Manual handling risk assessment
Under the Manual Handling Operations Regulations 1992 you must avoid hazardous manual handling where reasonably practicable, assess what can’t be avoided, and reduce the risk of injury. The usual way to assess it is TILE: the Task, the Individual, the Load and the Environment.
The TILE method
| Factor | Questions to ask | Site example |
|---|---|---|
| Task | Twisting, stooping, reaching up, carrying far, repetition? | Lifting blocks from ground level to a scaffold lift |
| Individual | Training, fitness, new or young workers, pregnancy, injuries? | Apprentice in their first week |
| Load | Heavy, bulky, unstable, sharp, hard to grip? | Plasterboard sheets in wind |
| Environment | Uneven ground, stairs, poor light, cold, cramped? | Muddy access route, steep driveway |
Guideline weights
The HSE’s lifting and lowering guidelines suggest that, for lifting close to the body at waist height, most men can handle around 25 kg and most women around 16 kg without excess risk. The figures fall as the load moves away from the body or above shoulder or below knee height. They are a filter, not a legal limit: over them, or with twisting or frequent lifts, you need a closer assessment. Cement and similar bags are supplied in 25 kg sizes for this reason.
Typical controls on site
- Avoid: deliver materials to the point of use by crane, telehandler or forklift.
- Mechanical aids: hoists, block grabs, vacuum lifters, board trolleys, wheelbarrows.
- Lighter loads: smaller blocks or half-size bags; team lifts with a plan.
- Environment: clear, firm, lit routes; no carrying on ladders.
- Training: a manual handling toolbox talk on safe lifting technique.
Manual handling is in your RAMS already. RAMS Maker includes manual handling hazards and controls for each trade, and the toolbox talk generator has a ready manual handling talk. Free to make and download.
Make RAMS Toolbox talksQuestions
Is there a maximum weight a worker can lift in the UK?
No. The law requires a risk assessment, not a fixed limit. The HSE guideline figures help you decide when a lift needs closer assessment.
Does a manual handling assessment have to be written?
Significant findings must be recorded if you employ five or more people. A simple task covered in your RAMS is enough for most site work.
What is the MAC tool?
The HSE’s Manual handling Assessment Charts, a free scoring tool for lifting, carrying and team handling, useful for repetitive tasks.
Checked against the Manual Handling Operations Regulations 1992, HSE guidance L23 and INDG143, November 2026. Related: hierarchy of control.