A manual handling risk assessment helps employers identify risks and prevent injuries from lifting, carrying, pushing or pulling loads.
Manual handling is one of the most common causes of injury in the workplace. According to the Health and Safety Executive, around 511,000 workers in Great Britain were suffering from work-related musculoskeletal disorders (MSDs) in 2024/25, resulting in approximately 7.1 million working days lost.
This guide explains how to carry out a manual handling risk assessment, including legal requirements, key risk factors, and practical steps to reduce risk and ensure compliance with UK legislation.
What is a manual handling risk assessment?
A manual handling risk assessment is the structured process of identifying and reducing risks associated with lifting, lowering, pushing, pulling, carrying or supporting loads by hand or bodily force.
These activities can place significant strain on the body, particularly where tasks are repetitive, involve awkward movements or are carried out in unsuitable working conditions.
An assessment focuses on identifying where these risks occur and determining what changes are needed to reduce them, such as adjusting the task, improving the environment or introducing appropriate equipment.
Why are manual handling risk assessments important?
A risk assessment for manual handling helps employers identify hazardous tasks and put in place practical solutions to reduce harm.
Without proper controls, even simple or repetitive tasks can lead to serious injury. For example, an employee who repeatedly lifts and carries boxes throughout the day may develop pain or strain in their wrists, shoulders or arms over time.
Data from the Chartered Society of Physiotherapy shows that upper limb disorders such as repetitive strain injury (RSI) affect around 1 million people in the UK, with approximately 450,000 cases linked to work. These conditions are among the most common forms of work-related ill health and are strongly associated with repetitive manual handling tasks and poor working postures.
Is a risk assessment for manual handling a legal requirement?
A risk assessment for manual handling is a legal requirement under UK health and safety law.
This duty is set out in the Manual Handling Operations Regulations 1992, Regulation 4 which require employers to avoid hazardous manual handling operations so far as is reasonably practicable. Where manual handling cannot be avoided, employers must carry out a suitable and sufficient assessment of the manual handling tasks and take appropriate steps to reduce the risk of injury to the lowest level reasonably practicable.
This requirement is reinforced by the Management of Health and Safety at Work Regulations 1999 (Regulation 3), which place a duty on employers to assess risks to employees’ health and safety.
These regulations make it clear that if manual handling cannot be eliminated, a risk assessment must be carried out and acted upon.
When is a manual handling risk assessment required?
Under the Manual Handling Operations Regulations 1992 (Regulation 4), a manual handling risk assessment is required where hazardous manual handling operations cannot be avoided.
Manual handling assessments should be carried out:
- Before introducing new tasks
New activities may introduce unfamiliar risks, particularly if they involve different loads, movements or working conditions. Assessing risks in advance helps ensure appropriate control measures are in place from the outset. - When workplace layouts change
Changes to the working environment, such as altered workflows, reduced space or new storage arrangements, can affect how manual handling tasks are carried out and may introduce new hazards. - When new equipment is introduced
New tools or equipment can change how tasks are performed and may reduce or increase risk depending on how they are used. A reassessment ensures equipment is suitable and used safely. - When there is evidence of injury or discomfort
Reports of pain, strain, near misses or injuries may indicate that existing controls are not effective. Reviewing the assessment helps identify underlying issues and prevent further harm.
Taking a proactive approach to risk assessment manual handling helps prevent injuries rather than reacting to them.
How often should a manual handling risk assessment be reviewed?
The Health and Safety Executive (HSE) advises that risk assessments are reviewed and updated where there is reason to believe they are no longer valid or where there have been significant changes in the workplace. This includes changes to work activities, equipment, or working conditions, as well as situations where incidents such as injuries or near misses suggest that existing control measures may not be effective.
Who is responsible for conducting a manual handling risk assessment?
The employer is responsible for ensuring a manual handling risk assessment is carried out. This duty is set out in the Manual Handling Operations Regulations 1992 (Regulation 4).
This responsibility sits alongside the Management of Health and Safety at Work Regulations 1999 (Regulation 3), which require employers to assess risks to the health and safety of their employees. Employers may appoint a competent person to assist in carrying out the assessment, in line with Regulation 7. A competent person is someone with sufficient training, knowledge and experience.
A manual handling risk assessment may be conducted by managers, supervisors or health and safety professionals so long as they are competent, but the employer is still legally accountable.
Employees must also be involved in the risk assessment, as required by the Health and Safety at Work etc. Act 1974 (Section 2), which places a duty on employers to consult employees on matters affecting their health and safety.
The TILEO framework: key elements of manual handling risk assessment
The elements of manual handling risk assessment are usually assessed using the TILEO framework, which reflects current best practice:
- Task – Does the task involve repetition, twisting, or awkward movements?
- Individual – Is the person capable, trained, and physically suited to the task?
- Load – Is the load heavy, unstable, or difficult to grasp?
- Environment – Are there hazards such as poor lighting, uneven floors, or limited space?
- Other factors – Equipment, PPE, workload pressures, and communication
These manual handling risk assessment factors ensure a comprehensive assessment of all risks associated with an activity.
For more information, please read our article, Tile manual handling – what are TILE and LITE?
What to do after a manual handling risk assessment
Once the assessment has been completed, you should take steps to reduce the identified risks. Measures could include:
- Use mechanical equipment to move the load.
- Improve flooring, lighting and ventilation.
- Remove any obstacles.
- Make loads lighter or smaller.
- Make loads more stable by, for example, adding handles.
- Adapt workplace procedures to reduce carrying distances and the need for twisting and bending.
- Reduce the need for items to be lifted from floor level or above shoulder height.
- Provide workers with more frequent breaks.
Where there is risk of injury, employers are legally obliged to provide employees with manual handling training, such as our Manual Handling Awareness or Manual Handling in the Office eLearning courses.
How many steps in a manual handling risk assessment?
There is no fixed number of steps set out in law for a manual handling risk assessment. However, the process is defined by duties in the Manual Handling Operations Regulations 1992 (Regulation 4) and the Management of Health and Safety at Work Regulations 1999 (Regulation 3).
These legal requirements are usually applied through five clear steps, which provide a structured and practical framework for carrying out a manual handling risk assessment.
1. Identify manual handling hazards
Employers must first identify any manual handling activities that may pose a risk of injury. Under Regulation 4(1)(a) of the Manual Handling Operations Regulations 1992, employers are required to avoid hazardous manual handling so far as is reasonably practicable. This involves identifying tasks involving lifting, carrying, pushing or pulling that may present a risk.
2. Assess the level of risk
Where manual handling cannot be avoided, Regulation 4(1)(b)(i) requires employers to make a suitable and sufficient assessment of the risk of injury. This includes considering factors such as the task, load, working environment and individual capability.
This aligns with the broader requirement under Regulation 3 of the Management of Health and Safety at Work Regulations 1999 to assess risks to health and safety.
3. Implement control measures
Following the risk assessment, employers must take steps to reduce the risk of injury so far as is reasonably practicable, as required by Regulation 4(1)(b)(ii). This includes introducing appropriate manual handling risk assessment control measures, such as mechanical aids, task redesign or training.
4. Record the findings
Under Regulation 3(6) of the Management of Health and Safety at Work Regulations 1999, employers with five or more employees must record the significant findings of the risk assessment and any groups of employees identified as being especially at risk. This includes key hazards, the level of risk, and the control measures in place. Recording these findings also supports communication, training and ongoing compliance.
5. Review and update the assessment
Risk assessments must be kept up to date.
Regulation 3(3) of the Management of Health and Safety at Work Regulations 1999 requires employers to review assessments if there is reason to suspect they are no longer valid or if there has been a significant change in the work. In practice, this includes reviewing assessments following incidents, changes in tasks or equipment, or new information about risks.
Manual handling risk assessment checklist
When carrying out a manual handling risk assessment, consider the following:
- Can the manual handling task be avoided altogether or automated? (as required under Regulation 4(1)(a) of the Manual Handling Operations Regulations 1992)
- Can mechanical aids such as trolleys, hoists or conveyors be used to reduce the need for manual effort?
- Is the load safe to lift and carry in terms of weight, size, shape, stability and grip?
- Are workers trained, competent and physically capable of carrying out the task safely?
- Does the working environment introduce risks, such as poor lighting, uneven flooring, restricted space or temperature extremes?
- Are there organisational factors, such as time pressure or workload, that could increase the risk of injury?
The Health and Safety Executive (HSE) recommend using structured assessment tools to support this process. In particular, the Manual Handling Assessment Charts (MAC) tool is widely used to assess lifting, carrying and team handling tasks. It uses a colour-coded Red-Amber-Green (RAG) system to indicate risk levels and prioritise action.
Manual handling training
Manual handling training reduces the risk of musculoskeletal disorders (MSDs), as well as associated costs such as absence, lost productivity and potential legal action.
Our Manual Handling Awareness eLearning course supports compliance with the Manual Handling Operations Regulations 1992 and is suitable for employees across all sectors.
For desk-based or low-risk environments, our Manual Handling in the Office course provides targeted guidance on common office-based handling tasks, helping to prevent strain and injury in everyday activities. Find out more about Manual Handling Awareness and Manual Handling in the Office on our website, or contact our friendly team to
Adam Clarke
Managing Director (Consulting)
