1. Purpose and Scope
This Standard Operating Procedure sets out how [Organisation Name] manages manual handling risks at [Site/Location]. It covers all tasks requiring manual lifting, lowering, carrying, pushing, or pulling of loads by human effort.
This procedure applies to all personnel, including full-time, part-time, temporary, and agency workers.
This procedure does not apply to moving or assisting individuals. For care and support operations, refer to separate people-handling policies and procedures.
Working through related paperwork at the same time? See also our US Safe Lifting & Materials Handling Procedure Template, Accident & Incident Reporting Procedure Template and NY Retail Worker Safety Act Policy Template.
2. Legal Framework and Guidance
This procedure implements key health and safety legislation, including:
- The Manual Handling Operations Regulations 1992: Requires us to avoid hazardous manual handling where reasonably practicable, assess unavoidable tasks, and reduce risk to the lowest reasonably practicable level.
- The Health and Safety at Work etc. Act 1974: Places general duties on employers to ensure worker health, safety, and welfare.
National regulations do not set a maximum legal weight limit for manual handling. Health and Safety Executive (HSE) guidance provides screening figures to identify tasks requiring formal assessment. These figures are not safe limits or legal maximums; individual lifting capacity varies based on posture, task frequency, load characteristics, and worker capability.
3. Operational Application
This procedure applies to routine and non-routine manual handling activities, including:
- Unloading, unpacking, moving, and storing deliveries or inventory.
- Relocating equipment, machinery, tools, office furniture, or waste materials.
- Handling awkward or hazardous loads of any weight, such as unstable, sharp, hot, hard-to-grip, or bulky items that block vision.
- Continuous or high-frequency handling tasks where cumulative stress creates risk.
- Ad-hoc or one-off handling tasks (such as equipment installations, facility alterations, or temporary events). These require dedicated risk reviews rather than standard routines.
4. Responsibilities
4.1 Procedure Owner ([Job Title])
- Maintains up-to-date manual handling risk assessments across all operational areas.
- Oversees the manual handling training program.
- Evaluates incident, strain, and near-miss reports to identify control improvements.
4.2 Managers and Supervisors
- Design work processes and environments to eliminate hazardous manual handling where reasonably practicable.
- Ensure appropriate mechanical aids and lifting equipment are accessible, functional, and regularly inspected.
- Monitor workplace practices and correct improper lifting techniques or non-compliance.
4.3 All Personnel
- Comply with this procedure and instruction received during manual handling training.
- Use provided mechanical handling equipment and safety devices correctly.
- Seek assistance when handling loads that exceed personal capability.
- Report physical pain, discomfort, strain, or equipment defects immediately.
5. Risk Management Hierarchy (Avoid, Assess, Reduce)
Apply this statutory hierarchy before performing any manual handling task:
- Avoid: Reorganise tasks to eliminate manual handling entirely. For example, arrange for deliveries to move directly to their point of use, order items in smaller unit sizes, or automate the process.
- Assess: Where manual handling cannot be avoided, perform a formal task assessment using the TILE framework and record it in [System/Location].
- Reduce: Implement controls to lower risk. Prioritise altering task design, modifying the load, improving the working environment, providing mechanical handling aids, and delivering practical technique training.
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6. Task Assessment Criteria (TILE Framework)
Every risk assessment must evaluate four TILE factors:
- Task: Physical demands such as twisting, stooping, reaching upward, carrying items over long distances, or high repetition. Redesign workflow layouts to remove these factors where possible.
- Individual: Worker capability, physical stature, level of training, and health status. Pay specific attention to young workers, new and expectant mothers, and employees returning from injury.
- Load: Weight, dimensions, stability, outer surface properties (such as sharp edges or high temperature), handholds, and potential movement of internal contents.
- Environment: Floor surfaces, slopes, steps, lighting levels, temperature, humidity, and space constraints that restrict movement.
7. Safe Lifting Procedure
Follow this step-by-step method whenever manual lifting is required:
- Plan the Lift: Check the destination, clear the route of hazards, and confirm the set-down area is ready to receive the load.
- Test the Load: Nudge or rock the load to test its weight and stability. Get help or use mechanical equipment if the load feels unmanageable or unstable.
- Establish Stance: Position feet apart around the load, placing one foot slightly forward to maintain balance.
- Adopt Correct Posture: Bend at the knees and hips while keeping the natural curve of the spine. Secure a firm grip before lifting.
- Position the Load: Keep the load close to your waist throughout the lift, placing the heaviest side against your body.
- Execute the Lift: Raise the load smoothly using leg strength. Do not jerk, snatch, or twist your body. Change direction using your feet, not your spine.
- Maintain Line of Sight: Ensure the load does not block forward or side vision during movement.
- Lower and Position: Lower the load smoothly by bending your knees. Place it securely before sliding or adjusting it into place.
8. Mechanical Aids and Team Lifting
8.1 Mechanical Aids
- Use mechanical equipment (such as trolleys, sack trucks, pallet trucks, or conveyors stored at [Storage Location]) whenever available.
- Conduct a visual and functional check of aids before use. Inspect wheels, handles, platforms, and brakes.
- Report damaged or malfunctioning equipment to [Job Title] immediately and tag it out of service.
- Do not exceed rated weight capacities or stack loads above [Designated Line-of-Sight Height / Limit].
8.2 Team Lifting
- Use team lifts when required by a risk assessment or when a load exceeds individual capability.
- Plan the route and timing with all team members before lifting.
- Match handlers by height and physical capability where possible.
- Appoint a single leader to direct the lift and coordinate verbal commands.
9. Incident and Injury Reporting
- Report any work-related strain, musculoskeletal discomfort, or injury to your manager on the day it occurs.
- Log incidents in line with [Organisation Name]’s accident and incident reporting procedure.
- Re-assess any manual handling task linked to a reported injury or strain immediately before resuming work under the same conditions.
10. Training, Records, and Procedure Review
10.1 Training
- Personnel must complete approved training before performing manual handling tasks unsupervised.
- Complete refresher training at a frequency of [Frequency].
10.2 Records Management
- Store risk assessment records, employee training logs, and handling incident reports in [System/Location].
10.3 Review Schedule
- Review this procedure and associated task risk assessments:
- At least every [Frequency, e.g., 12 months].
- Following any handling-related incident, strain, or near-miss.
- When equipment, task routines, environment, or load specifications change significantly.
Procedure Owner: [Job Title] Next Scheduled Review Date: [Date]
FAQs on a manual handling procedure
What is a manual handling procedure?
A manual handling procedure sets out how your organisation manages manual handling risks at your site. It covers all tasks requiring manual lifting, lowering, carrying, pushing, or pulling of loads by human effort.
Having it written down means the same rules apply to everyone, so managers are not making judgement calls case by case under pressure.
What does a manual handling procedure include?
This template covers legal framework and guidance, operational application, risk management hierarchy (avoid, assess, reduce) and task assessment criteria (tile framework).
Every section is written to be filled in. The bracketed placeholders mark the decisions that are yours to make, such as timescales, approval owners and retention periods.
How to implement a manual handling procedure with Whale
Copy this template into Whale and work through the bracketed placeholders so it reflects how your organisation actually operates.
Assign it to the teams it applies to so it sits where people work rather than in a shared drive, and set a review date so it gets revisited on schedule instead of quietly going out of date.
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