Manual lifting is one of the most common causes of workplace accidents and occupational diseases in Belgium. Back pain, muscle strains, and joint problems cost companies a great deal in lost productivity each year and cause unnecessary suffering among employees. Yet there is still a great deal of uncertainty surrounding the legislation on manual lifting: how many kilograms is an employee allowed to lift, what risk factors are involved, and what are the employer’s obligations?
This article explains, step by step, how to correctly apply Belgian lifting standards, how to assess risks, and what measures you can take to protect your employees. Whether you’re an HR manager, a safety advisor, or a supervisor, after reading this article, you’ll have a concrete action plan.
An Overview of the Legal Lifting Standards in Belgium
First, identify the legal framework that applies to your situation. In Belgium, the legislation governing manual handling of loads is set forth in the Royal Decree of August 12, 1993, which transposes European Directive 90/269/EEC into Belgian law. This decree is included in the Codex on Workplace Well-Being.
What does that legislation specifically say about the maximum lifting weight for employees? Belgian regulations do not set absolute limits in kilograms, but refer to a requirement to conduct a risk assessment. Nevertheless, in practice, the following reference values are used as guidelines:
- Adult men: up to 25 kg under ideal lifting conditions
- Adult women: up to 15 kg under ideal lifting conditions
- Young people (under 18): lower limits depending on age and gender
- Pregnant employees: special protection, significantly lowered limits
After this step, check whether your current work conditions fall within these reference values. If a task exceeds these limits, you, as an employer, are required to take action. Important: These values apply only under optimal conditions. In practice, the safe limits are often lower due to additional risk factors.
Risk factors that affect the maximum lifting limit
Next, determine which risk factors lower the actual lifting limit in your situation. The regulations governing manual lifting explicitly require that you assess not only the weight but also the conditions under which the lifting takes place. A 20-kg load can be completely safe in one situation and pose a serious risk in another.
Systematically analyze the following categories of risk factors:
- Characteristics of the load: Is the load too heavy, too large, difficult to grip, unstable, or does it contain hazardous materials? An unwieldy 15-kg box can be more dangerous than a compact 20-kg load.
- Physical exertion: Does the employee have to turn, bend, reach, or assume an uncomfortable position while lifting?
- Characteristics of the work environment: Is the floor slippery, uneven, or sloped? Is there insufficient space? Are the temperature or humidity levels extreme?
- Task Frequency: How often is lifting performed per hour or per day? How long does the lifting task last continuously?
- Individual factors: Does the employee have limited physical ability, little experience, or is he wearing protective clothing that restricts movement?
Verify your analysis by noting, for each risk factor, whether it is present and to what extent. The more risk factors that are present, the lower the safe lifting limit will be in practice. This forms the basis for the next step: the NIOSH method.
Applying the NIOSH Method for Safe Lifting
Now apply the NIOSH method to calculate an objective, scientifically based lifting limit for a specific lifting task. The NIOSH method (developed by the U.S. National Institute for Occupational Safety and Health) is internationally recognized and is also recommended in Belgium by the FPS Employment as a tool for ergonomic lifting.
Calculate the recommended lifting limit
The method calculates a Recommended Weight Limit (RWL) based on six measurable variables. First, collect the following data for the lifting task you want to assess:
- Horizontal distance (H): Measure the horizontal distance in centimeters between the center of the load and the center of the body at the moment of lifting.
- Vertical height (V): Measure the height of the hands relative to the floor at the start of the lift.
- Vertical displacement (D): Measures the difference in height between the start and end of the lift.
- Rotation Angle (A): Measure the angle, in degrees, by which the worker rotates while lifting.
- Grip Quality (C): Assess whether the load is easy (good handles), moderate, or difficult to grip.
- Lifting Frequency (F): Count the number of lifting movements per minute and the total lifting time per day.
Next, calculate the RWL by multiplying the base value of 23 kg by six multiplication factors—one for each variable. Each factor has a value between 0 and 1, with a more severe situation resulting in a lower factor. The final result is the maximum weight that can be safely lifted under those specific conditions. Then, divide the actual weight of the load by the RWL to calculate the Lifting Index (LI). An LI greater than 1 indicates an increased risk that requires corrective action.
Using Assistive Devices to Reduce Lifting Risks
Once you know which lifting tasks pose an increased risk, the next step is to take action. Belgian law requires employers to first consider technical and organizational measures before using personal protective equipment. Technical aids are the most effective solution in this regard.
Choose the right tool based on the type of load and the work environment. Review the available applications for an overview of solutions by load type. Consider the following categories:
- Vacuum lifters and hoists: Ideal for handling sheets, boxes, and other flat or smooth loads. They virtually eliminate the need for manual lifting. More information about vacuum lifters and hoists will help you make the right choice.
- Mobile lifts: Suitable for lifting and moving heavy loads at various work locations. Browse our selection of mobile lifts to see the available options.
- Pallet trucks and pallet handling: For moving pallets without manual lifting. Essential for pallet handling in warehouses and production environments.
- Ergonomic work positions: Adjustable work surfaces, lifting platforms, and tilting tables ensure that employees always work at the correct height, which reduces bending and reaching.
After implementation, verify that the Lifting Index for the relevant lifting tasks has fallen below 1. If necessary, perform a new NIOSH calculation based on the changed conditions to confirm the effectiveness of the assistive device.
Employer Obligations Regarding Manual Handling of Loads
Finally, make sure that, as an employer, you are in full compliance with all legal obligations. Belgian law establishes a clear hierarchy of obligations regarding manual handling of loads. Follow these steps to ensure compliance:
- Conduct a risk analysis: Identify all lifting tasks in your company and systematically assess them for risk, preferably using the NIOSH method or an equivalent tool.
- Take preventive measures: Avoid manual lifting whenever possible by using mechanization or automation. Use technical aids if manual lifting cannot be completely avoided.
- Informing and Training Employees: Every employee who manually handles loads must be informed about the risks and trained in proper lifting techniques.
- Documenting the workstation analysis: Record the risk analysis and the measures taken in writing in the general prevention plan or the annual action plan.
- Organizing Health Monitoring: Employees who regularly handle heavy loads are subject to enhanced health monitoring. Involve the occupational physician in a timely manner.
Check annually to ensure that your measures are still up to date, especially in the event of changes to work processes, new employees, or changing production conditions. The law requires a dynamic prevention policy, not a one-time action.
How Logitrans Handling Helps Ensure Ergonomic and Safe Lifting
We understand that the transition from risk analysis to a concrete solution can be complex in practice. Logitrans Handling supports you at every stage of this process, from the initial workstation analysis to the implementation of the right tool.
Here's what we do for you, specifically:
- Free Workstation Analysis: Our specialists will visit your workplace and identify lifting risks so you know exactly where action is needed.
- Customized Solutions: Based on your specific situation, we select the most suitable ergonomic lifting equipment, whether it’s vacuum lifters, mobile lifters, or pallet-handling solutions.
- Demonstration Area in Drongen: You can test the lifting solutions with your own materials before making a decision.
- Training upon installation: We ensure that your employees use the equipment correctly and safely from day one.
- Maintenance Contracts: Through our service department, we keep your material-handling equipment in top condition to ensure continued safety.
Would you like to know how you can specifically reduce lifting risks in your company and ensure full compliance with Belgian law? Contact us, and we’ll be happy to assist you with a no-obligation consultation.
Related Articles
- What type of lifting aid do I need to move rolls?
- How can I reduce absenteeism due to physical strain in my warehouse?
- How can I prevent goods from falling or getting damaged while lifting them?
- Does an ergonomic lifting solution work even at a high picking pace?
- Can I receive a grant for ergonomic equipment in Belgium?
