Safety packs > Manual handling

Manual handling

For any firm where people lift, carry, push or pull loads by hand. The pack covers avoiding the handling, assessing it on a real task, and reducing the risk.

The hazard

The duty comes in a set order under regulation 4 of the Manual Handling Operations Regulations 1992: avoid the handling where reasonably practicable, then assess what cannot be avoided, then reduce the risk of injury. A lifting technique course on its own does not do the avoiding or the assessing.

The pack works through avoiding the handling where possible, a TILE assessment of the task, individual, load and environment recorded on a real task, safe lifting technique including moving the feet to turn rather than twisting the spine, team lifts, and when to stop and ask for help: a load heavier than expected, a blocked route, or any pain or strain.

The law that applies

What is in the pack

One hazard, done completely, for the whole firm.

Implementation guidethe legal position and the order to do it in
Risk assessmentevery hazard and control, ready to make site-specific
Safe system of workthe one to put up where the work happens
Inspection and monitoring recordpre-use checks and periodic review
Training delivery packthe session your own supervisor delivers
Theory test candidate paperblank, to be answered in ink
Practical assessment recordon your machine or task, on your site
Written authorisationnames the person and the equipment or task
Toolbox talkswith attendance sheets
Register and refresher trackerturns a one off into a system
One document held back

The pack also has a theory test answer key. It is supplied separately to the employer, not published in the pack itself, so the test stays a genuine assessment when your own supervisor marks it.

An optional verified certificate per person

Available where a customer, principal contractor or insurer wants third-party evidence.

You assess your own people in-house using the pack, and send PHW the completed records. PHW checks the records and, where they hold up, issues a certificate carrying a QR code that resolves to a live verification page. The certificate states plainly that the assessment was carried out in-house and verified by PHW, recording PHW's verification of that in-house assessment; records that are too thin are rejected rather than certified.

Which trades need this

Goods in and goods out

View →

Construction and civils

View →

Manufacturing and engineering

View →

Warehousing

View →

Agriculture

View →

Real cases

HSE prosecutions in this line of work.

Manufacturing and engineering · Buckingham

Puratos Limited fined £120,000 after exposure to dust above workplace exposure limits and manual handling risk

£120,000 + £6,270 costs · 2026-07-17

Workers were exposed to inhalable dust above exposure limits and were required to manually lift 25kg ingredient sacks daily.

Read the case →
Goods in and goods out · Middlesbrough

Ward Bros (Malton) Ltd fined £250,000 after unsecured metal frames fell back onto a worker during container devanning

£250,000 · 2025-10-31

While devanning a shipping container in the yard, a worker was fatally trapped when 120kg metal frames that had not been secured to the container wall fell back onto the worker.

Read the case →

See all real cases →