5 Key Principles of
Manual Handling
Manual handling injuries are the most common cause of workplace injury in the UK. These 5 principles — based on the TILE framework from the Manual Handling Operations Regulations 1992 — help you assess and control the risks.
The TILE Framework
The HSE's recommended approach to manual handling assessment. TILE stands for Task, Individual, Load, and Environment — the four factors you must assess for every manual handling activity.
The 5th principle — correct technique — sits on top of TILE. It's the final control after you've assessed and addressed the other four factors.
The 5 Principles Explained
Assess the Task
Before any manual handling activity, evaluate what the task actually involves. Can you eliminate the need for manual handling entirely? If not, can you reduce it?
Questions to Ask
- ?Does the task involve twisting, stooping, or reaching?
- ?Is there prolonged pushing, pulling, or carrying?
- ?Does it require sudden movements or awkward postures?
- ?How far does the load need to be moved?
- ?Is there repetitive handling involved?
Control Measures
- Use mechanical aids (trolleys, hoists, conveyors) to eliminate manual handling where possible
- Break large loads into smaller, manageable portions
- Redesign storage layouts to minimise carrying distances
- Use team lifts for loads that exceed individual capacity
Example: On a construction site, delivering plasterboard to upper floors. Rather than carrying sheets up stairs (high risk), use a hoist or crane to lift materials to the correct level.
Assess the Load
Examine the load itself. Weight alone doesn't determine risk — shape, size, grip, stability, and contents all matter.
Questions to Ask
- ?How heavy is the load? (HSE guideline: 25kg max for men, 16kg for women at waist height)
- ?Is it bulky, awkward, or difficult to grip?
- ?Is the weight evenly distributed or likely to shift?
- ?Is the load hot, cold, sharp, or otherwise hazardous?
- ?Can the load be broken down into smaller parts?
Control Measures
- Add handles, handholds, or grip points to loads where practical
- Label loads with weight and handling instructions
- Secure loose contents to prevent shifting during transport
- Provide appropriate PPE (gloves, safety boots) for the load type
Example: A bag of cement (25kg) at ground level requires careful technique. But a sheet of plywood (lighter but large surface area) can be more dangerous in wind. Assess both weight and characteristics.
Assess the Environment
The working environment dramatically affects manual handling risk. The same load can be safe in one environment and dangerous in another.
Questions to Ask
- ?Are floors clean, dry, and even? Any slopes or steps?
- ?Is there adequate lighting to see obstacles and trip hazards?
- ?Is the space restricted (narrow corridors, low ceilings, tight doorways)?
- ?Are there temperature extremes (cold reduces grip, heat causes fatigue)?
- ?Is there other work happening nearby that creates additional hazards?
Control Measures
- Maintain clear, well-lit access routes for all manual handling activities
- Clean up spills immediately — wet or dusty surfaces multiply slip risk
- Remove obstructions from walkways before handling operations begin
- Provide adequate ventilation and rest breaks in hot environments
Example: Moving furniture in an office refurbishment. The load is manageable, but narrow corridors, fire doors, and changes in floor level between areas create the real risk. Clear the route first.
Assess Individual Capability
Every worker has different physical capabilities. A manual handling task that's safe for one person may not be safe for another.
Questions to Ask
- ?Does the worker have any pre-existing injuries or health conditions?
- ?Are they physically capable of the specific handling task?
- ?Have they received manual handling training?
- ?Are they pregnant or recently returned from injury?
- ?Are they fatigued from previous tasks or long shifts?
Control Measures
- Provide manual handling training for all workers who handle loads
- Consider individual health conditions during risk assessment
- Implement job rotation to prevent fatigue and repetitive strain
- Ensure workers know they can request help without stigma
Example: A new apprentice on site shouldn't be expected to handle the same loads as an experienced labourer. Assess competence and physical capability individually — not by job title.
Use Correct Technique
Even when the first four principles are addressed, correct lifting and handling technique is essential. This is the principle most people know — but it's the last line of defence, not the first.
Questions to Ask
- ?Is the worker using a stable base with feet shoulder-width apart?
- ?Are they bending at the knees, not the waist?
- ?Is the load held close to the body throughout the lift?
- ?Are they avoiding twisting — moving feet instead of rotating the spine?
- ?Is the lift smooth and controlled, without jerking?
Control Measures
- Train workers in correct lifting technique: plan, position, pick up, proceed, place
- Encourage the 'power zone' — keep loads between shoulder and knee height
- Teach workers to test the load weight before committing to a full lift
- Never twist with a load — turn the whole body by moving the feet
Example: The correct sequence: plan your route, stand close to the load, bend at the knees with a straight back, grip firmly, lift smoothly using your legs, keep the load close to your body, and set down by bending the knees again.
UK Manual Handling Legislation
These regulations establish your legal duties around manual handling at work.
Manual Handling Operations Regulations 1992 (as amended 2002)
- Avoid hazardous manual handling where reasonably practicable
- Assess any hazardous manual handling that cannot be avoided
- Reduce the risk of injury as far as reasonably practicable
- Review assessments when conditions change
Health and Safety at Work etc. Act 1974
- General duty to ensure health, safety, and welfare of employees (s.2)
- Provide safe systems of work (s.2(2)(a))
- Provide information, instruction, training, and supervision (s.2(2)(c))
- Employees must take reasonable care of themselves and others (s.7)
Management of Health and Safety at Work Regulations 1999
- Carry out suitable and sufficient risk assessments (reg.3)
- Implement preventive and protective measures (reg.4)
- Provide health surveillance where appropriate (reg.6)
- Provide adequate training (reg.13)
HSE Guidance L23 (4th Edition)
- Guideline weights for lifting and lowering (25kg men, 16kg women at waist height)
- TILE assessment framework (Task, Individual, Load, Environment)
- Ergonomic approach to risk reduction
- Practical guidance for employers and employees
HSE Guideline Weights
These are guidelines, not legal limits. Exceeding them doesn't automatically mean unsafe — but it does mean you need a more detailed assessment.
Men — Guideline Weights
Women — Guideline Weights
Source: HSE L23 (4th Edition). These figures assume the load is held close to the body. Reduce by 50% if arms are extended, and by 80% if held at arm's length.
Manual Handling FAQs
What is the maximum weight you can lift at work in the UK?
There is no legal maximum weight limit in UK law. The Manual Handling Operations Regulations 1992 require employers to assess the risk and reduce it as far as reasonably practicable. The HSE guidelines suggest 25kg for men and 16kg for women at knuckle height as a starting point — but these are guidelines, not legal limits.
What does TILE stand for in manual handling?
TILE stands for Task, Individual, Load, and Environment. It's the HSE's recommended framework for assessing manual handling risks. Each factor must be considered when deciding whether a manual handling activity is safe and what controls are needed.
Do I need a risk assessment for manual handling?
Yes, if manual handling cannot be avoided, the Manual Handling Operations Regulations 1992 (Regulation 4) require employers to carry out a suitable and sufficient assessment. This should use the TILE framework and be recorded in writing.
Who is responsible for manual handling safety?
Employers have the primary duty to assess and reduce manual handling risks. Employees have a duty to follow safe systems of work, use equipment provided, and report any problems. On CDM projects, the principal contractor must ensure manual handling arrangements are included in the construction phase plan.
How often should manual handling training be refreshed?
There's no legal frequency, but the HSE recommends refresher training at regular intervals (typically annually), when tasks change, after incidents, or when workers are new to the role. Training should be practical and task-specific, not just a generic classroom session.
What is the correct lifting technique?
Plan the lift, position yourself close to the load with feet shoulder-width apart, bend at the knees (not the waist), grip firmly, lift smoothly using your legs, keep the load close to your body, avoid twisting (move your feet instead), and set down by bending the knees again. This is Principle 5 — but it's the last line of defence after assessing Task, Individual, Load, and Environment.
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