“How much can a person lift?” is one of the most common questions in a safety class, and one of the hardest to answer in one number. The honest answer is that it depends on where the load starts, where it ends, how far from the body it is held, and how often it is lifted. This guide breaks it down so you can screen a task quickly.

Choose the posture below, and the guide will show the guideline weight.

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What are guideline lifting weights?

Guideline weights are figures that help you spot lifting jobs that are probably low risk, and jobs that need a closer look. The best known set comes from the UK Health and Safety Executive (HSE). It splits the body into zones, from the ankle up to above the shoulder, and gives a weight for each zone.

The key idea is simple. A load is easiest to handle when it is close to the body and between the knuckle and the elbow. The further the load is from that zone, the lower the weight should be.

An important warning first

These figures are not safe limits. They are a screening filter. If a task is inside the guideline, the risk is low for most people, but not zero. If it is outside, you do not have to stop, but you must make a fuller assessment. Always think about the person, the load and the place, not just the number.

Guideline weights by zone

The figures below are for lifting and lowering, in kilograms. The first number is for the load held close to the body. The second is for the load held at arm’s length.

Above shoulder height: men 10 / 5, women 7 / 3
Elbow to shoulder height: men 20 / 10, women 13 / 7
Knuckle to elbow height: men 25 / 15, women 16 / 10
Mid-lower leg to knuckle height: men 20 / 10, women 13 / 7
Below mid-lower leg: men 10 / 5, women 7 / 3

The best zone, knuckle to elbow height with the load close, gives the well-known 25 kg for men and 16 kg for women. Notice how fast the figures fall when the load is lifted from the floor or held above the head.

Other guideline figures

Handling while seated: about 5 kg for men and 3 kg for women
Pushing and pulling: a starting or stopping force of about 25 kg for men and 16 kg for women, and about 10 kg for men and 7 kg for women to keep a load moving
Carrying: the lifting figures can be used if the load is held against the body and carried no more than about 10 metres without a rest

When you must reduce the weight

Twisting: reduce the figure by about 10 percent if the body twists 45 degrees, and about 20 percent for 90 degrees
Frequent lifting: the figures assume lifting is not repeated too often. If lifting is frequent, reduce the weight a lot, or make a fuller assessment
Awkward loads: a load that is bulky, hot, slippery, unstable or hard to grip is riskier than its weight suggests
Poor place: wet floors, steps, tight spaces and poor light all raise the risk

Worked example

A warehouse worker lifts an 18 kg box from a shelf at about waist height. It is close to the body, in the knuckle to elbow zone. The worker also turns about 45 degrees to place it on a trolley.

Men: 25 kg, less 10 percent for twisting = 22.5 kg. The 18 kg box is within the guideline.
Women: 16 kg, less 10 percent for twisting = 14.4 kg. The 18 kg box is over the guideline.

So the task passes the screen for one group and fails for the other. Since a workplace should not depend on who happens to be on shift, the better fix is to make the task easier for everyone: lighter boxes, a trolley placed in line with the shelf, or a team lift.

The four things to look at: TILE

Task: How far is the load moved? Is there twisting, stooping or reaching? Is the pace forced?
Individual: Does the person have the strength, training and health for the job? Is there any injury or condition to take into account?
Load: Is it heavy, bulky, unstable or hard to hold? Does it have handles?
Environment: What is the floor like? Is there enough space, light and a comfortable temperature?

Better ways to handle loads

The best manual handling job is the one that does not exist. Try these in order:

Avoid it: deliver goods already at the point of use, or use a conveyor
Use equipment: trolleys, pallet trucks, hoists, vacuum lifters and lift tables
Make the load smaller: split it into smaller packs, or add handles
Improve the layout: store heavy items at waist height and light ones high or low
Team lifts: use them when a load cannot be split, but plan them, because a team lift has its own risks
Train people: teach good handling technique, but never use training as the only fix

Step by step

Note where the load starts and where it ends.
Find the zones that the hands pass through.
Check whether the load is close to the body or at arm’s length.
Read the guideline weight for those zones, using the lowest one.
Reduce the figure for twisting and for frequent lifting.
Compare the real weight with the guideline.
If it is over, make a full assessment and add controls.

Common mistakes

Treating 25 kg as a safe limit for any lift
Using the best zone figure when the lift starts from the floor
Ignoring twisting and repeated lifting
Looking only at the weight and not at the shape or grip
Training people to lift “properly” instead of fixing a poor layout
Applying the same figure to every person, when a fuller assessment should look at the individual

Linking it to your wider risk work

For tasks that are repeated all day, check the strain on the body with an ergonomic assessment. Place the hazard on your risk matrix using the risk matrix calculator, and show the effect of a new trolley or lift table with the residual risk calculator. If handling injuries keep happening, check the DART rate to see how many of them lead to restricted work.

Frequently asked questions

What is the maximum weight a person can lift at work?

There is no single legal maximum in most places. HSE gives guideline figures, such as 25 kg for men and 16 kg for women in the best zone, but these are not safe limits.

Why are the figures lower for women?

The guidelines are based on lifting data for groups of men and women. They describe averages for groups, not what any one person can do, so individual ability should always be considered.

What changes the guideline weight?

The zone, the distance of the load from the body, twisting, how often you lift, and the grip and shape of the load.

Can I lift more than the guideline?

Sometimes, but only after a proper assessment of the task, the person, the load and the place.

Do these figures apply outside the UK?

They are a respected starting point worldwide. Check your own local law and company rules too.

Learn this properly

Manual handling and lifting risk are covered in NEBOSH, IOSH and OSHA courses. ISH Institutes teaches these in Peshawar. Chat with us on WhatsApp and we will help you pick the right course.

Manual Handling Weight Guide