'Yes' you may go straight to Section C if you wish.	Yes/No*

SECTION C - Overall assessment of risk:

 

Q

What is your overall assessment of the risk of injury? If not 'Insignificant' go to Section D. If 'Insignificant' the assessment need go no further.

Insignificant/Low/Med/High*

SECTION D - Remedial action:

 

Q

What remedial steps should be taken, in order of priority? (i) (ii) (iii) (iv)

 

SUMMARY OF ASSESSMENT Operations covered by this assessment ............................................................ ............................................................ Locations:............................................... Personnel involved:.................................... Date of assessment: ...................................

Overall priority for remedial action: Nil/Low/Med/High* Remedial action to be taken........................... ............................................................ ............................................................ Date by which action is to be taken .................. Date for reassessment ................................. Assessor's name ....................................... Signature ................................................

Section B - More detailed assessment, where necessary:

Questions to consider: (If the answer to a question is 'Yes' place a tick against it and then consider the level of risk)

Level of risk: (Tick as appropriate)

Possible remedial action: (Make rough notes in this column in preparation for completing Section D)

 

The tasks - do they involve: *holding loads away from trunk? *twisting? *stooping? *Reaching upwards? *large vertical movement? *long carrying distances? *strenuous pushing or pulling? *unpredictable movement of loads? *repetitive handling? *insufficient rest or recovery? *a work rate imposed by a process? The loads - are they? *heavy? *bulky/ unwieldy? *difficult to grasp? *unstable/unpredictable? *intrinsically harmful (eg sharp/hot?) The working environment - are there: *constraints on posture? *poor floors? *variations in levels? *hot/cold/humid conditions? *strong air movements? *poor lighting conditions? Individual capability - does the job: *require unusual capability? *hazard those with a health problem? *hazard those who are pregnant? *call for special information/training? Other factors: Is movement or posture hindered by clothing or personal protective equipment?

Yes

Low

Med

High

Deciding the level of risk will inevitably call for judgement. The guidelines in Appendix 1 may provide a useful yardstick. When you have completed Section B go to Section C.