Manual Handling Weight Limits – Why They Are Important

The legal definition of manual handling is any act that involves the ‘transporting or supporting of a load (including the lifting, putting down, pushing, pulling, carrying or moving thereof) by hand or by bodily force’, as stated by the Manual Handling Operations Regulations 1992. A ‘load’ is defined as any type of heavy object, including people or animals.

Care should always be taken when completing any manual handling task to avoid injuries or accidents.

Unfortunately, manual handling injuries are commonplace. Some 27% of reportable accidents were caused by manual handling in 2021-22, as documented in the Health and Safety at Work Summary Statistics for Great Britain 2022.

Around 139,000 people reported new injuries caused by manual handling, while 477,000 cases involved long-term injuries caused by manual handling. In total, over 7.3 million working days were lost during the 2021-2022 period.

The most common risks associated with manual handling tasks are:

• Back Injuries
• Hand and Foot Injuries
• Shoulder Injuries
• Neck Injuries
• Strains and Sprains
• Slips, Trips and Falls
• Lacerations and Cuts
• Hernias
• Work-Related Musculoskeletal Disorders (WRMSDs)

Many of the reported manual handling injuries could have been avoided if the right techniques were used and the correct manual handling lifting limits were followed.

At present, there is no maximum lifting weight set by the Manual Handling Operations Regulations 1992.

It is virtually impossible to set a maximum weight limit because manual handling tasks vary from job to job as do the capabilities of the individuals performing the tasks. Maximum weight limits are also redundant, because any manual handling task can cause an injury if it is performed incorrectly.

The Health and Safety Executive (HSE), however, does provide recommendations on the safe maximum lifting weights for men and women. These limits depend on the weight of the load, how it is being carried, and how far away from the body it is being held.

In general, the weight limits apply to lifts where the load remains at the same height. If a load is to be moved between the designated zones, such as lifting an object from knuckle height and then moving it to head height, the lower weight recommendation must be followed.

• Load at Head Height
  • Held Close to the Body – 10 kg
  • Held at Arm’s Length – 5 kg
• Load at Shoulder Height
  • Held Close to the Body – 20 kg
  • Held at Arm’s Length – 10 kg
• Load at Elbow Height
  • Held Close to the Body – 25 kg
  • Held at Arm’s Length – 15 kg
• Load at Knuckle Height
  • Held Close to the Body – 2 kg
  • Held at Arm’s Length – 10 kg
• Load at Mid-Lower Leg Height
  • Held Close to the Body – 10 kg
  • Held at Arm’s Length – 5 kg

• Load at Head Height
  • Held Close to the Body – 7 kg
  • Held at Arm’s Length – 3 kg
• Load at Shoulder Height
  • Held Close to the Body – 13 kg
  • Held at Arm’s Length – 7 kg
• Load at Elbow Height
  • Held Close to the Body – 16 kg
  • Held at Arm’s Length – 10 kg
• Load at Knuckle Height
  • Held Close to the Body – 13 kg
  • Held at Arm’s Length – 7 kg
• Load at Mid-Lower Leg Height
  • Held Close to the Body – 7 kg
  • Held at Arm’s Length – 3 kg

Employers and managers must keep in mind that the HSE maximum weight limits are recommendations only. They are not legally enforceable and are meant to act as guidelines, rather than as strict rules. Best practices and safe lifting techniques should be used when performing any manual handling task.

When lifting a load make sure to:

• Remove any obstacles
• Ensure there is enough light
• Check that the flooring is stable and not wet
• If possible, use lifting equipment
• Break the load into smaller pieces and move it in stages if you can
• Share the weight if possible
• Use personal protective gear (PPE) such as gloves or steel-capped boots
• Make sure you have a good grip
• Use your knees rather than your back
• Do not twist or turn when lifting and carrying
• Lift the load and put the load down with smooth motions
• Do not lift more than you can handle

All lifts should be carefully planned using the TILE method. This requires that a lift be planned by taking into account the nature of the Task, the capabilities of the Individual, the nature of the Load, and the work Environment.

The main piece of legislation associated with manual handling tasks in the UK is the Manual Handling Operations Regulations 1992. According to manual handling regulations, employers are responsible for ensuring that the risks surrounding any manual handling task are eliminated or kept as low as is reasonably practicable.

An employer must first consider if the manual handling task can be avoided. If the task can’t be avoided, then the employer must take steps to lower the risk of injury as far as is reasonably practical. A risk assessment must be conducted and measures to eliminate or control the risks must be implemented.

Providing access to proper training is the most effective way of making sure that your people know how to perform manual handling tasks correctly. A manual handling training course will teach your team the right way to move heavy loads and make sure they are aware of all the risks involved.

We run a range of industry-specific manual handling courses. On our website, you’ll find manual handling training that covers risk assessments and manual handling techniques for factory workers, managers, office and construction workers.

Our all Manual Handling Training courses can be taken online at your convenience.