Safety & Compliance · SOP

Manual Material Handling Risk Assessment Form

This document provides a standardized procedure to complete a risk assessment for any manual material handling task — lifting, lowering, pushing, pulling, or carrying. It helps identify ergonomic hazards, calculate risk scores, and implement effective controls to prevent musculoskeletal injuries.

Estimated Time

20 min

Difficulty

Intermediate

Regulation

CSA Z1008 / WorkSafeBC

Version

1.2

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Purpose

The purpose of this SOP is to provide a consistent, step-by-step method for performing a manual material handling risk assessment. By following the structured form, workers and safety coordinators can systematically evaluate task demands, load characteristics, environmental conditions, and individual worker factors to determine risk levels and implement appropriate controls. This procedure reduces the incidence of sprains, strains, and overexertion injuries.

Scope

This procedure applies to all manual handling tasks performed in industrial, warehouse, and manufacturing environments under the jurisdiction of Canadian occupational health and safety regulations. It covers single-person lifts, team lifts, repetitive handling, and the use of assistive devices. This SOP does not apply to rigging operations, powered industrial trucks, or tasks already covered by a dedicated safe work procedure.

Safety Precautions

LOTOEnsure all mechanical aids (lift tables, carts, hoists) are locked out and tagged out if any maintenance or adjustment is required before the assessment.
PPEWear steel‑toed boots, cut-resistant gloves, and a high‑visibility vest when entering the assessment area. Do not handle loads without proper hand protection.
E-STOPIdentify emergency stop locations for any powered equipment that may be used during the assessment. Do not approach moving parts.

Required Tools & Materials

Manual Material Handling Risk Assessment Form (paper or digital copy)
Measuring tape (metric) and digital scale or load rating from manufacturer
Camera or smartphone for documenting task conditions
NIOSH Lifting Equation app or printed chart (optional for advanced scoring)
Pen and clipboard (if using paper form)
Stopwatch or timer for repetitive task cycle measurement

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Procedure: Step-by-Step

1 Identify the task. Select the specific manual handling task to be assessed (e.g., lifting boxes from floor to waist height, carrying drums 20 m). Record the task name, frequency, and duration.

2 Assess the load. Measure or obtain the weight (kg), dimensions, handle/surface condition, and stability of the load. Note any sharp edges, slippery surfaces, or unstable centres of gravity.

3 Evaluate the working environment. Document floor type and condition (wet, uneven, slope), lighting level, temperature, and any obstacles or restricted headroom that affect posture.

4 Evaluate the individual. Verify the worker has received manual handling training, is physically fit for the task, and is wearing required PPE. Note any temporary or permanent restrictions.

5 Calculate the risk score. Use the NIOSH lifting equation or a risk matrix (combining load weight, frequency, distance, and posture) to assign a rating: Low (green), Medium (yellow), or High (red).

6 Determine controls. For Medium/High risks, specify engineering controls (lift table, mechanical assist), administrative controls (job rotation, rest breaks), and required PPE. For Low risk, confirm current measures are sufficient.

7 Implement and review. Implement the selected controls, train affected workers, and set a review date (typically 30 days for High risk, 90 days for Medium). Document the completed form and file in the safety management system.

Manual Material Handling Risk Assessment Form

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