How do I conduct a risk assessment for manual lifting tasks at my company?

You conduct a risk assessment for manual lifting by systematically identifying the physical strain associated with each lifting task, evaluating the risk factors, and then implementing appropriate measures. In Belgium, this is not merely a voluntary exercise: the law requires every employer to actively manage the risks associated with manual handling. This article answers the most frequently asked questions about assessing lifting risks, from the legal basis to concrete steps and tools.

What are the risks associated with manual lifting?

Manual lifting involves significant physical risks, including back pain, muscle pain, joint disorders, and chronic musculoskeletal conditions. These conditions do not always develop suddenly, but build up over time due to repeated exposure to overexertion. They are one of the most common causes of long-term sick leave in industrial and logistics settings.

The risks depend on several factors that together determine the overall burden:

• Weight and size of the load: Heavy or awkward loads greatly increase the risk of overexertion.
• Postures while lifting: Bending over, twisting, or reaching increases the strain on the spine.
• Frequency and duration: Repeated lifting without adequate recovery leads to cumulative damage.
• Work Environment: Confined spaces, slippery floors, or extreme temperatures increase the risk.
• Individual factors: Age, physical condition, and work experience all play a role in an employee’s vulnerability.

A thorough analysis of the application always begins with identifying these risk factors for each workstation, so that no element is overlooked.

What are the legal requirements for manual lifting in Belgium?

In Belgium, employers are legally required to identify, assess, and control the risks associated with manual handling. The legal basis for this is the Codex on Well-Being at Work, specifically the provisions regarding the manual handling of loads. This legislation requires employers to first implement organizational and technical measures before resorting to personal protective equipment or instructions.

In practical terms, this means that every employer must conduct a risk assessment for manual lifting for all positions in which employees manually move loads. Preventive measures must be taken based on that assessment. Belgian legislation follows European Directive 90/269/EEC, which establishes minimum standards for the protection of workers engaged in manual handling.

The internal occupational safety and health department or an external occupational safety and health consultant plays a central role in preparing and following up on these analyses. In the event of a work-related accident or occupational disease resulting from manual lifting, the employer may be held liable if no verifiable risk analysis was conducted.

How do you conduct a step-by-step risk analysis for lifting operations?

A risk analysis for lifting involves five consecutive steps: identify the lifting tasks, assess the risk factors, determine the risk level, propose measures, and evaluate their effectiveness. This approach provides a structured and repeatable method that complies with legal requirements.

1. Identify all lifting tasks: Determine which employees lift which loads, how often, and under what conditions. Observe the workstation and interview the employees directly.
2. Assess the risk factors: Analyze the weight, lifting frequency, body postures, reach distance, and work environment. Use a validated method or checklist.
3. Determine the risk level: Combine the factors to arrive at an overall assessment: low, moderate, or high risk. This determines the urgency of the measures.
4. Propose measures: Develop an action plan that includes technical aids, organizational changes, or training. Prioritize measures that address the root cause.
5. Evaluate and revise: After implementation, verify that the risks have been effectively reduced. Repeat the analysis whenever there are changes to the workstation or the production process.

What tools and methods are used in a lifting risk assessment?

There are various validated methods and tools for assessing lifting risks, each with its own scope of application. The most commonly used are the NIOSH Lifting Task Equation, the KIM method, and the REBA method. The choice depends on the complexity of the lifting task and the available expertise.

NIOSH Lifting Task Comparison

The NIOSH method calculates a recommended weight limit based on factors such as lifting frequency, reach distance, trunk rotation, and the ability to grip the load. The result is a lifting index: a value above 1 indicates an increased risk. This method is particularly suitable for repetitive lifting tasks involving a fixed load.

KIM Method (Key Indicator Method)

The KIM method is a tool developed in Germany that can be quickly and practically applied in the workplace. It assesses key indicators such as duration, weight, body posture, and working conditions. The method generates a score that indicates the level of risk and helps prioritize measures. It is also suitable for less specialized users.

When is a free job analysis the right first step?

A free workstation analysis is the right first step if, as an employer, you suspect that lifting tasks in your company pose a risk but do not yet know how serious that risk is or what measures are appropriate. It is also recommended when setting up a new workstation, following a workplace accident, or in the event of repeated complaints from employees about physical strain.

A workstation analysis conducted by a specialist offers more than just an internal checklist: an outside perspective identifies risks that are overlooked internally, and the recommendations can be directly translated into concrete solutions. It serves as the bridge between the risk analysis and the implementation of ergonomic measures.

For companies that work with a variety of materials, such as pallets, boxes, or bags, a workstation analysis is particularly valuable, as lifting risks can vary significantly depending on the specific application.

What measures reduce the risks associated with manual lifting?

The risks associated with manual handling can be reduced through a combination of technical aids, organizational measures, and training. The most effective approach is to eliminate the cause of the strain rather than merely mitigating its effects. Technical solutions such as hoists, lifting aids, and transport equipment are generally the most sustainable.

Specific measures include:

• Ergonomic lifting equipment: Vacuum lifters, mobile lifters, and pallet trucks reduce the physical strain on employees. They are available for a wide range of loads and applications.
• Workstation adjustments: Height-adjustable work surfaces, improved access to loads, and sufficient space to move around help reduce poor posture.
• Organizational measures: Job rotation, adequate rest breaks, and limiting the frequency of lifting reduce cumulative strain.
• Training and instruction: Employees learn how to lift properly and are made aware of the risks associated with poor posture.
• Smaller packaging units: By reducing the weight per unit, the load per lifting operation is significantly reduced.

Choosing the right product is crucial: a lifting aid that isn't suited to the specific application won't solve the problem and may even create new challenges.

How Logitrans Handling Helps with Risk Analysis for Manual Lifting Operations

We guide companies through the entire process of addressing lifting risks in the workplace. Our approach combines practical expertise with a wide range of ergonomic solutions:

• Free Workstation Analysis: Our specialists will analyze your lifting operations on-site and identify the specific risk factors for each workstation.
• Customized Solutions: Based on the analysis, we propose an ergonomic lifting solution tailored to your specific load, frequency, and work environment.
• Extensive product range: From vacuum lifters and mobile lifters to pallet trucks—we have the right tools for every application.
• Demonstration Area in Drongen: You can test our lifting solutions with your own materials to ensure you make the right choice for your situation.
• Training and Maintenance: We provide user training upon installation and offer maintenance contracts to ensure a consistently safe workstation.

Would you like to know how your workstations rate in terms of lifting risks? Contact us for a no-obligation workstation analysis and discover which ergonomic measures can make a difference for your employees and your business results.

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