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University of Newcastle upon Tyne
Local Rules for Manual Handling Operations
UNIVERSITY OF
NEWCASTLE UPON TYNE
Manual Handling Operations
First Published February 1994 Revised March 2001
University of Newcastle upon Tyne
Local Rules for Manual Handling Operations
Introduction
These Local Rules are produced in response to the Manual Handling Operations Regulations 1992. They
are based upon guidance from the Health and Safety Executive and follow the approach, endorsed by the
Committee of Vice-Chancellors and Principals, being adopted by the majority of Universities.
A great variety of manual handling is carried out every day in the University. Some tasks present a
significant risk of injury while many do not. It is worth noting that nearly a third of all accidents we report
to the Health and Safety Executive (i.e. those causing over 3 day's absence) are caused by manual handling
operations and between January 1990 and June 1993 almost 500 working days were lost through such
accidents.
If time is not to be wasted on trivial and low risk activities, the legal requirements must be approached in a
systematic and structured way that will ensure that those tasks that pose the greatest risks of injury are
identified and given priority. These Local Rules have been designed with this aim in mind.
Contents
Introduction
Summary
Preliminary appraisal
Detailed Assessment
Action Plan
APPENDICES
Appendix 1 Numerical guidelines
Appendix 2 Optional numerical risk-ranking system
Appendix 3 A systematic guide to reducing risk
Appendix 4 Principals of correct manual handling
University of Newcastle upon Tyne
Local Rules for Manual Handling Operations
Summary
Although these Local Rules demand that systematic thought is given to all manual handling operations, they
have been designed to ensure that time is not wasted on unnecessary assessments of low risk activities. The
legal requirements are summarised in Table I and a précis of the Local Rules is given below.
The Local Rules have three distinct stages: preliminary appraisal; detailed assessment (in certain
circumstances only); and an action plan (which normally will be required).
Preliminary appraisal.
This consists of two parts, in the following order of priority:-
i) An initial sift
This is designed to exclude from further attention those operations that pose relatively little
real risk of injury.
Guideline figures are given in Appendix 1. For lifting and lowering they consist of a chart of
weights and lifting positions.
ii) Avoidance
Those tasks not eliminated by the initial sift must, as far as possible, be avoided, redesigned,
or mechanised to reduce the manual handling effort to below the threshold applied in the sift
(i.e. the guidelines in Appendix 1).
Where this cannot be done a detailed risk assessment must be carried out.
Detailed Assessment.
This stage is applied only to those manual handling operations where,
i) there is a risk of injury, and,
In this scheme, a 'risk of injury' arises if the guidelines in Appendix 1 are exceeded.
(See Table 2)
ii) there is no practical alternative to manual handling.
Assessment provides a structured way of analysing the manual handling task to determine
what can be done to reduce the risk of injury to an acceptable level.
Action Plan
Finally, a programme of work must be drawn up to put into effect the remedial action identified in
stages 1 and 2.
University of Newcastle upon Tyne
Local Rules for Manual Handling Operations
TABLE 1
Summary of Requirements of the
Manual Handling Operations Regulations 1992
The Regulations apply only to employees at work.
Manual handling operations that involve a 'risk of injury' must be avoided,
where reasonably practicable, by elimination, automation or mechanisation.
Note: 'Risk of injury' is a defined term. See TABLE 2.
Where it is not reasonably practicable to avoid manual handling, you must:-
a) Assess the task
b) Identify what can be done to reduce the risk to the lowest level
reasonably practicable.
c) Implement those measures.
d) Review assessments if the circumstances change.
Information must be provided on the weight of the load, and, if the centre of
gravity is offset, its heaviest side must be identified.
TABLE 2: Definition of terms used in the Local Rules
In these Local Rules the following definitions apply:
Manual Handling
Transporting or supporting a load (including persons and animals) by hand or
bodily force and including lifting, putting down, pushing, pulling, carrying or
moving.
Injury
Only includes that which results from the weight, shape, size, external state,
rigidity (or lack of it) of the load, or from movement of the contents.
Does not include anything caused by leakage, spillage, or contamination from
toxic or corrosive substances contained in the load.
Risk of Injury
Arises if the guidelines given in Appendix 1 are exceeded.
So far as is Reasonably Practicable
Weigh up the likely injury against the cost in time, trouble and money required
to remove it. Remedies are not reasonably practicable if the costs are grossly
disproportionate to the benefit.
University of Newcastle upon Tyne
Local Rules for Manual Handling Operations
Preliminary Appraisal
Use Form MH1:
1. Think systematically about all the manual handling tasks carried out in your area.
2. Discount any manual handling tasks which are obviously trivial.
3. List in column 1 the tasks you have not immediately, by common sense, dismissed as trivial. If in
doubt about a particular task, include it.
N.B. Group similar tasks together as far as possible.
4. Study the Guidelines given in Figure 1 of Appendix 1.
These are for lifting and lowering only (the most common manual handling operation).
5. For each task in turn, check whether the weights involved are lower than the values given. If they
are, complete column A and go no further.
6. If the task is not lifting and lowering, study the more detailed guidelines in the rest of Appendix 1. If
they are not exceeded, complete column A and go no further.
7. Use Form MH1 to guide you through the hierarchy of measures for each task. Remember that they
follow an order of priority set in the Regulations.
8. If, for a particular task, you decided that avoidance by elimination, redesign or mechanisation is
possible, note the remedial action to be taken in Column D.
9. At the end of the preliminary appraisal you will have generated:-
a) A list of manual handling operations that can be eliminated.
b) A list of tasks where some work is required to redesign or mechanise.
c) A list of manual handling tasks that now require further, more detailed assessment.
10. Proceed to Section 3 and carry out detailed assessment of the specific tasks identified in 9c above.
The following Flow Chart overleaf summarises the steps to follow (i.e. 1 to 8 above) before concluding that
a detailed assessment is necessary.
University of Newcastle upon Tyne
Local Rules for Manual Handling Operations
Manual Handling Operations Regulations 1992
Flow chart summarising steps to be taken before undertaking a detailed assessment of a task
NOTES:
Step 1 See definitions in Table 2.
Step 2 See definitions in Table 2.
APPLY THE NUMERICAL GUIDELINES in Appendix 1.
Step 3 You are legally obliged to do this as the FIRST PRIORITY if it is reasonably practicable to
do so. Use the numerical guidelines to re-assess whether your action has gone far enough to
reduce the risk.
Step 4 This is the second choice if step 3 cannot be done.
Step 5 Any tasks which cannot be dealt with by steps 1 to 4 must be given detailed assessment.
University of Newcastle upon Tyne
Local Rules for Manual Handling Operations
Detailed Assessment
1. For each task or group of tasks shown by preliminary appraisal to require detailed assessment,
complete Form MH2.
This form provides a structured and standardised method that breaks tasks down into component
parts allowing a systematic search for risk reduction measures.
2. The "level of risk" column calls for a judgement to be made. Use the Guidelines in Appendix 1 to
help gauge response. If in doubt about which of two responses to give, use the higher.
3. Remember that the purpose of this part of the exercise is to tease out steps that can be taken to
reduce risk to an acceptable level. These may be changes to systems of work, or provision of
equipment or both.
4. Use the notes from Form MH2 to complete Form MH3 for each task or group of tasks.
5. Collect the action plans for all assessed operations and rank them in order of priority i.e. those
involving greatest risk first.
If you think it will help, there is a crude numerical system that may be used to rank assessed tasks in
order of degree of risk. This is explained in Appendix 2. Its use is not obligatory.
Any training should :
• be specific to the 'trade'
• deal with those risk factors identified in the assessment
• aim to ensure that the employee understands the reason for doing the job in a certain way and
recognises the risks
Action Plan
This is the most important stage as it is the purpose of the whole exercise.
1. Both the preliminary appraisal and the detailed assessment have generated lists of remedial work.
These now need to be formulated into an overall plan of work that will ensure that tasks presenting
the greatest risk of injury are dealt with first.
2. The work plan should:-
• Set objectives.
• Specify who is responsible for each element .
• Specify time scales for the completion of each item.
• Allocate dates on which progress in meeting the objectives will be reviewed.
University of Newcastle upon Tyne
Local Rules for Manual Handling Operations
APPENDIX 1
Numerical Guidelines for Assessment of Manual Handling
Operations
Source of the guidelines
These guidelines have been drawn up by the Health and Safety Executive's medical and ergonomics experts
on the basis of a careful study of the published literature and their own extensive practical experience of
assessing risks from manual handling operations.
Individual capability
There is a wide range of individual physical capability, even among those fit and healthy enough to be at
work. For the working population the guideline figures will give reasonable protection to about 95% of
people. (Note the reduced figures for women)
It is important to understand that the guideline figures are not limits. They may be exceeded where a more
detailed assessment shows that it is appropriate to do so, having regard always to the duty to avoid or reduce
risk of injury where this is reasonably practicable. However, even for a minority of fit, well-trained
individuals working under favourable conditions any operations which would exceed the guideline figures
by more than a factor of about two should come under very close scrutiny.
Guidelines for lifting and lowering
Basic guideline figures for manual handling operations involving lifting and lowering are set out in Figure 1.
Twisting
The basic guideline figures for lifting and lowering should be reduced if the handler twists to the side during
the operation. As a rough guide the figures should be reduced by about 10% where the handler twists
through 45° and by about 20% where the handler twists through 90°.
Frequent lifting and lowering
The basic guideline figures for lifting and lowering are for relatively infrequent operations - up to
approximately 30 operations per hour - where the pace of work is not forced, adequate pauses for rest or
recovery are possible and the load is not supported for any length of time. They should be reduced if the
operation is repeated more frequently. As a rough guide the figures should be reduced by 30% where the
operation is repeated once or twice per minute, by 50% where the operation is repeated around five to eight
times per minute and by 80% where the operation is repeated more than about 12 times per minute.
University of Newcastle upon Tyne
Local Rules for Manual Handling Operations
Figure 1 Guidelines for Lifting and Lowering
Original Source – Health and Safety Executive.
1. If the loads being handled do not exceed the values given here then no action is required under this
scheme. However you should note that the HSE advice is that you should still try to avoid such
operations or make them less demanding wherever you can.
2. These figures are NOT weight limits. They may be exceeded but only where a detailed risk
assessment has shown it to be appropriate. However, exceeding them by more than a factor of about
2 is highly questionable.
3. Certain assumptions lie behind the figures:-
• The load can be readily grasped by two hands.
• The operations are relatively infrequent (less than 30 per hour)
• The pace of work is not forced.
• Adequate pauses for rest or recovery are possible.
• The load is not supported for any length of time.
Guidelines for carrying
Basic guideline figures for manual handling operations involving carrying are similar to those given for
lifting and lowering, though the hands would not normally be below knuckle height.
It is also assumed that the load is held against the body and is carried no further than about 10 metres
without resting. If the load is carried over a longer distance without resting the guideline figures may need
to be reduced.
University of Newcastle upon Tyne
Local Rules for Manual Handling Operations
Where the load can be carried securely on the shoulder without first having to be lifted (as for example when
unloading sacks from a lorry) a more detailed assessment may show that it is acceptable to exceed the
guideline figure.
Guidelines for pushing and pulling
The following guideline figures are for manual handling operations involving pushing and pulling, whether
the load is slid, rolled or supported on wheels. The guideline figure for starting or stopping the load is a
force of about 25kg for men and 17kg for women (i.e. about 250 and 170 Newtons respectively). The
guideline figure for keeping the load in motion is a force of about 10 kg for men and 6.5 kg for women (i.e.
about 100 and 65 Newtons respectively).
It is assumed that the force is applied with the hands between knuckle and shoulder height and if this is not
possible the guideline figures may need to be reduced. No specific limit is intended as to the distance over
which the load is pushed or pulled provided there are adequate opportunities for rest or recovery.
Guidelines for handling while seated
The basic guideline figure for handling operations carried out while seated is given below and applies only
when the hands are within the box zone indicated. If handling beyond the box zone is unavoidable or, for
example, there is significant twisting to the side a more detailed assessment should be made.
Figure 2 Guidelines for Lifting and Lowering Whilst Seated
5 Kg for Men and 3 Kg for women.
Original source Health and Safety Executive.
University of Newcastle upon Tyne
Local Rules for Manual Handling Operations
Appendix 2
Optional Numerical Risk Ranking System
This scheme is only relevant for those tasks that have been subjected to detailed assessment.
For the majority of manual handling tasks it will not be appropriate and will be unnecessary.
This numerical ranking system is provided as an optional tool which can be used to help in putting tasks into
an order of priority for action. In many cases the order will be so obvious that there will be no point in using
this method. For others it can provide a useful aid to setting out a plan of work and deciding upon time
scales. It needs to be used with care and with the footnotes in mind.
How to use the system
After the completion of FORM MH2 for a particular task or group of tasks, score as follows where a tick
has been placed against one of the 26 elements:-
Where you assess the level for that element score
of risk as : :
Low 1
Medium 2
High 3
Add up the total score.
Use the table below to allot one of three categories to the overall task.
Overall Score Risk Category
for whole task
Less than 20 Low
Between 20 and 30 Medium
Greater than 30 High
NOTES
1. It is important not to dwell to much on the absolute scores since these only serve as an aid to ranking
the risks into categories.
2. The scheme is crude and simplistic, and should not be used slavishly but as an aid to be tempered
with common sense by the assessor.
3. In some circumstances, an overall category of 'low' might arise yet there may be several specific '
high risk' responses to the 26 elements in Form MH2. In such circumstances the assessor should still
be attaching significance to these elements.
University of Newcastle upon Tyne
Local Rules for Manual Handling Operations
APPENDIX 3
SYSTEMATIC GUIDE TO REDUCING RISK
Risk Assessment - Control Measures
This Appendix considers what may be done to reduce the risk of injury from manual handling. It is intended
as a guide and its use is not obligatory.
The various ways in which to achieve risk reduction may be considered under the four headings: the Task;
the Load; the Working Environment; Individual Capability.
1 TASK
a) Using different actions or movements
i) Reduction of lifting/lowering effort
ii) Reduction of pushing/pulling effort
iii) Reduction of bending movements
iv) Reduction of twisting movements
v) Reduction of reaching movements
vi) Reduction of carrying effort
vii) Reduction of holding effort
b) Modifying task by using mechanical assistance
c) Modifying task by team lifting
2 LOAD
a) Modifying object
3 WORKING ENVIRONMENT
a) Modifying workplace layout (including equipment/tools/furniture)
b) Rearranging materials flow
4 INDIVIDUAL CAPABILITY
a) Training
In the following pages each of these headings is broken down into more detailed elements. It is presented in
a format which can be copied and used to produce notes.
Note: Use of this checklist is optional. It is not intended that it be used for every task. It may be
photocopied and used to analyse tasks systematically in searching for risk reduction methods.
University of Newcastle upon Tyne
Local Rules for Manual Handling Operations
Yes No Details (Where yes response)
Task
Using different
actions and
movements
Can Lifting and Lowering effort
be reduced by:-
Eliminating the need to lift and lower
manually by using lift tables, forklifts,
cranes, hoists, balancers, elevating
conveyors and similar aids
Raising the working height
Lowering or raising the operator
Using gravity dumps and chutes
Reducing object weight by reducing
load size; reducing capacity of
containers; reducing the number of
objects lifted or lowered at one time.
Increasing object weight so that it must
be handled mechanically by using a unit
or bulk load concept; using palletised
loads
Reducing holding position away from
the body by changing object shape;
providing suitable grips or handles;
providing greater access to the load;
improving workplace layout
Converting to Pushing or Pulling
Can Pushing or Pulling effort be
reduced by:-
Eliminating the need to push or pull by
using powered conveyors; using
powered trucks or movers; using slides,
rollers or chutes
Reducing load weight; using non-
powered conveyors, air bearings, ball
castor tables, monorails and similar
aids; using four-wheel hand trucks,
hand trolleys with good bearings and
large diameter wheels or castors
Reducing required forces by providing
good maintenance of equipment and
floor surfaces or removing changes in
level
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Local Rules for Manual Handling Operations
Yes No Details (Where yes response)
Reducing the travel distance by
improving work area layout; relocating
production or storage area, or similar
system change
Can Bending be reduced by:-
Using lifting tables, work dispensers
and similar mechanical aids
Raising work level
Lowering the person
Providing all material at work level
Keeping materials at work level (eg
don't lower that which must later be
lifted)
Eliminating horizontal reaches over
400mm
Can Twisting movements be
reduced by:-
Providing all tools and materials in
front of the person
Using conveyors, chutes, slides or
turntables to change material flow
direction
Providing adjustable swivel chair
Providing sufficient work space for the
whole body to turn
Improving layout of the work area
Can Reaching be reduced by:-
Providing tools and machine controls
close to the person (less than 400mm)
Placing materials, workpieces and other
heavy objects as near the body as
possible
Enabling the object handled to be kept
close
Reducing load or container size
Enabling the person to walk around the
load or to rotate it
Can carrying effort be reduced
by:
Converting to pushing or pulling by use
of conveyors, air bearings, ball castor
tables, monorails, slides, chutes and
similar aids, using forklifts, two or four-
wheel hand trucks, trolleys etc.
University of Newcastle upon Tyne
Local Rules for Manual Handling Operations
Yes No Details (Where yes response)
Reducing object weight by reducing
object size, reducing capacity of
containers; reducing container weight;
reducing load in each container;
reducing the number of objects carried
at one time
Reducing travel distance by improving
work area layout; relocating storage or
production area, or similar system
change
Can holding effort be reduced
by:
Reducing object weight
Reducing object size
Reducing holding time
Eliminating holding by using jigs and
fixtures, etc.
Using mechanical loading and
unloading
Modifying task by
using mechanical
assistance
Could the risk be reduced by
using mechanical handling
equipment such as:-
Simple aids, eg levers, sliding rails
conveyors, belt conveyors, roller
conveyors, screw conveyors, chutes,
hooks, suction pads.
Note on Conveyors Conveyors are generally useful when:
• loads are uniform;
• materials move continuously;
• routes do not vary,
• loads are constant;
• movement rate is relatively fixed;
• conveyors can bypass cross traffic;
• the path to be followed is fixed
Cranes and hoists, eg jib cranes,
overhead travelling cranes, gantry
cranes, mobile hoists etc.
Note on Cranes and Hoists Cranes and hoists are most commonly used when
• movement is within a fixed area;
• moves are intermittent;
• loads vary in size and weight;
• cross traffic will interfere with conveyors;
• and/or loads handled are not uniform
Positioning equipment, eg lifts, jacks
University of Newcastle upon Tyne
Local Rules for Manual Handling Operations
Yes No Details (Where yes response)
Industrial vehicles, eg fork lift trucks,
platform trucks, two wheeled hand
trucks, trolleys
Note on Lift Trucks Industrial trucks are generally used when loads are
• moved intermittently;
• movement is over varying routes;
• loads are uniform;
• cross traffic would prohibit conveyors;
• clearances and running surfaces are adequate
and suitable;
• most of the operation consists of pallet-lifting,
manoeuvring, stacking, etc
Fixed, but adjustable, platforms (eg
scissors lifts); trestle stands to support
load etc.
Notes on mechanical handling • should be easy to use
equipment • should be designed to suit the load
• needs adequate space in which to be used and
stored
• should be readily available even in
emergencies
• and information, instruction and training should be
provided
Modifying task by
team lifting
Can team lifting be used to reduce the
risk from manual handling:
Notes on team lifting Whenever team lifting is used it is essential to
ensure:
• that there is an adequate number of persons in
the team
• that one is appointed to co-ordinate the task(s)
• that the team members are of similar capacity
• that there is adequate access to load
• that there are sufficient hand holds
• that appropriate training is provided
Load Control Options
Modifying object
Can the object be made lighter?
Can it be packaged in smaller
containers?
Can the object be made less bulky, so
that it can be handled closer to the
body's centre of gravity
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Local Rules for Manual Handling Operations
Yes No Details (Where yes response)
Can the shape be changed or surface be
cleaner or cooler, or the edges less
sharp, so the object can be held against
the body?
Can handles be provided, or some type
of sling used to move the object?
Is the object designed or the material
packaged so that it will not shift
unexpectedly while it is being moved?
Working environment
Modifying workplace
layout
(including equipment / tools /
furniture)
Can layout of workplace be
modified by:-
storing heavier items at waist level
using adjustable storage
improving storage
using adjustable work heights
provision of improved tools and
implements (to influence working
posture, movements and physical stress)
Notes on tools Tools should be:
• as light as function will permit
• supported/suspended if heavy or to minimise
force used
• well balanced
• provided with well designed handles, which, if
required, allow change of grip
• in good condition (thereby preventing use of
excessive force)
• provided with adequate vibration, insulation, if
necessary
• suitable for all staff (left handed/right handed)
Re-arranging
materials flow
Can the way materials are
moved be altered, by:
providing rollers, conveyors etc to
avoid carrying
using mechanical aids to avoid lifting
and carrying etc
modifying plant to avoid lifting for
pouring eg fit taps, put on swivel frame
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Local Rules for Manual Handling Operations
Yes No Details (Where yes response)
facilitating movement by providing
automatic doors
Individual capability
control options
Training
Would particular training reduce the
risk of injury from manual handling
Note on training Any training should :
• be specific to the 'trade'
• deal with those risk factors identified in the
assessment
• aim to ensure that the employee understands
the reason for doing the job in a certain way
and recognises the risks
University of Newcastle upon Tyne
Local Rules for Manual Handling Operations
APPENDIX 4
PRINCIPLES OF CORRECT MANUAL HANDLING
For purposes of job design, training and education programs the following principles apply for most
handling techniques:
Plan
The person undertaking the manual handling should assess the load and determine how it will
be handled and where it will be placed.
By assessing the situation first one can decide if a handling aid, a transporter, or another
person is needed to move the object, animal or person.
Determine the best technique
All factors should be taken into account when determining the best technique. A person
undertaking a lift should lift efficiently and rhythmically, avoiding bending of the lower back.
The best handling technique involves suitable balance and avoidance of unnecessary bending,
twisting and reaching.
Take a secure grip on the object being handled
The grip helps to determine how safe the task will be. Wherever possible, a comfortable
power grip (with the whole hand) should be used rather than a pinch grip (with fingers only).
Pull the load in close to the body
For lifting in particular, it is important to have the centre of gravity of the load close to the
body to prevent excessive stress on the back and to make the strongest muscles of the arms
available to hold the load.
It is important to minimise the effects of acceleration by lifting slowly, smoothly and without
jerking.
Vary handling tasks with lighter work
The job/task should be designed so as to provide alternative tasks that do not heavily stress
the same muscles. Lighter tasks allow the active muscles to recover and should be alternated
with heavier handling tasks.
Team Lifting
To enable load sharing, lifting partners should be of similar height and build and should be
trained together. There should be a person nominated as team leader to co-ordinate the lift.
University of Newcastle upon Tyne
Local Rules for Manual Handling Operations
MANUAL LIFTING
It is difficult to generalise about the optimum or maximum weight of a load to be lifted, because
there are so many factors involved besides the actual weight to be lifted.
The following points should be considered:
• Lifting aids should be used if possible.
• There should be sufficient space for lifting to be done in the right position and with
correct body movements.
• There should be no obstructions when moving things.
• The start and finish height of the load should be a suitable level (50-100cm) above the
floor.
• The load should be as close to the body as possible.
• The back should not be twisted.
• Carrying with one hand should be avoided.
A load is more difficult (heavier) to lift or carry if it is not close to the body. For example, 10kg held
at a distance of 80cm imposes the same load as 50kg right next to the body.
If lifting has to be frequently repeated, the acceptable weight of the load rapidly diminishes.
