7 Practical Ways to Manage Manual Handling Risks in the Workplace

The HSE's Work-related Musculoskeletal Disorders Statistics in Great Britain, 2025 report states that an estimated 511,000 workers were suffering from work-related musculoskeletal disorders (new or long-standing) in 2024/25, resulting in 7.1 million working days lost. The report also identifies manual handling as one of the main work factors cited as causing work-related musculoskeletal disorders.

While manual handling is often associated with lifting heavy objects, it also includes pushing, pulling, carrying, lowering and supporting loads. From warehouses and construction sites to theatres, film sets, exhibition halls and live events, manual handling activities form part of many everyday tasks.

Understanding where these activities take place, and how the associated risks can be managed, is an important part of protecting employees and meeting your legal responsibilities.

1. Identify Manual Handling Activities

The first step is to identify where manual handling takes place within your organisation. It is not limited to warehouses or factories and may include activities such as:

• Loading and unloading vehicles.

• Moving flight cases and AV equipment.

• Setting up staging, barriers or seating.

• Handling exhibition stands and display materials.

• Carrying catering supplies.

• Moving office furniture or archive boxes.

Identifying manual handling activities helps employers determine where further assessment may be required.

2. Avoid Hazardous Manual Handling Where Reasonably Practicable

The Manual Handling Operations Regulations 1992 require employers to avoid hazardous manual handling operations so far as is reasonably practicable.

This may involve redesigning the task, changing the process or using suitable mechanical handling equipment to eliminate the need for manual handling.

3. Assess the Risks

Where hazardous manual handling cannot be avoided, the Regulations require employers to carry out a suitable and sufficient assessment of the operation.

The HSE recommends considering:

• The task – Does it involve repetitive movements, twisting, reaching or long carrying distances?

• The individual – Does the person have the capability, training and experience to undertake the task safely?

• The load – Is it heavy, bulky, unstable or difficult to grasp?

• The working environment – Are there space constraints, uneven surfaces, poor lighting or other hazards?

These factors are commonly referred to as TILE and provide a practical framework for assessing manual handling risks.

4. Provide Suitable Equipment

Where reasonably practicable, employers should provide suitable equipment to reduce manual handling risks.

Depending on the activity, this may include trolleys, pallet trucks, lifting tables, hoists or other mechanical handling aids. Equipment should be appropriate for the task, maintained in good condition and available when required.

5. Provide Appropriate Information, Instruction and Training

Employees should receive appropriate information, instruction and training to enable them to carry out manual handling activities safely.

Training should reflect the tasks employees undertake and be reviewed whenever work activities, equipment or procedures change.

6. Encourage Early Reporting

Employees should be encouraged to report manual handling concerns, near misses and any difficulties carrying out manual handling activities.

Early reporting allows employers to review existing control measures, identify emerging risks and make improvements before incidents occur.

7. Review Your Manual Handling Arrangements

Manual handling risk assessments should not be regarded as one-off documents. They should be reviewed whenever there is reason to believe they are no longer valid, or following significant changes to work activities, equipment, workplaces or the workforce.

Regular reviews help ensure that control measures remain suitable and continue to reflect the way work is carried out.

How Calvin Hanks Can Help

Calvin Hanks provides practical support to organisations across the events, TV/Film, hospitality and commercial sectors, including manual handling risk assessments, workplace inspections and bespoke training tailored to the activities your employees undertake. Most recently, we have delivered bespoke manual handling training for clients in the higher education and arts sectors, ensuring the training reflected the specific manual handling activities and risks within their working environments.

Whether you are reviewing existing arrangements or looking to improve manual handling practices across your organisation, our experienced consultants can help you implement practical, proportionate solutions that support compliance and reduce workplace risk. Get in touch today to speak to one of our advisors.