Manual Handling Risk Assessment Template – Download PDF

Manual handling risk assessment template

Managing manual handling hazards is a daily reality for supervisors and safety leads overseeing lifting, carrying, and material transport. This template helps you systematically identify risky manual handling activities, assess the potential for injury, and document your safety controls. According to the UK Health and Safety Executive (HSE), manual handling, lifting, and carrying are the primary causes of work-related musculoskeletal disorders (MSDs).

What sets this resource apart is its focus on the real-world demands of manual handling, such as repetitive lifting in logistics or moving awkward loads on busy sites. If your needs extend beyond manual handling, check out our dedicated fire, COSHH, or dynamic risk assessment templates as well.

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Preview of the template

Audit

General Information

Task Description

Are there indications that the task is high risk?

Select appropriate response

Kindly specify

Load weight and lift/carry frequency

Risk Rating

Note the weight of the load and the repetition rate of the lifting operation.

Lift

Carry

Hand distance from the lower back

Observe the task and examine the horizontal distance between the operative's hands and their lower back.

Lift

Carry

Vertical lift region

Observe the position of the operative’s hands at the start of the lift and as the lift progresses.

Lift

Trunk twisting/sideways bending

Observe the operative's trunk as the load is lifted.

Lift

Asymmetrical trunk/load

Load and hands are symmetrical in front of the trunk.

Carry

Postural constraints

The movements of the operative are unhindered.

Lift

Carry

Grip on the load

• Containers with well-designed handles or handholds, fit for purpose • Loose parts enabling comfortable grip

Lift

Carry

Floor surface

Dry and clean floor in good condition

Lift

Carry

Other environmental factors

Observe the work environment and the lifting operation that takes place: in extremes of temperature; with strong air movements; or in extreme lighting conditions (dark, bright or poor contrast).

Lift

Carry

Carry distance

Observe the task and estimate the total distance that the load is carried.

Carry

Obstacles en route

Observe the route

Carry

Completion

Recommendations

Inspector's Full Name and Signature

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Frequently asked questions

What are the main hazards you need to look for during a manual handling risk assessment?

Key hazards include lifting heavy loads, awkward or repetitive movements, poor posture, slippery floors, and inadequate space. You should also watch for environmental factors like poor lighting or tight corners that increase the risk of injury during manual handling.

Which industries most frequently require manual handling risk assessments?

Industries such as logistics, warehousing, manufacturing, healthcare, construction, and hospitality routinely perform manual handling risk assessments. These environments involve frequent lifting, moving, and transporting of goods or materials by hand.

Why do manual handling injuries remain so common despite existing safety rules?

Injuries persist because of rushed work, poor technique, lack of training, or underestimating the weight of loads. Changing processes, time pressures, and not having suitable equipment also contribute to the problem, even when guidelines exist.

What should you do if an employee reports pain after manual handling activities?

Take every complaint seriously. Review the task, check if current controls are working, and if needed, pause the activity. Adjust loads, provide extra training, and make sure the employee is assessed by occupational health before they return to those duties.

This template, developed by Lumiform employees, serves as a starting point for businesses using the Lumiform platform and is intended as a hypothetical example only. It does not replace professional advice. Companies should consult qualified professionals to assess the suitability and legality of using this template in their specific workplace or jurisdiction. Lumiform is not liable for any errors or omissions in this template or for any actions taken based on its content.