Handling
Manual handling check for a fabricated part (HSE guideline weights)
- where
- adjusted guideline weight (kg)
- guideline weight for the lifting zone (kg)
- twisting reduction (%)
- frequency reduction (%)
- weight to guideline ratio
- weight of the part (kg)
- people needed at the guideline (rough)
Explain this equation
Compares the weight of a fabricated part with the HSE guideline weights for manual lifting. Use it to decide whether a part can be handled by hand or needs a lifting aid.
G is the HSE guideline weight for where the hands are during the lift (close to the body at waist height is the highest). Twisting and frequent lifting both reduce what is reasonable, so each takes a percentage off. Dividing the part's weight by the adjusted guideline shows how far over or under it is; rounding up gives a rough number of people.
Simple percentage reductions, then a ratio.
Sense check: a 30 kg part against a 25 kg guideline is 1.2 times over, so it needs a more detailed assessment or two people. Twisting 90° drops the guideline to 20 kg.
Watch out: guideline weights are a filter, not a safe limit. Team lifts do not simply multiply capacity; over twice the guideline, use lifting equipment.
Compares the weight of a part you have just worked out with the HSE guideline figures for lifting and lowering, adjusted for twisting and how often it is lifted.
Enter your values to see the result.
Good to know
INDG143 Figure 1 guideline weights for men are 25 kg close to the body at waist (knuckle to elbow) height, 20 kg between elbow and shoulder or between mid-lower-leg and knuckle, and 10 kg at floor level or above shoulder; at arm's length the figures roughly halve (15, 10 and 5 kg). For women they are 16, 13 and 7 kg close in, and 10, 7 and 3 kg at arm's length. L23 reduces them by about 10% for a 45° twist, 20% for 90°, and by 30%, 50% and 80% for lifting once or twice, five to eight, or more than twelve times a minute. The base figures assume fewer than about 30 lifts an hour.
Common mistake
Treating the guideline as a safe limit. It is a filter: below it most people are not at significant risk; above it you must assess. Team lifts do not simply multiply capacity, since two people can usually manage about two-thirds of their combined individual capacity.
Limits
Simplified filter only, for lifting and lowering. Does not cover pushing, pulling, carrying long distances, awkward or sharp loads, or individual capability. Use the HSE MAC or RAPP tools for a detailed assessment.
Sources
- HSE INDG143 (rev 4) Manual handling at work: a brief guide (Figure 1 lifting and lowering guideline weights; more detailed assessment for twisting or more than one lift every two minutes)
- HSE L23 Manual Handling Operations Regulations 1992 (as amended): Guidance on Regulations (Appendix: twisting 45° about 10%, 90° about 20%; frequency 1–2/min 30%, 5–8/min 50%, more than 12/min 80%)
- University of St Andrews: Manual handling operations (restates the L23 guideline reductions for twisting and frequency)
Results are calculations from the published methods and figures shown, and depend on the data you enter. Follow the welding procedure specification (WPS), BS EN ISO 15614/9606, BS EN 1090, BS EN 1993 and manufacturers’ data. Structural welds need qualified welders and engineered designs.