Manual Handling Training

OBR Construction — Mandatory Health & Safety Module

~25 minDuration

10Questions

75%Pass Mark

12 MonthsCertificate Validity

Your Full Name

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! Why This Training Matters

Manual handling injuries are the most common cause of workplace injury in the UK, accounting for over a third of all work-related injuries reported each year. In construction, workers regularly lift heavy, awkward, or cumbersome materials — making the risk even higher.

Musculoskeletal disorders (MSDs) resulting from poor manual handling include back injuries, joint damage, and repetitive strain injuries. Many of these are permanent and life-changing — but the vast majority are preventable with the right knowledge and technique.

⚠️ Note: This training covers manual handling awareness and safe technique. It does not replace task-specific assessments for very heavy or specialist lifting operations, which require separate evaluation.

1 The Legal Framework

Manual handling is governed by the Manual Handling Operations Regulations 1992 (MHOR 1992), as amended in 2002. These regulations implement a European Directive and apply to all workplaces.

The Hierarchy of Control under MHOR 1992:

Avoid the hazardous manual handling operation if it is reasonably practicable to do so — use mechanical aids, restructure the task
Assess any manual handling operations that cannot be avoided — using the TILE or TILEO framework
Reduce the risk of injury as far as is reasonably practicable — through task redesign, mechanical aids, team lifting, training

📋 Employer Duties:

Avoid hazardous manual handling wherever reasonably practicable
Assess the risk for unavoidable operations
Reduce the risk of injury as far as possible
Provide workers with information on the weight of loads and the heaviest side of any load

👷 Your Duties:

Follow safe systems of work and training provided
Use equipment provided correctly
Report injuries, near misses, or conditions that create risk

2 Risk Assessment — The TILE Framework

Before any manual handling operation, assess the risks using the TILE framework (sometimes extended to TILEO). Each letter represents a category of risk factors to consider:

T — Task

Does the task involve twisting, stooping, or reaching? Repetitive movements? Carrying over long distances? Pushing/pulling? Unpredictable movement of loads? Insufficient rest or recovery time?

I — Individual

Does the task require unusual strength or height? Does it create a hazard for pregnant workers or those with health conditions? Does the worker have the knowledge and training to do it safely?

L — Load

Is the load heavy, bulky, or unwieldy? Is it difficult to grasp? Is the contents likely to shift or spill? Does it have sharp edges, hot surfaces, or other hazards? Is the weight distribution uneven?

E — Environment

Are floors uneven, slippery, or unstable? Is there restricted space for movement? Are there changes in floor level or stairs? Extreme temperatures? Poor lighting? Ventilation issues?

O — Other factors (TILEO extension)

PPE — does the requirement to wear gloves, boots, or other PPE affect grip or movement? Does it add weight or restrict mobility significantly?

💡 Tip: If any TILE factor increases the risk, consider how to reduce it — can a mechanical aid be used? Can the load be broken down into smaller parts? Can the route be improved?

3 Safe Lifting Technique

The correct lifting technique dramatically reduces the risk of back and joint injury. Follow these steps every time you lift a load from the ground:

1

Think before you lift

Plan the lift. Where is the load going? Is the route clear? Will you need help? Check the weight and test the load first by moving a corner.

2

Position your feet

Stand close to the load with your feet shoulder-width apart. One foot slightly forward beside the load, the other foot back to give a stable base.

3

Adopt a good posture

Bend your knees — not your back. Keep your back straight (not necessarily vertical — a slight forward lean is natural). Avoid stooping or squatting excessively.

4

Get a firm grip

Get as close to the load as possible. Use the whole hand — not just fingers. Hug the load to your body where possible to keep the centre of gravity close.

5

Lift smoothly

Lift using your legs, keeping your back straight. Move smoothly and don't jerk the load. Keep the load close to your waist throughout the lift.

6

Turn with your feet — not your back

If you need to change direction, move your feet to turn. Never twist your back while holding a load. This is one of the most common causes of back injury.

7

Set down carefully

Lower the load by reversing the lift — bend your knees, keep your back straight. If precision positioning is needed, set down first then slide the load into place.

4 Weight Guidelines & Mechanical Aids

The regulations do not set specific maximum weights — risk depends on the whole task, not just the weight. However, the HSE provides guideline figures as a starting point for assessment. These are not safe limits — they are thresholds above which detailed assessment is essential.

📊 HSE Guideline Figures (lifting and lowering):

Men: up to 25kg at knuckle height, reducing to 10kg with arms fully extended
Women: up to 16kg at knuckle height, reducing to 7kg with arms fully extended
These figures are reduced by up to 30% for frequent lifting (more than once every 2 minutes)
Loads that are bulky, asymmetric, or difficult to grip count as heavier than their actual weight

When mechanical aids should be used:

Loads above the guideline figures for the individual
Repetitive lifting that could lead to cumulative strain
Lifting in awkward spaces or across long distances
Team lifting is required but co-ordination is difficult

🔧 Common Mechanical Aids on Site

Pallet trucks and sack trucks
Wheelbarrows and trolleys
Forklifts and telehandlers
Hoists and cranes
Conveyor systems

👥 Team Lifting

When a load requires two or more people: nominate one person to give clear instructions, ensure everyone is ready before lifting, move in step, communicate throughout the lift, and set down together on a clear command.

⚠️ Never attempt to lift a load alone if it clearly requires mechanical assistance or a team lift. The cost of a back injury far outweighs any time saved.

5 Pushing, Pulling & Carrying

Manual handling is not limited to lifting — pushing, pulling, and carrying loads over distance all carry significant injury risk if done incorrectly.

Pushing vs. Pulling:

Pushing is generally safer than pulling — you can use your body weight and keep a better posture
When pushing, lean into the load with hands at waist height and walk forward
When pulling, keep the load close and avoid twisting
Always check the route before moving a load — clear obstructions first

🛞 Wheeled Equipment: Sack trucks and trolleys greatly reduce manual handling risk, but still require care. Check wheels are in good condition, ensure the load is stable and secured before moving, and never move loads faster than a brisk walking pace.

Carrying:

Keep the load close to your body — the further it is from your centre of gravity, the greater the strain
Keep your vision clear — never carry a load so large you cannot see where you are going
Avoid carrying loads up ladders — use a hoist or make multiple trips
On uneven terrain, take smaller steps and slow down
Don't carry loads for long distances without a rest — use trolleys or intermediate rest points

💡 Remember: Cumulative strain matters. A load that seems manageable once may cause injury when repeated dozens of times per day. Report any tasks you feel are causing cumulative strain to your supervisor.

6 Key Summary — What You Must Remember

✅ DO

Avoid manual handling where possible — use aids
Assess using TILE before every lift
Bend your knees, keep your back straight
Keep loads close to your body
Turn with your feet, not your back
Ask for help or use a mechanical aid for heavy loads
Report pain, near misses, or risky tasks

❌ DON'T

Bend at the waist to pick up loads
Twist your back while holding a load
Carry loads that block your vision
Ignore pain or discomfort — report it early
Jerk or snatch loads when lifting
Carry heavy loads up ladders
Work through cumulative strain without reporting it

🔁 Certificate Validity: This Manual Handling certificate is valid for 12 months from the date of issue. Annual refresher training is required.

? Knowledge Assessment

Answer all 10 questions. You must score 75% or above (8/10) to pass and receive your certificate.

Question 1 of 10

What does the "T" stand for in the TILE manual handling risk assessment framework?

Tools Task Training Time

Question 2 of 10

What is the PRIMARY approach you should take when faced with a manual handling task?

Lift it carefully using correct technique Avoid the manual handling operation altogether if reasonably practicable Ask a colleague to help Wear a back support belt

Question 3 of 10

When lifting a load from the floor, which of the following describes the correct posture?

Bend at the waist with straight legs to keep the centre of gravity low Squat fully with knees together and the load held at arm's length Bend your knees, keep your back straight, and hold the load close to your body Stand with legs together, bend forward, and grip with fingertips

Question 4 of 10

The HSE guideline figure for men lifting at knuckle height is up to:

10kg 16kg 25kg 40kg

Question 5 of 10

You need to turn and place a load onto a shelf to your right. What is the correct way to do this?

Twist your back to the right while holding the load at arm's length Move your feet to face the shelf before placing the load Lean across to the right keeping your feet still to maintain a stable base Throw the load gently onto the shelf to avoid twisting

Question 6 of 10

The primary legislation covering manual handling in the UK workplace is:

The Health and Safety at Work Act 1974 The Manual Handling Operations Regulations 1992 The Workplace (Health, Safety and Welfare) Regulations 1992 The Provision and Use of Work Equipment Regulations 1998

Question 7 of 10

When organising a team lift, who should give the instructions and co-ordinate the movement?

The strongest person in the team One nominated person who gives clear instructions before and during the lift Everyone simultaneously on the count of three The person closest to the heaviest side of the load

Question 8 of 10

Which of the following is generally SAFER when moving a heavy load on flat ground?

Pulling the load behind you Pushing the load in front of you Both are equally safe Carrying it is always better than pushing or pulling

Question 9 of 10

Manual handling injuries account for approximately what proportion of all work-related injuries in the UK?

One in ten One in five Over one third Over half

Question 10 of 10

You are asked to carry a large sheet of plywood up a ladder to a first-floor platform. What should you do?

Carry it carefully under one arm whilst holding the ladder with the other Strap it to your back to keep your hands free for climbing Use a hoist or alternative means to raise the load rather than carrying it up a ladder Ask a colleague to push the sheet up from below while you pull from above

Certificate of Completion

Manual Handling

This is to certify that

Manual Handling Awareness Training

Has successfully completed the OBR Construction Manual Handling online training module in accordance with the Manual Handling Operations Regulations 1992 and HSE guidance on safe manual handling in the construction industry.

Score Achieved

Date of Issue

Valid Until

Trainer

Martin Jones

Reference

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