MAN/Mechanical Aids/TBT-MAN-024
Manual Handling Risk Assessment (MAC Tool)
Manual Handling › Mechanical Aids › Manual Handling Risk Assessment (MAC Tool)
Toolbox Talk
Manual Handling Risk Assessment (MAC Tool)
The Manual Handling Assessment Charts (MAC) tool is a practical method developed by the HSE to help assess the risk of common manual handling tasks on construction sites. It uses a simple colour-coded scoring system to identify tasks that need improvement. Supervisors should use the MAC tool to evaluate lifting, carrying, and team handling operations. This talk explains how the MAC tool works and when to use it.
Key Hazards
Musculoskeletal injuries from unassessed manual handling tasks
Back injuries from lifting loads that exceed safe guidelines
Cumulative strain from repetitive handling tasks assessed as low risk individually
Workers continuing unsafe handling practices when no assessment is in place
Control Measures
- Use the MAC tool to assess all routine manual handling tasks before work begins on site.
- Score each task against the MAC criteria: load weight, posture, grip, floor conditions, and frequency.
- Take immediate action on any task scored in the red or high-risk category.
- Implement improvements for tasks scored in the amber or medium-risk category.
- Review the assessment whenever the task, load, or working conditions change.
- Involve the operatives performing the task in the assessment to capture practical insight.
- Record all MAC assessments and keep them on site for reference and inspection.
- Consider mechanical aids, team lifting, or task redesign for all tasks scoring above green.
- Brief operatives on the assessment findings and the control measures to be followed.
Remember
- Use the MAC tool to assess all routine manual handling tasks before they start
- Tasks scored in the red category require immediate action to reduce the risk
- Involve the operatives who carry out the task in the assessment process
- Review the assessment whenever the task, load, or working conditions change
- Consider mechanical aids or task redesign for all tasks scoring above green
Applicable Legislation: Manual Handling Operations Regulations 1992 · MHSWR 1999 · Health and Safety at Work etc. Act 1974 · HSE INDG383 (MAC Tool)
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