Understanding the Misleading "No Maximum Weight" Guidance in Manual Handling

When it comes to manual handling in the workplace, one of the most commonly misunderstood pieces of advice from the Health and Safety Executive (HSE) is the idea that "there is no maximum weight limit for lifting." While this guidance aims to promote a risk-based, case-by-case approach, it can lead to misinterpretations and unsafe practices if the full context isn’t understood.

Results From My Recent Poll

It is really interesting to see that 74% of people who voted went for the correct legal stance as the word "must" in the context of the MAC tool is not, by itself, a direct legal requirement. Instead, it reflects the need for action based on the level of risk identified. The legal requirement is derived from the Manual Handling Operations Regulations 1992.

25% of people went for the famous "25kg" which is a common myth explained below

Historical Context of the 25kg Myth

• In the past, 50kg was the standard maximum weight for certain commercial sacks, such as those used in agriculture, construction, or transport.
• Over time, there was a recognition of the high injury rates and the unsuitability of such heavy loads for the majority of workers. As a result, many industries voluntarily reduced the standard sack weight to 25kg to mitigate risks.
• This reduction created an association between 25kg and what people perceived as a "safe" or "legal" maximum weight.

Why the Myth Persists

• The reduction to 25kg in commercial practices became well-publicised and was widely adopted as a guideline by businesses. Over time, this number became ingrained as a perceived "maximum weight."
• Poor manual handling training courses and casual discussions often mention this figure, reinforcing the misconception that it's a universal legal standard.
• People may not be aware that safe manual handling depends on multiple factors, including posture, grip, and the physical characteristics of the individual performing the task.

The other votes went to 50kg and none went to 75kg which is great to see!

The Role of L23 Manual Handling Guidance

The L23 Manual Handling Operations Regulations 1992 guide emphasises the need for individual assessments when determining whether a manual handling task is safe. The guidance stresses that there isn’t a universal weight limit for lifting because factors such as the task, individual capabilities, environment, and load characteristics all influence what is considered safe.

The intention is to move away from rigid rules and encourage employers and employees to make informed decisions depending on circumstances. Workers are advised to assess whether a task is comfortable for them, with the understanding that manual handling varies greatly between individuals.

The MAC Tool and the Weight Risk Threshold

An important, often overlooked part of the HSE’s manual handling guidance is the Manual Handling Assessment Charts (MAC tool). This tool provides a structured method for evaluating lifting and lowering tasks, and it introduces specific thresholds to guide risk assessments.

In the MAC tool’s Section A - Load weight/frequency, tasks are categorised based on risk levels:

• Green Zone: Indicates a low risk, generally acceptable.
• Amber Zone: Moderate risk; steps should be taken to reduce risks if reasonably practicable.
• Red Zone: High risk; requires urgent improvement.
• Purple Zone: "Unacceptable level of risk."

For lifting tasks performed by a single person, the purple zone begins at 50kg. The MAC tool specifies that operations falling into this category “may represent a serious risk of injury and must be improved.” This introduces a practical limit, clearly establishing that loads of 50kg or more require significant risk controls or should not be performed by one individual without intervention. However this is based on lifting that item only once a day if that individual was to start lifting that item once a minute this drops to 45kg and then if it was around one lift every 5 seconds then it drops to around 24kg.

Clarifying the HSE's Guidance

While it’s true that there isn’t a fixed universal weight limit applicable to all situations, the MAC tool provides specific thresholds that act as practical guidance. This is particularly critical for high-risk tasks, where exceeding 50kg represents a clear boundary requiring additional controls or mechanical assistance.

By not fully incorporating the MAC tool’s risk categories, some employers may mistakenly believe that subjective judgment alone is sufficient for compliance. However, relying solely on individual comfort can lead to serious risks, especially for tasks involving heavy or awkward loads.

The use of "must" in the context of the purple risk level indicates a strong recommendation for improvement. However, it's essential to understand this within the framework of the Manual Handling Operations Regulations 1992 (MHOR). MHOR establishes a hierarchy of measures for managing manual handling risks:

1. Avoid hazardous manual handling operations as far as reasonably practicable.
2. Assess any hazardous manual handling operations that cannot be avoided.
3. Reduce the risk of injury to the lowest level reasonably practicable.

The term "reasonably practicable" implies that the extent of the risk should be balanced against the time, trouble, and cost of the measures needed to control it. Therefore, while the MAC tool's "must be improved" highlights the necessity for action, MHOR requires that any improvements be implemented to the extent that they are reasonably practicable.

In summary, identifying an "unacceptable level of risk" using the MAC tool necessitates action to mitigate that risk. The legal obligation is to reduce the risk as far as reasonably practicable, which may involve reducing the load weight or implementing other control measures. Employers should assess the specific circumstances and determine appropriate actions to ensure compliance with health and safety regulations.

What Employers Should Do

To ensure manual handling practices are both safe and compliant, employers should:

1. Use the MAC Tool in Risk Assessments: Include the MAC tool when evaluating manual handling tasks.
2. Avoid Over reliance on Subjectivity: While individual assessments are important, they should complement—not replace—objective risk evaluation tools.
3. Mitigate Risks for High-Weight Loads: For tasks involving weights near or exceeding 50kg, implement mechanical aids, team lifting, or eliminate manual handling altogether where possible.
4. Train Employees in Safe Practices: Ensure that all workers understand the HSE’s guidance and how the MAC tool informs safe weight limits.

Conclusion

The HSE’s guidance of “no maximum weight set” encourages flexibility and risk-based decision-making in manual handling tasks. However, without referencing the MAC tool’s weight thresholds, this guidance can be misinterpreted, leading to unsafe practices. Recognising that loads exceeding 50kg for a single person fall into the "unacceptable risk" category ensures employers are not only compliant but proactive in protecting their workforce.

Effective manual handling is about more than just the weight of the load—it’s about understanding and applying risk management principles. By integrating the MAC tool into your assessments, you can move beyond the myth of "no limits" and embrace a safer, more structured approach.