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TBT-05: Manual Handling

Reference: TBT-05 | Issue Date: 14/03/2026 | Review Date: Sep 2026 Applicable Standards: ISO 45001 Cl. 8.1.2 | Manual Handling Operations Regulations 1992 Related Documents: HPOL04, HPOL19, HFORM15, HREG03

Role-Specific

This toolbox talk applies to all CRGI Solutions staff who visit client sites or handle equipment during surveys, inspections, and fieldwork activities.

What is Manual Handling?

Manual handling means moving or supporting a load by hand or bodily force. This includes lifting, carrying, pushing, pulling, and lowering objects. For CRGI staff, this covers carrying survey equipment to sites, moving equipment during inspections, handling sample materials, setting up measurement instruments, and carrying laptops and bags through client facilities.

Why Manual Handling Matters

Musculoskeletal disorders (MSDs) caused by manual handling are the leading cause of workplace absence in the UK. Back injuries, strained shoulders, and repetitive strain injuries can have long-term health impacts and affect your ability to work. Proper technique and awareness prevent these injuries.

The Hierarchy: Avoid, Assess, Reduce

Avoid manual handling where possible — use trolleys, mechanical lifts, or request assistance. Assess the load and task using the TILE method (see below). Reduce risk through better technique, breaks, or sharing the load.

TILE Assessment

Before lifting, assess using TILE:

  • Task: Are you bending, twisting, or reaching? Is the lift repetitive? Avoid awkward positions.
  • Individual: Consider fitness, injuries, pregnancy, fatigue, and capability. Know your limits.
  • Load: Weight, size, stability, and grip points. Awkward shapes without handles increase risk.
  • Environment: Space constraints, temperature, lighting, and floor conditions. A cramped stairwell is higher risk than a spacious corridor.

Safe Lifting Technique

  1. Plan the lift — check the load weight, grip points, and destination before starting.
  2. Position your feet — stand with feet shoulder-width apart, one foot slightly forward.
  3. Bend your knees — not your back. Lower yourself into a squat position.
  4. Keep your back straight — maintain the natural curve of your spine.
  5. Grip firmly — use your whole hand, not just fingers.
  6. Lift smoothly — no jerking. Let your leg muscles do the work.
  7. Keep the load close — hold objects near your body to reduce strain on your back.
  8. Don't twist — turn your whole body, not just your torso.

Know Your Limits

If a load feels too heavy, don't lift it alone. Get help from a colleague, use mechanical aids (trolleys, hand trucks, sack trucks), or request assistance from client site staff. A typical safe manual lift for most adults is around 20 kg. Lighter limits apply for repetitive tasks, overhead lifts, or awkward loads.

Pushing and Pulling

Pushing is generally safer than pulling. If you must pull, use correct posture: keep your back straight, bend your knees, and pull in a smooth, controlled manner. Avoid pulling loads toward your body at shoulder height.

Awkward Loads

Be extra cautious with large items, unstable loads, items without handles, or loads with irregular shapes. These require more careful assessment. Break them into smaller parts if possible, or use equipment to assist.

Personal Factors

Your individual circumstances matter. If you are unfit, have existing injuries or pain, are pregnant, or are fatigued, be more conservative with lifting. Inform your manager if manual handling causes discomfort — medical or personal factors may affect your ability to perform this task safely.

On Client Sites

Always use the client's mechanical aids and equipment where available. Follow their manual handling procedures and site rules. If you're unsure about safe practices at a client site, ask before lifting.

Report Injuries and Discomfort

Any strain, pain, or injury from manual handling must be reported immediately using HFORM03. Do not ignore discomfort — early reporting prevents minor issues from becoming chronic injuries.

Key Takeaways

  • Manual handling causes the most workplace absences in the UK — prevention is critical.
  • Avoid manual handling where possible; assess every lift using TILE.
  • Safe technique: plan, position feet, bend knees, straight back, grip, lift smoothly, keep close, no twisting.
  • Know your limits and ask for help when needed.
  • On client sites, use their equipment and follow their procedures.
  • Report any injury or discomfort immediately.

CRGI Solutions HSQE Department | HSQEMS v2.0 | Classification: CRGI Information