Manual lifting is one of the most common causes of workplace accidents and musculoskeletal disorders. A well-designed risk assessment for manual lifting helps you identify hazardous situations early on, implement the appropriate preventive measures, and comply with legal requirements regarding workplace well-being. In this step-by-step guide, you’ll learn how to set up a comprehensive risk assessment for lifting, from preparation to follow-up.
Follow the steps below in order. Each phase builds on the previous one, and together they provide you with a structured and well-reasoned document that can be used immediately in the workplace.
What You'll Need Before You Begin
A thorough risk assessment of manual lifting does not begin by filling out a form, but by gathering the right information and bringing the right people together. Without this preparation, you run the risk of overlooking important lifting operations or misjudging risks.
Make sure you have the following items ready before you begin:
- An overview of all jobs and workstations that involve manual lifting
- Access to the workplace for direct observation
- Involvement of immediate supervisors and, preferably, the employees themselves as well
- A recognized assessment method, such as the NIOSH lifting formula, the KIM method, or the MAC tool
- A template or registration document for the analysis
- Information about previously reported absences due to illness, complaints, or incidents related to lifting
Also check to see if there is already an existing risk assessment for the workstation. This can serve as a starting point and prevent duplication of effort. Once you’ve gathered everything, you’re ready to map out the actual lifting operations.
Map out the lifting operations
Identify all tasks in which employees manually lift, carry, push, or pull loads. This is the actual assessment step: you document what is being lifted, how often, by whom, and under what conditions.
- Walk around the workplace and observe the employees as they go about their normal work. Make a note of every lifting task you see.
- Ask employees themselves what loads they lift and whether there are any situations they find difficult or uncomfortable.
- For each lift, record the following: the weight of the load, the lifting technique, the lifting frequency, the distance over which the load is lifted, and the lifting height.
- Group similar actions together to keep the analysis organized.
After this step, you will have a complete list of all relevant lifting activities on the work floor. Check whether your list matches what managers and employees describe. Discrepancies often point to activities that aren’t visible during a standard observation, such as lifting outside regular working hours or during specific seasonal peaks. You can also use the applications by material type as a reference to ensure you aren’t missing any specific activities.
Assess the risk factors for each lifting operation
With the inventory in hand, you will now assess the risk factors for each lifting task. This is the core of the lifting risk analysis: you determine the extent to which each task poses a risk to the employee’s health.
Use a standardized method to score objectively. The most commonly used factors in assessing the hazards of manual lifting are:
- Weight of the load: the heavier it is, the higher the risk. The European directive sets indicative thresholds, but the actual risk depends on several factors.
- Posture and body position: a hunched back, a twisted torso, or reaching significantly increase the risk.
- Lifting frequency and duration: Repeated lifting over an extended period increases the cumulative strain.
- Work environment: confined spaces, slippery floors, temperature, or poor lighting increase the risk.
- Characteristics of the load: an awkward shape, unstable contents, or poor grip make lifting more dangerous.
- Individual factors: the employee's age, physical condition, and experience also play a role.
Assign a risk level to each lifting task: low, medium, or high. Document the scores for each factor so that you can later demonstrate the basis for your assessment. After scoring, you’ll have a clear picture of which tasks require priority attention.
Develop preventive measures for each risk level
Now translate the risk assessment into concrete actions. The hierarchy of prevention dictates that you first implement technical and organizational measures before resorting to personal protective equipment or behavioral instructions. Ergonomics in lifting starts with adapting the workstation, not with training the employee to lift better.
- High risk: Eliminate manual lifting whenever possible. Introduce a lifting aid or hoist that takes over some or all of the lifting.
- Moderate risk: Adjust the workstation. Consider raising the work surface, reducing the frequency of lifting by dividing tasks, or adjusting the package size.
- Low risk: Instruct employees on proper lifting techniques and ensure sufficient rest time between lifting tasks.
For each measure, also designate a person responsible and set an implementation deadline. Measures without an assigned owner and a deadline are rarely implemented. After implementation, verify whether the measure has had the expected effect by recalculating the risk score.
Document and validate the risk analysis
From a legal standpoint, a risk analysis that is not documented does not exist. Record all steps, findings, and decisions in writing in a structured report. This document serves as evidence of your duty of care and as a reference for future reviews.
- For each lifting operation, record the following information: a description of the operation, the employees involved, the risk score for each factor, the overall assessment, and the planned measures.
- Have the document reviewed by the in-house occupational safety and health advisor or the external occupational safety and health service.
- Discuss the findings with the affected employees and their representatives. Their feedback can help refine the analysis and increase support for the measures.
Once validated, the risk analysis is official, and you can proceed with implementing the measures. Store the document in an accessible location and ensure that the safety officer and supervisors always have access to it. You can also contact our service and maintenance department for technical support with the implementation of lifting solutions.
Schedule follow-up and review
A risk assessment for manual lifting is not a one-time document. The workplace is constantly changing: new products, different employees, modified processes, or a renovation can completely alter the risk situation. Therefore, be sure to plan for ongoing monitoring.
- Establish a fixed review frequency, at least once a year or after any significant change to the workstation or production process.
- Evaluate the effectiveness of the preventive measures taken based on complaint records, absenteeism rates, and observations on the job.
- Update the risk analysis based on new insights, incidents, or changes in legislation.
- Inform employees about changes to the analysis and the corresponding measures.
After each revision, document the changes and have the document revalidated. This ensures that the workstation risk assessment remains up to date and that your organization continues to demonstrably comply with its obligations regarding workplace well-being.
How Logitrans Handling Helps with Risk Analysis for Manual Lifting
A thorough risk analysis identifies hazardous lifting operations, but the next step is to effectively eliminate or reduce those risks. That is exactly where we make a difference. Logitrans Handling guides companies from analysis to solution, with a focus on ergonomics and practical applicability.
- Free workstation analysis: Our specialists will visit your site and identify ergonomic issues.
- Customized solutions: Whether you need vacuum lifters, mobile lifters, or other lifting equipment, we’ll recommend the system that best suits your situation.
- Demonstration area in Drongen: Test the lifting solution with your own materials before you make a decision.
- Training during installation: We ensure that employees use the equipment correctly and safely.
- Maintenance Contracts: To ensure a consistently safe and ergonomic work environment, even after installation.
Would you like to know which lifting solution best addresses the risks identified in your risk assessment? Contact us, and we’ll work with you to determine the most appropriate approach for your workplace.
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