Manual Handling

ISO 45001:2018 Clause 8.1.2 · Manual Handling Operations Regulations 1992 (as amended) — Avoidance, assessment and reduction of manual handling injury risk

Procedure overview

A M Water Services applies the Manual Handling Regulations 1992 hierarchy — avoid, assess, reduce. Manual handling operations carrying a risk of injury are first identified at risk assessment (per SOP 3.1). The Site Supervisor and HSQE Consultant assess whether the operation can be eliminated or avoided through change of operations, mechanical handling, supplier-led repackaging or work redesign; where elimination is not reasonably practicable, a Manual Handling Risk Assessment is performed under Regulation 4(1)(b)(i) using the LITE methodology (Load, Individual, Task, Environment). Control measures are introduced to reduce the residual risk to the lowest reasonably practicable level: mechanical aids (trolleys, trucks, lifting plant), team lifts, supplier deliveries in smaller packs, ergonomic redesign, and personal training. All operatives receive manual handling training during induction and through periodic toolbox talks (per SOP 4.2). Driven mechanical handling plant is operated only by trained, certificated personnel. Records are retained per SOP 4.7.

Manual Handling — Process Flow

Site Supervisor & HSQE Consultant

Jason May (Supervisor)
Sean Ashton

Avoid & Assess

Manual handling operations identified at risk assessment (per SOP 3.1)

Can manual handling be eliminated or avoided by change to operations?

Yes

Make changes to operations to eliminate manual handling — preferred outcome

Perform Manual Handling Risk Assessment per Regulation 4(1)(b)(i) using LITE methodology

Document the assessment

Manual Handling Risk Assessment

Site Supervisor

Jason May

Reduce Risk

Identify control measures to reduce the risk of injury to the lowest reasonably practicable level

Introduce mechanical handling methods where practicable (trolleys, trucks, telehandlers, cranes)

Provide suitable trolleys / trucks / lifting equipment

Driven mechanical handling plant (forklift, telehandler, crane) operated only by trained, certificated personnel (NPORS / IPAF / appropriate ticket)

Arrange supply of materials in smaller / lighter packs where practicable (engage with suppliers via SOP 5.3)

Site Supervisor & Operatives

Jason May
Team Leaders · Operatives

Train & Record

Provide manual handling instruction and training during site induction and toolbox talks — common handling tasks, correct technique, recognition of overload, escalation

SOP 4.2 / SOP 4.3

Maintain records of assessments, training and any manual handling injuries

SOP 4.7 Control of Records

Process / Activity

Decision Point

Document / Cross-reference

Eliminate / Continue

HSE manual handling guideline weights and LITE assessment

The Manual Handling Operations Regulations 1992 (as amended) do not set legal weight limits, but HSE provides indicative guideline weights. Loads above the guideline weight, or in awkward positions, require a full risk assessment. The guideline figures assume the load is held with both hands close to the body in stable conditions; halve the figure for twisting, awkward postures or unstable footing.

Lift zone	Men — guideline weight	Women — guideline weight
Above shoulder height	10 kg	7 kg
Shoulder to elbow	20 kg	14 kg
Elbow to knuckle (optimal lifting zone)	25 kg	16 kg
Knuckle to mid-lower leg	20 kg	14 kg
Mid-lower leg to floor	10 kg	7 kg

The LITE assessment method is applied to every operation that exceeds these figures: Load (weight, size, shape, stability, sharp/hot edges); Individual (capability, training, health, pregnancy, clothing/PPE); Task (distance, frequency, duration, posture, twisting, carrying); Environment (space, floor condition, temperature, lighting, weather). Common AMWS manual handling hazards: water main pipework (DI/PE pipe sections), valves and hydrants, kerbstones, paving slabs, road plates, plant attachments, gas bottles, drainage materials. Where any LITE element pushes the operation above the guideline weight, mechanical aids are introduced or the task is redesigned. Manual handling injuries are reported per SOP 8.1; over-7-day absences are RIDDOR-reportable; chronic musculoskeletal disorder requires occupational health review under SOP 8.7.

Manual Handling

Manual Handling — Process Flow

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