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Manual Handling Risk Calculator
Free manual handling risk calculator. Enter load weight, distance, frequency, posture, and environment to calculate a MAC-style risk score with traffic-light rating (green/amber/red) and action recommendations. Based on the UK HSE Manual Handling Assessment Charts (MAC) methodology.
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Frequently Asked Questions
What weight can workers legally lift at work?
There is no absolute legal weight limit in UK law. The Manual Handling Operations Regulations 1992 require employers to reduce risk as low as reasonably practicable. HSE guidelines suggest a maximum of 25 kg (men) and 16 kg (women) for loads held close to the body at waist height under ideal conditions. These figures reduce significantly for awkward postures, extended reach, or repetitive lifts.
What is the MAC tool?
The Manual Handling Assessment Charts (MAC) tool was developed by the UK HSE to help identify and assess manual handling risk factors in the workplace. It covers lifting/lowering, carrying, and team handling tasks. Each factor is scored using a colour code: green (low risk), amber (medium risk), red (high risk) — requiring immediate action.
When does manual handling need a full risk assessment?
Under UK law, employers must assess manual handling tasks that cannot be avoided and present a risk of injury. Triggers include: loads over 25 kg, awkward postures (below knee/above shoulder), repetitive handling (more than once per minute), slippery floors, and existing musculoskeletal disorders in the workforce.
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