How to identify poor manual handling practices in the workplace: a manual handling risk assessment guide

Manual handling remains one of the leading causes of workplace injuries across the UK. Tasks such as lifting, carrying, pushing, pulling or moving loads can place employees at risk of strains, sprains and other musculoskeletal disorders (MSDs) when not carried out safely. 

A thorough manual handling risk assessment helps businesses identify hazards, reduce risks and create safer working environments. By recognising poor manual handling practices early, organisations can take proactive steps to prevent injuries and maintain compliance with health and safety legislation. 

What is a manual handling risk assessment? 

A manual handling risk assessment is a process used to identify, evaluate and control risks associated with manual handling activities in the workplace. 

Under the Manual Handling Operations Regulations 1992 (as amended), employers must: 

• Avoid hazardous manual handling activities where reasonably practicable 
• Assess manual handling tasks that cannot be avoided 
• Reduce the risk of injury as far as reasonably practicable 

Regular reviews help ensure assessments remain relevant as workplaces, equipment and processes change. 

Why identifying poor manual handling practices matters 

Poor manual handling can result in: 

• Workplace injuries 
• Lost productivity 
• Increased sickness absence 
• Reduced employee wellbeing 
• Potential compliance issues 

Identifying unsafe behaviours through a manual handling risk assessment can help businesses take corrective action before incidents occur. 

Signs of poor manual handling practices in the workplace 

Employees use incorrect lifting techniques 

One of the most common indicators of poor manual handling is employees using unsafe lifting methods. 

Examples include: 

• Bending from the waist instead of the knees 
• Twisting while carrying a load 
• Reaching too far when lifting or lowering objects 
• Carrying loads that obstruct visibility 
• Attempting to lift heavy items without assistance 

These behaviours increase the likelihood of injury and may indicate the need for additional health and safety training or supervision. 

Loads are too heavy or difficult to handle 

A manual handling risk assessment should consider whether the load itself creates an unacceptable level of risk. 

Warning signs include: 

• Employees struggling to lift or carry items 
• Loads that are bulky or awkward to move 
• Unbalanced or unstable objects 
• Items with no suitable handholds 

Where risks are identified, businesses should consider alternative methods of moving materials or introducing suitable equipment. 

Mechanical aids are not being used 

Where handling equipment is available, employees should be encouraged and trained to use it correctly. 

Potential concerns include: 

• Trolleys or handling aids being ignored 
• Equipment being unavailable when needed 
• Employees choosing manual lifting instead of using suitable aids 
• Damaged handling equipment remaining in use 

A manual handling risk assessment should evaluate whether equipment is appropriate, maintained and being used effectively. 

The workplace layout creates unnecessary risks 

Poor workplace design can contribute significantly to manual handling problems. 

Common issues include: 

• Obstructed walkways 
• Limited space for lifting and carrying 
• Poor storage arrangements 
• Heavy items stored at difficult heights 
• Frequently used materials located far from work areas 

Improving workplace organisation can often reduce manual handling risks quickly and effectively. 

Employees report aches, pains or discomfort 

Employees are often the first to identify potential manual handling concerns. 

Reports of the following should be investigated: 

• Back pain 
• Neck and shoulder discomfort 
• Muscle strains 
• Repetitive movement injuries 
• Fatigue linked to manual tasks 

These warning signs may indicate that existing controls are not adequately managing risk. 

Injuries and near misses are occurring regularly 

Incident records can provide valuable insight into manual handling performance. 

Patterns to monitor include: 

• Dropped loads 
• Minor strains and sprains 
• Slips, trips and falls while carrying items 
• Near misses involving moving materials 

Investigating these events can help identify recurring hazards before more serious incidents occur. 

Training records are out of date 

Training plays an important role in supporting safe manual handling practices. 

Businesses should review: 

• Whether employees have received appropriate manual handling training 
• When training was completed 
• Whether refresher training is required 
• Whether training reflects current working practices 

If employees cannot demonstrate safe handling techniques, further instruction may be needed. 

Questions to ask during a manual handling risk assessment 

When assessing workplace activities, consider the following questions: 

• Can the manual handling task be avoided? 
• Is the load suitable for one person to move safely? 
• Are mechanical aids available where needed? 
• Does the workplace layout increase risk? 
• Have employees received appropriate training? 
• Are current control measures effective? 
• Have any injuries or near misses been reported? 

Regularly reviewing these areas helps organisations maintain a proactive approach to health and safety. 

Improving manual handling practices 

Effective risk management should focus on: 

• Eliminating unnecessary manual handling activities 
• Reviewing workflows and workplace layouts 
• Introducing suitable handling equipment 
• Maintaining up-to-date risk assessments 
• Providing appropriate training and guidance 
• Encouraging employees to report hazards and concerns 

Taking these steps can help reduce the likelihood of injuries while supporting a positive safety culture. 

How SafeWorkforce can help 

SafeWorkforce provides expert-led health and safety support to help businesses identify workplace risks, maintain compliance and improve safety performance. Services include health and safety consultancy, documentation reviews, health and safety audits, risk assessment support and expert guidance tailored to your business needs. SafeWorkforce can also act as your competent person under the Management of Health and Safety at Work Regulations and provide access to health and safety expertise when required.  

Ready to improve your manual handling processes? 

A well-structured manual handling risk assessment can help identify unsafe practices before they result in injuries, disruption or compliance issues. 

Speak to the SafeWorkforce team today to discover how our expert health and safety support can help you identify risks, strengthen compliance and create a safer workplace for your people. 

Frequently asked questions 

What is a manual handling risk assessment? 

A manual handling risk assessment is the process of identifying hazards associated with lifting, carrying, pushing, pulling or moving loads and implementing measures to reduce the risk of injury. It helps employers comply with the Manual Handling Operations Regulations 1992 (as amended). 

How often should a manual handling risk assessment be reviewed? 

A manual handling risk assessment should be reviewed whenever there are significant changes to tasks, equipment, working environments or workforce arrangements. It should also be reviewed following an accident, incident or near miss involving manual handling activities. 

What are the common signs of poor manual handling practices? 

Common warning signs include employees using incorrect lifting techniques, frequent reports of aches and pains, recurring manual handling injuries, poor storage arrangements, inadequate use of handling equipment and outdated risk assessments. 

Is manual handling training a legal requirement? 

Employers must provide appropriate information, instruction and training where manual handling risks exist. Training helps employees understand safe handling techniques and how to carry out tasks safely, reducing the risk of workplace injuries. 

How can SafeWorkforce help with manual handling risk assessments? 

SafeWorkforce provides expert-led health and safety support, including risk assessment guidance, health and safety audits, compliance advice and consultancy services. Our experts can help businesses identify workplace risks, implement practical controls and maintain compliance with health and safety requirements.