On average, a person should not lift boxes continuously for longer than a full workday without adequate breaks and variety in tasks. Belgian and European labor laws do not specify a fixed maximum number of lifting hours per day, but they do require employers to limit the lifting workload through risk assessments and ergonomic measures. How long it is safe to lift depends on the weight of the boxes, the frequency of lifting, the posture, and the employee’s individual capacity. In this article, we answer the most frequently asked questions about safe and ergonomic lifting in the workplace.
What are the legal limits for lifting at work?
The law does not impose an absolute maximum number of hours per day for lifting boxes, but it does require employers to limit and assess the manual handling of loads. European Directive 90/269/EEC, transposed into the Belgian Code on Well-Being at Work, requires every employer to conduct a risk assessment for tasks involving the manual handling of loads by employees. If that assessment identifies risks, the employer must take appropriate measures.
In practical terms, this means that employers are required to:
- to reduce the lifting load through technical or organizational measures
- to inform employees about safe lifting techniques
- to provide lifting aids when the risk is real
- take into account vulnerable groups such as pregnant employees and young people
So while there is no legal limit of “a maximum of four hours of lifting per day,” the obligation to actively manage risks is indeed enshrined in law. Any employer who fails to take action when a lifting risk has been identified is in violation of occupational health and safety laws.
What is the maximum weight in kilograms you're allowed to lift per day?
There is no legally established absolute maximum weight per lift in Belgium, but the generally accepted guideline is 25 kg for men and 15 kg for women under optimal lifting conditions. These values apply to occasional lifting, in a neutral posture, close to the body, and at a comfortable height. For repeated lifting or under unfavorable conditions, the safe limits are considerably lower.
To determine the total daily lifting load, ergonomists use the concept of the cumulative lifting index. This takes into account not only the weight per lift, but also the frequency, duration, and posture. An employee who lifts 10-kg boxes all day while bending over is at just as much risk as someone who lifts heavy loads only occasionally.
Practical guidelines for safe lifting at work:
- Lift boxes as close to your body as possible
- Keep your back straight and bend your knees
- Avoid twisting your torso while lifting
- Limit lifting motions above shoulder height or below knee height
- Alternate manual labor with other tasks to prevent overexertion
Less effort, more performance
Lift more efficiently with ergonomic lifting solutions. Our specialists are happy to work with you to find the right solution.
What factors determine how long you can lift boxes?
The amount of time a person is allowed to lift boxes each day is determined by a combination of factors that together make up the total lifting load. The weight of the box is only one variable. Equally important are the lifting frequency, the duration of lifting, the lifting technique, and the employee’s personal capacity.
Work-related factors
- Weight of the load: the heavier it is, the shorter the safe lifting time
- Lifting frequency: more than one lift per minute rapidly increases the risk
- Lifting height: Lifting above shoulder height or from a deep squat puts extra strain on the body
- Carrying distance: the farther the load is carried, the greater the load
- Ease of Grasping: Boxes without handles or with smooth surfaces require more muscle strength
Individual Factors
- Age: Young people and older adults are more susceptible to strain from lifting
- Physical condition: Back problems or a weak core increase the risk
- Experience and Lifting Technique: Proper Technique Significantly Reduces the Strain
- Pregnancy: Requires Adjusted Tasks and Lower Weight Limits
A thorough risk analysis takes all of these factors into account. The box-handling systems used in practice are specifically designed to systematically reduce these risk factors.
What are the risks of lifting boxes for too long or that are too heavy?
Lifting boxes that are too heavy or for too long can eventually lead to musculoskeletal disorders, the most common of which are back problems. Repeated strain on the spine, shoulders, and wrists causes wear and tear that builds up gradually and only becomes noticeable later as pain or limited mobility. Back pain caused by lifting is one of the leading causes of long-term sick leave in industrial settings.
The most common conditions caused by excessive lifting:
- Lower Back Pain and Herniated Discs: Caused by Strain on the Intervertebral Discs
- Shoulder and neck pain: when lifting above shoulder height or lifting asymmetrically
- RSI and wrist pain: from repeatedly gripping and carrying boxes
- Muscle tears and acute injuries: caused by sudden overexertion or improper lifting technique
In addition to the human cost, there are also direct business consequences: higher absenteeism costs, loss of productivity, and potential liability for the employer. Prevention therefore pays off in several ways.
How can you reduce the strain of lifting when handling boxes?
Reducing the lifting load when handling boxes starts with adapting the work environment and work organization, even before individual lifting techniques are considered. The most effective approach combines technical measures, organizational changes, and behavioral changes.
Technical measures to reduce lifting strain:
- Adjust work surfaces to the correct height to avoid lifting while bent over
- Use ramps, slides, or roller conveyors to move boxes without lifting them
- Divide heavy boxes into smaller, lighter units
- Provide handles or ergonomic packaging that makes it easier to grip
Organizational measures:
- Alternate between work and other tasks to allow muscle groups to recover
- Schedule enough breaks during intensive lifting work
- Never assign a single person to do nothing but lifting work all day long
- Offer training in ergonomic lifting techniques
When is it time to use lifting aids?
Lifting aids are recommended as soon as the lifting load exceeds safe limits or when employees regularly handle loads weighing more than 15 to 25 kg. The use of mechanical aids is also not a luxury but a necessity in cases of high lifting frequencies, unfavorable lifting heights, or when employees develop symptoms. Waiting until injuries occur is too late.
Clear signs that it's time for lifting aids:
- Employees lift more than 25 kg (men) or 15 kg (women) every day
- Lifting work is repeated more than once per minute for extended periods
- Boxes are lifted from a bent or twisted position
- Employees report back or shoulder pain after lifting tasks
- Absenteeism in the department is rising without any other apparent cause
In many cases, the available vacuum lifters and hoists are the most efficient solution for repeatedly lifting boxes, as they virtually eliminate physical strain while maintaining or even increasing the work speed.
How Logitrans Handling Helps with Ergonomic Box Lifting
We guide companies from analysis to solution when it comes to the safe and ergonomic handling of boxes. Our approach is practical and tailored to each client’s needs:
- Free workplace analysis: We assess the lifting loads in your workplace and identify the risk factors
- Customized solutions: from vacuum lifters and mobile lifters to fully integrated handling solutions tailored to your specific situation
- Demonstration Area in Drongen: Test the lifting solution with your own boxes before you decide
- Training and support: We ensure proper implementation and provide training for your employees if desired
- Maintenance Contracts: To ensure your lifting equipment always remains in top condition through our service department
An investment in ergonomic lifting equipment pays for itself through reduced absenteeism, increased productivity, and a healthier workplace. Contact us for a no-obligation consultation about the lifting situation at your company.
Less effort, more performance
Lift more efficiently with ergonomic lifting solutions. Our specialists are happy to work with you to find the right solution.
