Manual handling remains one of the most common causes of workplace injuries in the UK. According to the Health and Safety Executive (HSE), in the 2023/24 reporting year, manual handling accounted for 18% of all non-fatal injuries reported by employers under RIDDOR. Poor lifting technique is a key contributor to musculoskeletal disorders (MSDs), which affect hundreds of thousands of workers annually.
To protect your workforce and maintain productivity, it’s crucial to ensure your team is trained in proper lifting methods. Below, we outline practical training strategies, aligned with the HSE’s guidance, that will help instil safe habits and prevent injury.
1. Start with a manual handling risk assessment
Before any training takes place, employers must assess manual handling tasks under the Manual Handling Operations Regulations 1992 (MHOR). This assessment should identify:
- The weight and shape of objects
- The frequency of lifting tasks
- Postural risks
- Environmental constraints
This informs your training content and ensures it is task-specific.
2. Use the hierarchy of controls
Training should be built around the principle that manual handling should be avoided where reasonably practicable. If lifting can’t be eliminated, explore alternatives such as:
- Substitution
- Mechanical aids such as hoists
- Redesigning tasks or workflows
Training should reinforce that lifting manually is a last resort.
3. Provide task-specific, practical training
Generic training often fails. Tailor your sessions to reflect:
- The actual items being lifted
- The postures and movements involved
- Common workplace hazards (uneven surfaces, narrow spaces)
Include practical demonstrations and observed practice in the work environment, not just classroom theory.
4. Cover core lifting principles
Teach your team to apply the TILEO approach:
- Task – what’s involved?
- Twisting, stooping or bending?
- Lifting?
- Pushing or pulling?
- Positioning the load?
- Sudden movement?
- Repetitive movement?
- Team handling?
- Seated work?
- Do you need to move the load over a long distance?
- Individual – is the person capable? Are they…
- Pregnant?
- Disabled?
- Suffering from a health problem?
- Is there someone more suitable?
- Load – what’s the nature of the item? Is it…
- Heavy?
- Stable?
- Difficult to grip?
- Sharp?
- Hot or cold?
- Are the contents likely to move?
- Are there handles?
- Is the weight evenly distributed?
- Environment – are there hazards around? Such as…
- Space constraints
- Slippery or wet floors?
- Uneven floors?
- Different levels/ steps or slopes?
- Extreme conditions?
- Trip hazards?
- Insufficient lighting?
- Other factors – Other factors that need to be considered:
- Is PPE needed?
- Doest PPE hinder movement?
- Is the correct PPE being used?
- Are mechanical aids being used?
Also train correct physical technique:
- Feet shoulder-width apart
- Bend knees, not back
- Keep the load close to the body
- Avoid twisting
Tip: Use slow-motion video or side-on filming to review techniques and reinforce proper posture.
5. Refresher training and toolbox talks
Manual handling training should not be a one-off. Offer regular refresher sessions and short toolbox talks, especially after near-misses or when introducing new tasks.
The HSE recommends re-training every 12–24 months, depending on task complexity and injury rates.
6. Involve supervisors and encourage peer feedback
Supervisors should be trained to spot poor technique and offer constructive feedback. You can also empower experienced staff to mentor others – peer reinforcement often proves more effective than top-down reminders.
7. Track outcomes and use data
Monitor:
- Accident reports and near-misses
- Sick leave due to back or joint injuries
- Employee feedback on physical strain
This helps you evaluate the success of your training and fine-tune your approach.
According to the HSE’s Labour Force Survey, approximately 473,000 workers suffered from work-related musculoskeletal disorders in 2023/24, with 42% affecting the back – a sobering reminder of the importance of proper lifting technique.
Effective manual handling training isn’t just about avoiding legal breaches — it’s about protecting your team. By combining risk assessments, hands-on instruction, supervisor support, and continuous improvement, you can create a culture of safety that significantly reduces injuries and improves wellbeing.
How AssessNET’s Manual Handling Module supports safer lifting
Even with strong training programs in place, it’s essential to give your team the tools to apply what they’ve learned in everyday work. The AssessNET Manual Handling module is designed to reinforce safe lifting practices and help organisations minimise the risk of workplace injuries.
The module allows you to:
- Assess and reduce risks – Apply a risk matrix tailored to your organisation’s policies and processes.
- Capture supporting evidence – Attach documents, images, and notes to build a clear picture of manual handling risks.
- Integrate seamlessly – Link assessments directly with incident reports for a joined-up view of safety performance.
- Stay compliant – Maintain full version control to support traceability, transparency, ISO 45001, and HSG65 compliance.
- Save time – Complete manual handling assessments quickly with minimal typing, making it easy for staff at every level.
- Improve accessibility – Give employees fast access to assessments through the user-friendly Employee Portal.
By combining effective training with AssessNET’s purpose-built technology, organisations can build a sustainable culture of safe lifting, reducing the likelihood of injuries and ensuring compliance without adding unnecessary administrative burden.
