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Manual handling risk assessment template

Manual handling injuries are among the most common workplace injuries, and under the Health and Safety at Work etc. Act 1974 a employer must manage the risks of hazardous manual tasks. This template uses the TILEO method, examining the Task, Individual, Load, Environment and Other factors, to find where the risk actually sits.

Who it's for: health and safety managers and supervisors assessing lifting, carrying, pushing, pulling or repetitive handling tasks.

Free to use and adapt · Last updated 2026-07-27 · No email required

Assessment details

Assessor name and role
Task being assessed e.g. unloading stock deliveries to the storeroom, transferring a client from bed to chair
Location
How often the task is performed Times per shift or per week, and typical duration
Date of assessment
Scheduled review date

T - Task

Tick every factor that applies. Each tick is a risk factor to address in the controls table.

  • Holding loads away from the body
  • Twisting, stooping or reaching upwards
  • Large vertical movement, such as floor to shoulder height
  • Long carrying distances, over about 10 metres
  • Strenuous pushing or pulling, especially to start a load moving
  • Repetitive handling with insufficient rest or recovery time
  • Sudden or unpredictable movement of the load
  • Work rate imposed by a process, machine or schedule
  • Handling while seated or in a restricted posture

I - Individual

  • Task requires unusual strength or height
  • Workers new to the task or returning from injury perform it
  • Task performed by workers who are pregnant or have a known health condition affecting handling
  • Workers have not been trained in the technique for this specific task
  • Task creates pressure to rush or skip technique, such as end-of-shift deadlines

L - Load

  • Heavy for the person and posture involved
  • Bulky, unwieldy or blocks vision when carried
  • Difficult to grip: smooth, greasy, no handles
  • Unstable, unbalanced or contents that shift
  • Hot, cold, sharp or otherwise harmful to touch
  • A person or animal rather than an object, so movement is unpredictable

E - Environment

  • Constrained space restricting posture
  • Uneven, slippery or unstable floors
  • Steps, slopes or level changes on the route
  • Poor lighting along the handling route
  • Hot, cold or humid conditions
  • Obstructions, doors or congestion on the route

O - Other factors

PPE or clothing that restricts movement Gloves that reduce grip, respirators that limit vision
Equipment condition Trolley wheels, hoist service dates, worn handles
Anything else observed Workers' own reports of strain, discomfort or awkwardness with this task

Rate the risk and record controls

Rate the overall task low, medium or high, considering the ticks above and how often the task is done. Work down the hierarchy: eliminate the handling, reduce the load or distance, provide mechanical aids, and only then rely on technique and training.

Risk factor (from TILEO)RatingControlOwner and due date
    
    
    
    

Assessed by [assessor], approved by [manager] on [date]. Review by [review date], or sooner if the task, load or environment changes, an injury or near miss occurs, or a worker reports discomfort with the task.

How to use it

Getting the most out of this template

  • Watch the task being performed at normal pace before ticking anything. The real task often differs from the documented one.
  • Ask the workers doing the task where it hurts and what they would change. Discomfort reports are early warnings.
  • Prioritise controls that change the task, load or environment. Training in lifting technique is the weakest control, not the first one.
  • Re-assess whenever the load, layout or frequency changes, and after any strain injury or report of discomfort.

This template is general information, not legal advice. Requirements differ by jurisdiction and industry; check the guidance published by the Health and Safety Executive (HSE) and seek advice for your specific circumstances.

Questions

Frequently asked

Is there a maximum safe lifting weight?
No single number is safe or unsafe, which is why regulators stopped publishing fixed limits. The same 15 kg box can be low risk at waist height close to the body and high risk lifted from the floor at arm's length. Assess the task with TILEO rather than relying on a weight threshold.
What does TILEO stand for?
Task, Individual, Load, Environment and Other. It is a structured way to examine a manual handling task from every angle, because the risk usually comes from the combination of factors, not the load alone. Some guidance uses TILE, and the O simply adds a catch-all for equipment and PPE factors.
Is manual handling training enough on its own?
No. Technique training is an administrative control and sits near the bottom of the hierarchy. If the task forces twisting, long carries or awkward loads, training will not remove that risk. Change the task, the load or the environment first, then train people in the improved method.

The template covers the paperwork. Duress covers the response.