MANUAL HANDLING RISK ASSESSMENT TEMPLATE

Company: [COMPANY NAME]
Assessment Area/Task: [AREA/TASK]
Assessment Date: [DATE]
Assessed by: [NAME & POSITION]
Review Date: [DATE]
Assessment Reference: [REF NUMBER]

TASK INFORMATION:

Task Description: [DETAILED DESCRIPTION OF MANUAL HANDLING TASK]
Location: [SPECIFIC LOCATION]
Frequency: [HOW OFTEN TASK IS PERFORMED]
Duration: [HOW LONG TASK TAKES]
Workers Involved: [NUMBER AND TYPES OF WORKERS]
Shift Pattern: [DAY/NIGHT/ROTATING SHIFTS]

MANUAL HANDLING ASSESSMENT FACTORS:

1. THE LOAD
2. THE TASK
3. THE WORKING ENVIRONMENT
4. INDIVIDUAL CAPABILITY
5. OTHER FACTORS

DETAILED ASSESSMENT:

1. THE LOAD

Load Characteristics:
Weight: [WEIGHT IN KG/LBS]
Size/Dimensions: [LENGTH × WIDTH × HEIGHT]
Shape: □ Regular □ Irregular □ Awkward
Stability: □ Stable □ Unstable □ Shifting contents
Temperature: □ Normal □ Hot □ Cold
Surface: □ Smooth □ Rough □ Sharp edges □ Slippery

Load Assessment:
□ Heavy (>23kg for men, >16kg for women)
□ Bulky or unwieldy
□ Difficult to grasp
□ Unstable or unpredictable
□ Sharp, hot, or cold surfaces
□ Contents may shift

Risk Level: □ Low □ Medium □ High
Comments: [SPECIFIC CONCERNS ABOUT THE LOAD]

2. THE TASK

Task Characteristics:
Lifting: □ Yes □ No
Lowering: □ Yes □ No
Carrying: □ Yes □ No
Pushing: □ Yes □ No
Pulling: □ Yes □ No
Holding: □ Yes □ No

Lifting Details (if applicable):
Starting Height: [HEIGHT FROM FLOOR]
Ending Height: [HEIGHT FROM FLOOR]
Horizontal Distance: [DISTANCE FROM BODY]
Lifting Frequency: [LIFTS PER MINUTE/HOUR]
Team Lifting: □ Yes □ No

Task Assessment:
□ Frequent or prolonged physical effort
□ Repetitive handling
□ Insufficient rest or recovery time
□ Rate of work imposed by process
□ Unpredictable movement of loads
□ Long carrying distances
□ Strenuous pushing or pulling
□ Precise positioning of loads
□ Simultaneous lifting by two or more people
□ Frequent or prolonged bending
□ Frequent or prolonged reaching
□ Twisting or rotating the trunk

Risk Level: □ Low □ Medium □ High
Comments: [SPECIFIC CONCERNS ABOUT THE TASK]

3. THE WORKING ENVIRONMENT

Environmental Factors:
Space Constraints: □ Adequate □ Cramped □ Very restricted
Floor Conditions: □ Level □ Uneven □ Slippery □ Unstable
Lighting: □ Adequate □ Poor □ Glare problems
Temperature: □ Comfortable □ Hot □ Cold
Humidity: □ Normal □ High □ Low
Air Movement: □ Still □ Drafty □ Windy

Environmental Assessment:
□ Space constraints preventing good posture
□ Uneven, slippery, or unstable floors
□ Variations in floor levels
□ Poor lighting conditions
□ Adverse weather conditions
□ Hot, cold, or humid conditions
□ Strong air movements

Risk Level: □ Low □ Medium □ High
Comments: [SPECIFIC ENVIRONMENTAL CONCERNS]

4. INDIVIDUAL CAPABILITY

Worker Characteristics:
Age Range: [AGE RANGE OF WORKERS]
Gender: □ Male □ Female □ Mixed
Experience Level: □ Experienced □ New □ Mixed
Physical Fitness: □ Good □ Average □ Poor
Training Status: □ Trained □ Partially trained □ Untrained

Individual Assessment:
□ Requires unusual strength, height, or fitness
□ May be hazardous to pregnant women
□ May be hazardous to people with health problems
□ Requires special information or training
□ Workers lack experience or training
□ Inadequate clothing, footwear, or PPE

Risk Level: □ Low □ Medium □ High
Comments: [SPECIFIC INDIVIDUAL CAPABILITY CONCERNS]

5. OTHER FACTORS

Additional Considerations:
□ Movement or instability of loads
□ Inadequate information about load weight
□ Lack of training in manual handling techniques
□ Inadequate supervision
□ Time pressures
□ Incentive schemes encouraging unsafe practices
□ Inadequate personal protective equipment

Risk Level: □ Low □ Medium □ High
Comments: [OTHER SPECIFIC CONCERNS]

RISK EVALUATION:

OVERALL RISK ASSESSMENT:
Load Risk: □ Low □ Medium □ High
Task Risk: □ Low □ Medium □ High
Environment Risk: □ Low □ Medium □ High
Individual Risk: □ Low □ Medium □ High
Other Factors Risk: □ Low □ Medium □ High

COMBINED RISK LEVEL: □ Low □ Medium □ High

RISK CALCULATION:
Using Manual Handling Assessment Charts (MAC) or similar:
Lifting Score: [SCORE]
Carrying Score: [SCORE]
Team Handling Score: [SCORE]
Overall Score: [TOTAL SCORE]

CONTROL MEASURES:

HIERARCHY OF CONTROLS:

1. ELIMINATION:
□ Eliminate manual handling completely
□ Automate the process
□ Redesign work to avoid handling
Current Status: [FEASIBLE/NOT FEASIBLE]
Actions: [SPECIFIC ACTIONS IF FEASIBLE]

2. REDUCTION:
□ Reduce weight of loads
□ Reduce frequency of handling
□ Reduce carrying distances
□ Improve load design
Actions Required: [SPECIFIC REDUCTION MEASURES]

3. MECHANICAL AIDS:
□ Conveyor systems
□ Hoists and cranes
□ Trolleys and carts
□ Lift tables
□ Vacuum lifters
□ Powered trucks
Current Equipment: [LIST CURRENT MECHANICAL AIDS]
Additional Equipment Needed: [SPECIFY REQUIREMENTS]

4. IMPROVED HANDLING TECHNIQUES:
□ Team lifting procedures
□ Proper lifting techniques
□ Use of handles or grips
□ Improved packaging
□ Better storage arrangements
Training Required: [SPECIFY TRAINING NEEDS]

5. ENVIRONMENTAL IMPROVEMENTS:
□ Better lighting
□ Improved flooring
□ Climate control
□ More space
□ Better layout
Improvements Needed: [SPECIFY IMPROVEMENTS]

6. PERSONAL PROTECTIVE EQUIPMENT:
□ Safety footwear
□ Gloves for grip
□ Back support belts (if appropriate)
□ Protective clothing
PPE Required: [SPECIFY PPE REQUIREMENTS]

SPECIFIC CONTROL MEASURES:

IMMEDIATE CONTROLS (0-24 hours):
1. [CONTROL MEASURE]
   Responsible: [NAME]
   Target Date: [DATE]
   Cost: [ESTIMATED COST]

2. [CONTROL MEASURE]
   Responsible: [NAME]
   Target Date: [DATE]
   Cost: [ESTIMATED COST]

SHORT-TERM CONTROLS (1-30 days):
1. [CONTROL MEASURE]
   Responsible: [NAME]
   Target Date: [DATE]
   Cost: [ESTIMATED COST]

2. [CONTROL MEASURE]
   Responsible: [NAME]
   Target Date: [DATE]
   Cost: [ESTIMATED COST]

LONG-TERM CONTROLS (30-90 days):
1. [CONTROL MEASURE]
   Responsible: [NAME]
   Target Date: [DATE]
   Cost: [ESTIMATED COST]

2. [CONTROL MEASURE]
   Responsible: [NAME]
   Target Date: [DATE]
   Cost: [ESTIMATED COST]

TRAINING REQUIREMENTS:

MANUAL HANDLING TRAINING CONTENT:
□ Basic anatomy and physiology
□ Common manual handling injuries
□ Risk factors for injury
□ Proper lifting techniques
□ Team lifting procedures
□ Use of mechanical aids
□ When to seek help
□ Reporting procedures

TRAINING SCHEDULE:
Initial Training: [DATE]
Refresher Training: [FREQUENCY]
Specialized Training: [AS REQUIRED]

TRAINING RECORDS:
Training Provider: [PROVIDER]
Training Documentation: [LOCATION]
Competency Assessment: [METHOD]

HEALTH SURVEILLANCE:

HEALTH MONITORING:
Pre-employment Screening: □ Required □ Not Required
Periodic Health Checks: □ Required □ Not Required
Post-incident Evaluation: □ Required □ Not Required

HEALTH SURVEILLANCE PROGRAM:
Medical Provider: [PROVIDER NAME]
Examination Frequency: [FREQUENCY]
Health Records: [RECORD KEEPING SYSTEM]

INJURY REPORTING:
Reporting Procedure: [PROCEDURE]
Investigation Process: [PROCESS]
Return to Work Program: [PROGRAM DETAILS]

MONITORING AND REVIEW:

PERFORMANCE INDICATORS:
□ Injury rates
□ Absence rates
□ Worker complaints
□ Near-miss reports
□ Control measure effectiveness

MONITORING METHODS:
□ Regular workplace inspections
□ Worker feedback sessions
□ Injury/incident analysis
□ Control measure audits
□ Training effectiveness review

REVIEW SCHEDULE:
Routine Review: [FREQUENCY]
Triggered Review: [TRIGGERS]
Next Review Date: [DATE]

REVIEW TRIGGERS:
□ Significant changes to task
□ New equipment introduction
□ Injury or incident occurrence
□ Worker complaints
□ Control measure failure

COST-BENEFIT ANALYSIS:

CURRENT COSTS:
Injury Costs: $[AMOUNT] per year
Absence Costs: $[AMOUNT] per year
Insurance Costs: $[AMOUNT] per year
Total Current Costs: $[TOTAL]

CONTROL MEASURE COSTS:
Equipment Costs: $[AMOUNT]
Training Costs: $[AMOUNT]
Implementation Costs: $[AMOUNT]
Ongoing Costs: $[AMOUNT] per year
Total Control Costs: $[TOTAL]

EXPECTED BENEFITS:
Injury Reduction: [PERCENTAGE]
Cost Savings: $[AMOUNT] per year
Payback Period: [TIME PERIOD]
Return on Investment: [PERCENTAGE]

EMERGENCY PROCEDURES:

INJURY RESPONSE:
First Aid: [FIRST AID PROCEDURES]
Medical Emergency: [EMERGENCY PROCEDURES]
Incident Reporting: [REPORTING PROCEDURES]
Investigation: [INVESTIGATION PROCEDURES]

EQUIPMENT FAILURE:
Mechanical Aid Failure: [PROCEDURES]
Alternative Methods: [BACKUP PROCEDURES]
Repair/Replacement: [PROCEDURES]

APPROVAL AND SIGN-OFF:

Manual Handling Assessment Completed by:
Name: _________________ Position: _________________
Signature: _________________ Date: _________________

Reviewed by Supervisor:
Name: _________________ Position: _________________
Signature: _________________ Date: _________________

Approved by Manager:
Name: _________________ Position: _________________
Signature: _________________ Date: _________________

Occupational Health Review:
Name: _________________ Position: _________________
Signature: _________________ Date: _________________

DISTRIBUTION:
□ Department Manager
□ Supervisor
□ Safety Department
□ Occupational Health
□ Affected Workers
□ Training Department

DOCUMENT CONTROL:
Document ID: MHA-[TASK]-001
Version: 1.0
Created: [DATE]
Last Modified: [DATE]
Next Review: [DATE]
Retention Period: [YEARS]

APPENDICES:
A. Task Photographs
B. Load Specifications
C. Equipment Manuals
D. Training Materials
E. Medical Guidance
F. Regulatory Requirements