Manual Handling Weight Limit in the UK (For Man & Woman)

Each year, millions of people in the UK experience back pain due to unregulated manual handling. Also, people experience injuries to the back, neck, or spine due to the lack of maintaining the existing manual handling weight limit in the UK.

Working over limits can lead to excruciating pain, short-term disability, or long-term harm. Therefore, it would be helpful if you regulated the weight limits in manual handling jobs that could pose a risk to you or your factory workers.

What is Manual Handling?

Manual handling means applying muscular force to push, support, or move animate and inanimate objects. You may use tools to handle objects. In addition, it may involve the activities such as

lifting,
pushing,
pulling,
holding,
lowering,
throwing,
carrying,
packing,
and typing.

The phrase “manual handling” refers to doesn’t only to moving heavy objects; other examples include

trimming plants,
arranging products on a shelf,
using a broom,
and even using a keyboard.

You should work within the manual handling weight limit in the UK. Otherwise, if you use excessive force repeatedly or continuously, you are subjected to hazardous manual handling. In addition, the following actions will lead you to hazardous manual handling.

You adopt awkward postures or motions.
You perform tasks that would be challenging for most people due to the high force required.
You have exposure to continuous vibration.
You handle unstable loads that are challenging to grasp or hold.

What is the Maximum Weight You can Lift at Work?

Depending on how you lift the weight, how close you hold it to your body, and whether you lift it high or low, the maximum manual handling weight limit in the UK may vary.

According to the recommendations, men should only lift 25 kg when working. In addition, this limit applies when holding objects at or near the waist level close to the body. For weight held at arm’s length or higher than the shoulder, the recommended maximum weight is 5 kg.

For women, the standards advise lower weights. The recommended upper limit for women is 16 kg for weight held at waist height. It would be best if you followed the above chart of weight limits in the UK at work.

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Manual Handling Weight Limits for Men

When lifting, men should maintain the following weight limits.

10 kg, held close to the body and over the shoulder.

20 kg, gripped closely to the body, below the shoulder but above the elbow.

25kg, grabbed close to the body at a height below the elbow but above the knuckle.

20kg, picked close to the body, below knuckle height but above mid-leg height.

10 kg, clutched close to the torso below mid-leg height.

5 kg, held away from the body and over the shoulder.

10kg, carried away from the body, below the shoulder but above the elbow.

15 kg, held away from the body at a height below the elbow but above the knuckle.

Manual Handling Weight Limits for Women

When lifting, women, in general, should maintain the following weight limits.

7 kg, held close to the body and over the shoulder.

13 kg, gripped close to the body, below the shoulder but above the elbow.

16 kg, grabbed close to the body at a height above the knuckle but below the elbow.

13 kg, picked close to the body, below knuckle height but above mid-leg height.

7 kg, clutched close to the torso below mid-leg height.

3 kg, held away from the body and over the shoulder.

7 kg, carried distance from the body, below the shoulder but above the elbow.

10 kg, held away from the body at a height below the elbow but above the knuckle.

7 kg, grabbed away from the torso, just above mid-leg height but below knuckle height.

3 kg, picked close to the torso below mid-leg height.

Two-Person Weight Limits

Often, two people may lift a heavy object. However, the maximum manual handling weight limit in the UK does not double due to that. Two-person weight limits should be less than 2/3 of the total of both people’s lifting limits. For instance, if two guys, capable of lifting a maximum of 25 kg, are working together to raise an object, the thing shouldn’t weigh more than about 33 kg.

Moreover, three-person weight limits should not be more than half the combined lifting capacities of the three people.

Use these manual handling weight limits as a general guide. Different people will have different levels of difficulty with the manual handling weight Limit in the UK. When you evaluate the risk of manual handling work, you must have additional considerations. Many factors can limit a person’s capability to handle objects.

Health and Safety Advice for Manual Handling

Here’s some helpful information for ensuring health and safety in manual handling.

Health Issues

If you don’t maintain the weight limits, it can lead to musculoskeletal problems. Musculoskeletal problems mean injuries or illnesses hurting the back, joints, and limbs. For example, workers’ primary reason for back pain is manual handling.

There are risks associated with manual handling in many types of jobs, including

factories,
offices,
warehouses,
hospitals,
construction sites,
and delivery services.

Risk factors for musculoskeletal problems include

strenuous physical labour,
repetitive handling,
uncomfortable postures,
and previous or current injuries or conditions.

Additionally, a non-job-related injury, such as one sustained during sports, may worsen due to employment. Therefore, you must encourage your employees to notify you or the worker representative of any symptoms as soon as possible before the conditions worsen. So, you’ll be able to take precautions to lower the risk.

Moreover, it would be best to consider seeking guidance from an occupational health practitioner regarding a worker’s fitness for work. In addition, make necessary changes to their employment if your employees have manifested symptoms. Therefore, you can implement the proper manual handling weight limit in the UK.

Safety Issues

You should avoid manual handling at work as much as possible. However, if handling weight is unavoidable, employers must consider the hazards. In addition, you must put practical health and safety precautions in place to guard against harm. For example, in lifting weights, you must account for the person raising an object’s capacity. Also, define the load type. Additionally, ensure proper training of workers.

Furthermore, minimise your bending, stooping, and reaching. Avoid lifting from the floor or above shoulder height, especially with big loads. Organise storage spaces to reduce the necessity for these movements. Finally, think about ways to reduce transport distances.

It will help if you examine the load’s weight. In addition, you should evaluate whether the worker can move it safely or if they require assistance. Then, break the load down, if necessary, into smaller, lighter components.

What does TILE Stand for in Manual Handling?

Task, Individual, Load, and Environment are the four components of TILE. TILE simplifies the process of manual handling risk assessment. To evaluate the manual handling weight limit in the UK, you must use TILE.

It can assist you in accurately evaluating the risks associated with all manual handling operations. Additionally, the law mandates to do risk analyses for manual handling tasks.

If your worker has to perform potentially dangerous manual handling procedures, you must complete a proper and adequate risk assessment. In addition, you should identify

any potential dangers,
risks associated with the activity,
and methods for reducing or eliminating those risks.

All in all, you should complete the TILE assessment before a manual handling task.

The “Task”

Consider the actual manual handling work itself. It could involve pushing, dragging, hauling, raising, or lowering objects. Some of these behaviours impact your safety and health. The task could involve

repetitive motions,
heavy lifting,
vast distances,
or unequal weight distributions.

It would be best to diminish the risk factors as much as feasible. If not, you should rethink your task. Finding alternatives to the current completion method can aid in lowering the risk of injuries. In addition, you should think about whether there will be enough time for relaxation and recovery before, during, or after the task. Overall, reduce or eliminate manual handling as much as you can.

The “Individual”

Consider the person(s) performing the manual handling task. Ensure they are capable, powerful, and fit. In addition, make sure you can complete the manual handling on your own before starting the work. If not, get assistance to finish the task.

Additionally, you might need to take into account whether

the person is a new or pregnant mother,
they have a handicap or injury,
they have other health issues that could increase risk,
and they have the necessary skills and training for the job.

The risk assessment may indicate a high level of danger involved with a specific individual. Then, you should advise a different person to perform the task. A person’s abilities can change over time. Therefore, you might need to routinely examine a person’s capacity to perform manual handling jobs.

The “Load”

Consider the thing or person that you are moving. Examine the weight to see if it has specific characteristics. For example,

The load is abnormally heavy or bulky.
It is challenging to grasp and unstable.
The load is likely to impair visibility.
It contains hazardous materials.
It has a particular risk of leakage.

You may need to take additional safety precautions after accounting for all the load-related issues. Such as,

wearing the appropriate Personal Protective Equipment (PPE),
using machinery or equipment to help with handling,
or disassembling the load to make it safer to handle.

The “Environment.”

Consider from or to where you are transporting the cargo. There might not be enough room. In addition, the flooring may be uneven or wet. There need to be adequate lighting. Also, verify that there are no possible trip hazards. You must take necessary precautions to minimise or avoid environmental hazards to handle a load safely.

Learn more – Tile Manual Handling — TILE, LITE & TILEO Explained.

What is the Legislation Associated With Manual Handling?

You must evaluate your employee’s health and safety risks under the Management of Health and Safety at Work Regulations. In addition, it would be best if you strictly follow Manual Handling Operations Regulations, which identify dangerous manual handling of loads.

According to the Manual Handling Regulations, you must take the following steps to reduce the hazards associated with manual handling.

Avoid risky manual handling tasks “as far as reasonably practicable”.
Assess worker injury risks from any complex manual handling you cannot avoid.
Minimise the risk of worker injury to the least reasonably practical level.

If you are a worker, you also have obligations. It would help if you ensured that your activities do not endanger others. Therefore, you must adhere to the systems of work established for your health and safety. You should use any equipment provided for that purpose properly. In addition, cooperate with your colleagues on health and safety issues. All in all, inform them of any changes and identify hazardous handling activities.

As an employer, you must consult with and involve your staff. Ensure that your employees know the manual handling hazards at the workplace. In addition, you should frequently provide valuable suggestions to them for reducing handling risks. Following the standard manual handling weight limit in the UK will help you tackle the hazards associated with it.

When to Reduce the Weight of the Load Below the Maximum Guideline?

You may need to change a load’s weight below the maximum manual handling weight limit in the UK for various reasons. For example, maintain the weight restriction below maximum if you lift by bending or twisting. You shouldn’t raise the maximum weight when completing the work repeatedly or in a confined space.

To evaluate any such manual handling or lift that an employee must do, you should conduct TILE evaluations. So, avoid handling the maximum weight in the following scenarios.

You are not working in ordinary circumstances.
You cannot maintain a steady stance and are bowing or twisting your body.
You are repetitively performing the task.
You are putting strain on your fingers or hands.
Your shoulders are not equally levelled.

Action to Take if Your Employer Asks You to Lift More Than the Maximum Recommended Weight

If your manager asks you to lift more than the maximum amount of weight advised, you need to report it:

Speak with your employer or the person in charge of employee complaints about your concerns.
Writing to your employer and expressing your concerns could be helpful (keep a copy for your records).
You could find a trade union representative who can assist you in finding a solution.

However, you could feel that nothing has changed after raising concerns about workplace health & safety with your employer. Then, you might want to report the situation again. If you lift more weight than is safe while working, it could hurt you, your co-workers, or someone else involved in the business.

Increase your knowledge of Health and Safety at the Workplace. The Health & Safety Executive (HSE) enforces these regulations in collaboration with local authorities.

Inspectors from the HSE and the local authority have the power to look into any health and safety law violation that endangers the safety of others. You should find out which authority is in charge of your specific workplace or premises before you report any concerns about occupational health and safety. The HSE offers details on the kinds of workplaces covered by each authority.

Action to Take if You Sustain a Lifting Injury at Work

You must notify your employer of any manual handling accidents that resulted in your injuries if they occurred at work. You can request a copy of the accident report to help establish the facts since you must report the occurrence according to the law.

Take pictures of the accident scene. It might be worthwhile to attempt and record the size of the space you were working in and the load you were lifting to prevent manual lifting injuries. Before anything is taken away from the scene, try to accomplish this as quickly as possible.

Get medical attention for your injuries. In addition to aiding in your recovery, the authority may also utilise medical records to demonstrate the severity of your wounds. Inquire about any witnesses’ information. Request copies of any CCTV images taken in the area. Do it as soon as possible because it won’t be available for long. Take pictures of any apparent wounds you may have while you heal.

Once you have as much supporting documentation as possible, call and speak with an advisor. They’ll discuss your claim with you and let you know your choices. If the case is compelling enough, they might suggest a specialised attorney help you with your manual handling claim.

Safe Manual Handling Procedures:
HSE Guidance for Pushing, Pulling, and Repetitive Tasks of Upper Limbs

HSE has developed different types of tools to handle upper limb manual handling. In addition, it has designed tools, such as ART and RAPP. They are necessary to tackle the tasks that require the use of upper limbs.

Assessment of Repetitive Tasks (ART)

You can work on duties requiring you to move your upper body (arms and hands) repeatedly. To tackle such jobs safely, HSE established the Assessment of Repetitive Tasks (ART) tool. It aids in evaluating some of the typical risk variables associated with repetition that cause Upper Limb Diseases (ULDs). You may

create,
evaluate,
manage,
and inspect

repetitive tasks with the use of ART. It can assist in determining which tasks have significant risks and where to concentrate risk-reduction strategies. ART can benefit

employers,
safety representatives,
health and safety professionals,
consultants,
and ergonomists.

Repetitive tasks mean a series of quick upper-limb movements executed repeatedly and almost always look the same. For example, it can be stitching a piece of cloth and manufacturing or packaging one item. The best-suited tasks for ART recur every few minutes or even more often. In addition, the task can last at least 1-2 hours every day or shift. Also, it involves the regular use of hand tools. You’ll find repetitive work in product assembly, processing, packaging, and sorting.

Risk Assessment of Pushing and Pulling (RAPP)

Besides lifting or handling, pushing and pulling also require upper limb activities. HSE has developed the Risk Assessment of Pushing and Pulling (RAPP) tool to tackle pushing and pulling movements. It is a straightforward tool made to assist in identifying the significant dangers associated with manual pushing and pulling actions requiring full body power.

You can use the RAPP to evaluate two types of pulling and pushing operations.

1 – You use dragging/sliding, churning (pivoting and rolling), and moving.

2 – You use wheeled equipment such as hand trolleys, pump trucks, carts, or wheelbarrows.

Please follow the HSE guidelines on Risk assessment of the pushing and pulling (RAPP) tool and follow the instructions thoroughly.

Safe Lifting and Handling Techniques

You must follow the proper methods to lift and handle loads safely. The followings are some techniques that will help you maintain the manual handling weight limit in the UK.

Feasibility

First, you must remove roadblocks. Next, plan to rest the load halfway during a long lift on a table or bench, so you may switch grips.
While moving, you need to keep the load at or around your waist.
While lifting, the weight should remain as near to the body as feasible. In addition, keep the load’s heavier side close to your body.
Otherwise, try to slide the weight towards the body if you can’t keep the weight close.
You must make a firm stance with your feet apart and one leg slightly in front of the other to keep your balance.

Planned Lifting

You must pre-plan the upcoming lifting or handling.
Make a lift plan.
Then, eliminate barriers, such as leftover wrappings.
In addition, you must consider resting the load halfway on a table or bench during a long lift to switch hands.

Keeping Balance

You must adopt a steady stance.
The feet should be wide apart with one leg in front (alongside the load, if it is on the ground).
It would be best if you moved your feet in specific poses to keep your balance during the lift.
In addition, avoid wearing anything that can restrict your movement.
Also, you should not entirely extend your back (stooping), nor should the hips and knees be fully extended at the beginning of the lift (squatting).
Don’t twist the back. Especially, leaning sideways is dangerous when you bow your back.
Keep your shoulders level.
In addition, face the same way your hips do.
Instead of twisting and raising at the exact moment, turn by shifting your feet.
When handling, keep your head high.
Once you firmly grasp the load, look forward rather than down at it.
Moreover, you shouldn’t yank or snatch the weight. Doing so can make it more challenging to maintain control. And it raises the possibility of falls.

Capacity

You should never handle or lift more than you can manage.
Remember, what people can lift and what they can lift safely are two different things.
If unsure, request assistance or advice.
Before adjusting, first, put the load down. Next, slide it into the proper position if exact positioning is required.

Dos and Don’ts of Manual Handling

You must establish the proper manual handling methods. Then, to further assure safety, abide by these dos and don’ts guidelines.

Dos

Equalise the weight of the item.
Warm up your muscles before lifting anything.
Remove any obstacles from the path you’ll be travelling.
Stop halfway if you suddenly notice an obstacle.
Carefully put the load down on a table or in a designated area.
Keep your feet adequately spaced apart and your back straight.
Don’t stoop down. Instead, bend from the knees.
Keep the object as near to your body as you can.
Walk normally.
Slowly lower the thing to prevent entangling your fingers.

Don’ts

Move or walk too quickly or too slowly.
Bend, turn or twist your back.
Lift the object without knowing its destination.
Carry the item above your shoulders or below your waist.
Look down at the thing instead of looking in front while lifting.
Lift two or more objects simultaneously when you could have carried more than one item individually.
Carry a load without a good grip.

You should give them the proper training on “manual handling weight limit in the UK” to ensure your employees aren’t endangering themselves and you.

If your manager asks you to perform risky manual handling duties as an employer, you should report it. If you believe you’ve got injured due to dangerous lifting, you should involve HSE or the local authority and make a claim.

Examples of Manual Handling Weight Limit Breaches

You must follow the standard manual handling weight limit in the UK to avoid strain or injury. Every task is unique, so you may occasionally need to use your judgement to determine whether the load you are carrying is safe to bear. Sometimes you may not be aware of the risk right at the time of lifting. However, muscle and joint issues can lead to various problems later in life at work and home. Lift carefully and keep preventative measures in mind.

Observe the following instances of breaching manual handling weight while lifting or pushing.

Bulky and Uneven Loads

A huge, bulky, or heavy object is difficult to hold close to the body. For example, you may breach the limit if the load has uneven sides and exerts uneven pressure on the spine. In addition, it might be challenging to hold onto such objects due to improper handles, handholds, or surface textures.

Unpredictable Movements

Due to their physical and behavioural characteristics, handling people or animals may result in you exceeding the weight limit. For instance, it could involve unpredictable motions that call for sudden efforts to control them or that pose other injury hazards, such as the possibility of being hit, bit, or grabbed.

Improper Tools

The unbalanced weight distribution of a tool and improper handle design or orientation may contribute to limit breaches. Using inappropriate equipment for the work can increase the amount of force needed or encourage odd or prolonged postures. The weight of heavy hand tools might pose a risk, primarily if held for extended periods. For example, imagine using a 3-kilogram power drill unsupported in a production line.

Tools That Deliver Impact

Hammers, hammer drills, and nail guns are tools that deliver impact. These tools can cause damage to ligaments and may necessitate the employment of a tighter grip to retain control. They pose a significant risk if used frequently and for an extended period.

Tools that vibrate, in particular, raise the risk. Safety concerns may arise from improper maintenance. For instance, using an unsharp knife makes it harder to bone and cut meat.

Temperature Change

Working in cold or wet environments, cool spaces, freezers, or chilly stores can drop body and hand temperatures. Therefore, it becomes harder for you to handle and hold objects. In addition, you have to put increased grip force for wearing gloves or having cold hands, which impair sensitivity. The risk of hand-arm vibration might dramatically rise in cold weather. Low temperatures can make you more tired.

Handling and grasping objects might be challenging when working in hot environments, such as bakeries, restaurants, laundry rooms, and foundries. You may struggle to hold things due to hand sweat or may experience sudden or unexpected forces due to loads dropping.

Excess Humidity

An object may get wet through a process like steam cleaning, cooking, or humid weather. Therefore, you may have to increase your body force. If an item slips, you must apply sudden, unexpected forces. Also, humidity contributes to discomfort and exhaustion.

Slippery Surfaces

Slippery and uneven floor surfaces increase the force required for manual handling. Unsuitable floor coverings, such as carpets, can make transporting loads on trolleys more difficult. You will face problems, such as maintaining your stability.

Manual Handling Training

Learn how to work in compliance with UK health and safety legislation and ensure correct control measures at manual handling.

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Manual Handling Training

Learn how to work in compliance with UK health and safety legislation and ensure correct control measures at manual handling.

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FAQS About Manual Handling

Why Are Manual Handling Limits Different for Men and Women?

Studies have demonstrated that males and women have different muscular architecture. Women typically use their pelvis more when lifting due to weaker lower-back strength. Men tend to lift with a technique that emphasises trunk motion more. On the other hand, women employ more muscles in the pelvis, back, and trunk in lifting. Lifting like this lessens the strain on the spine. However, a woman’s spine can’t support as much weight as a man’s.

Women are more likely to sustain injuries when lifting heavy loads than men. That is why the manual handling weight limit in the UK is different for men and women. They have differences in muscle structure, body proportions, and spine load tolerances.

What to Do When You Can’t Lift the Maximum Weight Limit for Your Gender?

Lifting the maximum weight is not a mandatory requirement. In addition, you should avoid lifting the maximum weight for repetitive tasks. If your manager insists you lift the maximum weight, you must show a valid reason to decline the request.

What to Do When Lifting Cannot Be Avoided?

Sometimes, you cannot but lift big loads. In that case, follow the HSE Guidelines to properly lift and avoid any kind of injuries.

I Can Lift Over the Manual Handling Weight Limits – Why Can’t I Lift More at Work?

Just because you can, doesn’t mean you have to. Manual Handling weight limits are there for a reason. You might think lifting heavier loads doesn’t affect your health at all. However, extreme pressure and strain on the body are unavoidable. Even if you feel no pain, your body will suffer the consequences later in life. It can result in back pain, severe nerve damage, or even paralysis.

How Safe is it to Carry a Weight Below These Guidelines?

Without any planning or assessment, no type of carrying is safe. Carrying below the weight limits does not mean you are safe from workplace hazards. It is good to lift or move weight below the guidelines. However, you must also consider all other factors that play a part in manual handling.

I Suffered a Manual Handling Accident, What Should I Do?

If you have suffered a manual handling accident, you should immediately seek medical help. Once you are assured of no health hazards, notify your manager or employer. You can make a claim of a manual handling accident in case your manager ignores your report. You should also keep records of proof of the accident to enhance your claim further.

Is There a Maximum Weight Limit for Manual Handling?

There is NO legal maximum manual handling weight limit in the UK. The 25 kg-16 kg rule is a standard that you can follow. But HSE has not set any legal limit yet. However, you shouldn’t think lifting or pushing more weight than the standard limit is okay. It will put you in dangerous situations.

Can You Refuse to Lift Heavy Objects at Work?

You can refuse to lift heavy objects for many reasons.

You lack manual handling training.
The employer ignores doing risk assessments.
You are suffering an injury or health problems.
You are doing repetitive manual handling tasks.
The manager fails to give you any resting period.

However, if your employer has followed all applicable regulations, you might not be able to refuse to lift something without the danger of losing your job. Be aware of manual handling tasks and manual handling weight limit in the UK through our Manual Handling Training Course. In addition, taking this course will help you identify whether you are eligible to lift heavy objects or not.

Summary

Ignorance of manual handling weight limit in the UK and manual handling techniques will lead you to body pain, short-term disability, or long-term harm. The recommended maximum weight is 25 kg for men and 16 kg for women. It would be best to lift less than the maximum most of the time at work. If you don’t maintain the weight limits, it can lead to musculoskeletal problems. There are risks associated with manual handling in many types of jobs.

Follow TILE to assess a manual handling task. Report incidents to the manager. In addition, claim your accidents due to unregulated manual handling jobs. All in all, give your and your co-worker’s safety the most priority.