Manual Handling

Welcome to the Commodious Knowledge Bank guide on Manual Handling.

Manual Handling Explained: Key Concepts

Manual handling activities happen in almost every job, whether you’re stacking stock, moving equipment, helping a patient, or simply carrying items around the workplace. Because these tasks are so routine, it’s easy to underestimate the risk of injury.

But incorrect manual handling is one of the leading causes of workplace injuries. Understanding what counts as manual handling, the main risks, and your responsibilities under UK law is crucial for protecting employees and maintaining workplace safety.

This manual handling guide brings together everything you need to know, with links to our in-depth articles on risk assessments, MHOR, TILEO, training, equipment, and more.

Scroll to the bottom of this page for our complete collection of in-depth manual handling guides.

What Is Manual Handling?

Manual handling refers to any activity that involves using physical effort to move or support a load. This covers a wide range of workplace tasks, including:

• Lifting or lowering heavy objects

• Carrying loads

• Pushing or pulling items

• Moving people (such as in healthcare)

• Supporting, steadying, or manoeuvring equipment

It’s not limited to heavy lifting. Even a light object can be hazardous if it’s awkward to hold, repetitive, or handled in a poor posture.

Manual Handling in the Workplace (MHOR Definition)

Under the Manual Handling Operations Regulations 1992, manual handling means using bodily force to transport or support a load, including people and animals.

MHOR exists because the manual handling of loads is one of the biggest contributors to musculoskeletal disorders (MSDs). These injuries can cause long-term pain, time off work, and reduced quality of life.

For a more detailed breakdown of MHOR duties, see our Manual Handling Operations Regulations Guide.

Common Examples of Manual Handling Tasks

Manual handling takes many forms across different industries. Examples include:

• Lifting stock onto shelves

• Pushing trolleys or cages

• Carrying tools or equipment

• Pulling pallets or roll cages

• Lowering items from storage

• Repositioning patients in healthcare settings

Any of these can become hazardous manual handling operations if the load is too heavy, the technique is poor, or the environment creates additional risks.

See our article on Manual Handling in Warehousing, Construction, and Healthcare for sector-specific examples.

Why Manual Handling Safety Matters

Manual handling safety is essential for two key reasons:

1. Protecting Employee Health and Well-being

Incorrect manual handling is one of the leading causes of back injuries, sprains, strains, and chronic musculoskeletal disorders. These issues can develop suddenly or gradually, often leading to:

• Persistent back pain

• Joint or muscle strain

• Reduced mobility

• Time off work

• Long-term health problems

Early intervention and safe technique significantly reduce these risks.

Read our guide to the Most Common Manual Handling Injuries.

2. Meeting Legal Responsibilities

Employers have a legal duty under:

• Manual Handling Operations Regulations 1992 (MHOR)

• Health and Safety at Work etc. Act 1974

• Related reporting duties under RIDDOR

They must:

• Avoid hazardous manual handling where possible

• Assess unavoidable tasks

• Reduce risk “so far as is reasonably practicable”

• Provide training, information, and suitable equipment

Failure to comply can lead to enforcement action, fines, and reputational damage.

Our MHOR Guide explains employer responsibilities in more detail.

Understanding Manual Handling Hazards and Risks

A hazard is anything with the potential to cause harm.
A risk is the chance that harm will occur.

For manual handling, the most common hazards include:

• The Load – too heavy, bulky, unstable, or difficult to grip

• Repetition – repeated lifting or movement can lead to repetitive strain injuries.

• Posture – twisting, bending, or over-reaching

• Environment – poor lighting, uneven floors, clutter, restricted space

These hazards increase the likelihood of injuries if not managed effectively.

What Checks Should Be Done Before Manual Handling?

Before you lift, carry, push, or pull anything at work, it’s essential to stop and carry out a few quick checks. These pre-handling assessments take seconds, but they dramatically reduce the risk of strains, sprains, and back injuries.

Think of this as your “pause and plan” moment.

Here’s what you should check before starting any manual handling task:

1. Check the Load

Ask yourself:

• How heavy is it? Can I lift it safely?

• Is it bulky, unstable, sharp-edged, or awkward to grasp?

• Will it obstruct my view when carrying?

• Do I need someone to help me, or should I use a handling aid?

If you’re unsure, test the weight by gently rocking or lifting one corner.

2. Check the Environment

The area around you has a big impact on safety. Look for:

• Slippery floors or uneven surfaces

• Trip hazards or clutter

• Poor lighting or restricted space

• Doors, corners, or steps in your route

Make sure your path is clear and well-lit before you begin.

3. Check Your Own Capability

Everyone’s abilities differ, and they can vary day to day. Consider:

• Am I trained to handle this type of load?

• Am I physically able to do it safely today?

• Do I feel rushed or fatigued?

• Do I need help from a colleague?

Never ignore discomfort, dizziness, or pain.

4. Check Whether There’s a Safer Alternative

Before lifting manually, ask:

• Can the task be automated or mechanised?

• Would a trolley, pallet truck, hoist, or slide sheet reduce the risk?

• Can the load be divided into smaller parts?

If there’s a safer option, use it.

5. Check for Required PPE or Information

Depending on the load or environment, you may need:

• Gloves

• Foot protection

• High-visibility clothing

• Job-specific instructions or handling guidance

Make sure you have everything before starting.

6. Check Your Route and Final Position

Finally, plan the whole lift before you begin:

• Where is the load going?

• Can I place it down safely without twisting?

• Is the final location at a suitable height?

This final check prevents awkward adjustments mid-lift, which is when injuries commonly happen.

Why These Checks Matter

These simple assessments form the basis of a safe manual handling approach. They help you identify hazards early and prevent the kind of sudden, unexpected strain that leads to injury. They also align with the TILEO method (Task, Individual, Load, Environment, Other Factors) and support your legal duties under MHOR.

Manual Handling Risks in Different Industries

Risks vary widely depending on the sector:

For step-by-step guidance, see our full Manual Handling Risk Assessment Guide.

Key Principles of Safe Manual Handling (HSE Guidelines)

The HSE sets out three core principles:

1. Avoid hazardous manual handling where possible

2. Assess unavoidable tasks

3. Reduce risk through controls such as personal protective equipment, training, and safe systems of work

A simple way to assess tasks is by using TILEO.

TILEO Explained: Task, Individual, Load, Environment, Other Factors

TILEO is used to evaluate manual handling risks:

• Task: Does the task involve twisting, bending, or long carrying distances?

• Individual: Is the person trained, capable, and physically suited to the task?

• Load: Is it heavy, awkward, unstable, sharp, or hard to grasp?

• Environment: Is the space cramped, uneven, or poorly lit?

• Other Factors: PPE requirements, time pressures, weather, or equipment issues.

Learn more in our guide: What Does TILEO Stand For?

Essential Safe Manual Handling Techniques

Safe lifting techniques reduce strain on muscles and joints. Key principles include:

• Keep a straight back and bend your knees

• Hold the load close to your body

• Avoid twisting—move your feet instead

• Push rather than pull when moving loads

• Know your limits and ask for help with heavy or awkward loads

Mechanical aids such as sack trucks, trolleys, pallet trucks, and hoists should be used whenever possible.

See: Manual Handling Weight Limits
And: Manual Handling Equipment: Practical Guide

Conclusion

Safe manual handling is about understanding risks, applying the right controls, and using appropriate training and equipment. By following MHOR, conducting risk assessments, and embedding safe techniques, organisations can greatly reduce injuries and create a safer workplace.

Frequently Asked Questions

What does UK law require for manual handling at work?

Employers must avoid hazardous manual handling where possible. If tasks cannot be avoided, they must be risk assessed and controlled under applicable work regulations. These duties are set out in the Manual Handling Operations Regulations 1992 (MHOR).

Who is responsible for manual handling safety?

Employers have the primary responsibility for risk assessment, training, and safe systems of work. Employees must follow training and use equipment correctly.

Where can I find official guidance?

The Health and Safety Executive (HSE) provides official UK guidance on manual handling, risk assessments, and MHOR compliance.