Manual handling tools



The HSE has developed a collection of tools to help identify common risk factors covering manual handling operations including lifting and carrying, pushing and pulling and repetitive tasks. These have been designed to help people carrying out risk assessments to break down tasks, identify elements that could pose a risk to workers and evaluate potential solutions or improvements.



The tools and information on how to use them can be downloaded from the HSE website.



The Manual Handling Assessment Chart (MAC) tool helps to identify high-risk manual handling activities in workplaces and is aimed at employers, employees and safety reps.


The MAC incorporates a numerical and a traffic light approach (green — low level of risk, amber — medium level of risk, red — high level of risk and purple — very high level of risk) to highlight high risk manual handling tasks. Three types of assessment can be carried out with the MAC: lifting by one person, carrying by one person and team handling operations.



The HSE makes clear that, while using the MAC will help with the initial screening of possible high-risk manual handling activities within the workplace, it is “not appropriate for all manual handling operations and does not comprise a full ‘suitable and sufficient’ risk assessment. It is unlikely to be acceptable if relied upon alone.” It advises that a risk assessment will normally need to take account of additional factors such as an individual’s capabilities and should conform to the requirements in the manual handling operations regulations.



The Variable Manual Handling Assessment Chart (V-MAC) tool is for assessing manual handling operations where load weights vary, and the HSE advises that it should be used in conjunction with the MAC tool. It is best suited for order picking and distribution systems (parcel sorting, trailer loading/unloading and parts delivery in manufacturing for example) which can automatically generate the data for importing into V-MAC. The HSE also cautions that significant background knowledge, which can be gained through HSE support pages or training, is needed to use it successfully.


The Assessment of Repetitive Tasks (ART) Tool is designed to help assess tasks that require repetitive movement of the arms and hands. It assists in carrying out a risk assessment of some of the common risk factors in repetitive work that contribute to the development of upper limb disorders (ULDs). It uses a numerical score and a “traffic light” approach to indicate the level of risk for twelve factors, grouped into four stages:



• frequency and repetition of movements;



• force;



• awkward postures of the neck, back, arm, wrist and hand; and



• additional factors, including breaks and duration.



The factors are presented on a flow chart, which leads the person carrying out the risk assessment, step-by-step, to evaluate and grade the degree of risk. The tool is supported by an assessment guide, providing instruction to help score the repetitive task being observed and a worksheet to record the assessment.


The ART tool is intended for people with responsibility for the design, assessment, management, and inspection of repetitive work typically found in assembly, production, processing, packaging, packing and sorting work, as well as work involving regular use of hand tools. The HSE recommends that training is provided to ensure that assessors use the tool reliably and appropriately. It also makes clear that it is not designed for Display Screen Equipment risk assessments. The ART Tool can be downloaded from the HSE website.

The Risk Assessment of Pushing and Pulling (RAPP) tool is designed to consider pushing and pulling tasks, which the HSE says can often be ignored because they are often seen as solutions for manual handling: “put the load onto a trolley and push it”. However, it advises that there are still issues, such as distance, uneven surfaces, obstructions, and slopes or stairs.


The RAPP tool helps assess the key risks in manual pushing and pulling operations involving whole body effort. Like the MAC tool it uses colour-coding and numerical scoring. It helps to identify high-risk pushing and pulling activities and to evaluate the effectiveness of any risk-reduction measures. Two types of pulling and pushing operations can be assessed using the RAPP: 


• moving loads using wheeled equipment, such as hand trolleys, pump trucks, carts or wheelbarrows; and 


• moving items without wheels, involving dragging/sliding, churning (pivoting and rolling) and rolling.


For each type of assessment there is a flow chart, an assessment guide and a score sheet.