Manual Handling

MHOR 1992 — The 3-Step Hierarchy

Manual Handling Operations Regulations 1992 (MHOR). Applies to any transporting or supporting of a load by hand or bodily force.

1. Avoid — eliminate the manual handling task where reasonably practicable (e.g. use mechanical handling equipment, redesign the task).
2. Assess — if manual handling cannot be avoided, carry out a suitable and sufficient risk assessment.
3. Reduce — take appropriate steps to reduce the risk of injury to the lowest level reasonably practicable.

The hierarchy must be applied in order. There is no legal maximum weight — actual limits depend on the full TILE assessment.

TILE Risk Assessment Factors

• T — Task: does the task involve twisting, stooping, or reaching? Is there repetition or prolonged effort? Is the load held at distance from the body?
• I — Individual: does the worker have the physical capability? Are there health conditions, a pregnancy, or lack of training that increase risk?
• L — Load: is the load heavy, bulky, or difficult to grip? Is it unstable, sharp, hot, or otherwise hazardous?
• E — Environment: is there enough space to manoeuvre? Is the floor uneven, wet, or slippery? Is the lighting adequate?

TILE and LITE refer to the same four factors — the acronyms simply use a different order. Both are used in HSE guidance (INDG143).

HSE Guideline Weight Filter — Close to Body, Two-Handed (HSE L23 Figure 20 / INDG143)

These are filter values that trigger a full assessment — NOT legal maximum weight limits. If a lift stays within these weights AND all other conditions are favourable, a full detailed assessment may not be necessary.

• Head height (above shoulder): 10 kg (men) / 7 kg (women)
• Shoulder height: 20 kg (men) / 13 kg (women)
• Elbow height: 25 kg (men) / 16 kg (women)
• Knuckle height: 20 kg (men) / 13 kg (women)
• Mid lower-leg height: 10 kg (men) / 7 kg (women)

Loads held at arm's length reduce to approximately 60% of the close-to-body figures; follow the HSE guideline-weight mannequin diagram (INDG143 / L23) for the exact arm's-length values. Source: https://www.hse.gov.uk/msd/manual-handling-risk-filters.htm ; L23 https://www.hse.gov.uk/pubns/books/l23.htm

Pushing, Pulling & Seated Handling

• Pushing/pulling guideline forces (two-handed, on level ground):
• Starting or stopping a load: 20 kg (men) / 15 kg (women)
• Sustained pushing or pulling: 10 kg (men) / 7 kg (women)

Seated handling guideline: 5 kg (men) / 3 kg (women)

These are also filter values, not legal limits. A full risk assessment is required whenever any filter value is approached or exceeded, or where other risk factors are present.