As far as I interpret things there is no defined maximum limits on what you can lift - all down to risk assessment, the individual etc. The 25KG mentioned in the Regs is a guide and not set in stone. I work in Manufacturing and we would be closed if our limit was 15KG. The individual is one to focus on - I am built like a Rugby player but could not lift what my colleague (who was double my age and half-my-weight!) could. I think it was down to technique which I am sticking to!

Hi Rhodesia It all comes down to individual capabilities, what's being lifted, from what height to what height over what distance etc 25kg at waist height is normally seen as the guidance for maximum amount of weight however this has been reduced down to 20kg and 15kg but a lot of companies (bag of cement for example). At the end of the day as someone will mention, it comes down a risk assessment. I would say those weights being quoted are rather high and ask them where they are getting those weights from!

Hi Rhodesia It is necessary for you to follow the HSE guidance to employers, available as a free download from their website. http://www.hse.gov.uk/pubns/indg143.pdf Before setting a limit, go through the guidance and carry out manual handling risk assessments. The MAC tool on the HSE website is a quick way for getting through a lot of tasks accurately. http://www.hse.gov.uk/pubns/indg383.pdf Regards Ian

I think it is worth emphasising how much the Courts don't like fixed generic rules in circumstances where assessment is required; 15Kg could in fact be too heavy for some people, and setting a limit purely based on weight ignores all the other factor you have to consider. What if the load is hot (pan of potatoes), unstable (also a pan of potatoes as it happens!), cold, otherwise hazardous, andawkward shape, has teeth (ask a vet!), etc etc? You must always assess by looking at the Task, the Individual, the Load and the Environment (TILE). Setting arbitrary limits is also a barrier to doing what the law really requires; which is eliminating manual handling so far as reasonably practicable, John

If there were limits there would probably be no weight lifting in the Olympics

While this is true, the point of making comparisons with sport is to illustrate that the human being, suitably trained and strong, can do an amazing range of tasks. The difficulty with workplaces is that we sometimes lose sight of the varying capabilities of the individual. 'Weight limits' tend to get driven down to the lowest common denominator, if we are not careful. You will notice that the ambulance service does not operate to a 15 kg limit, otherwise you would need on average 6 to 8 crew members to get any ordinary member of the public onto a stretcher.

Not surprised at that Decimo considering the rise in obesity in this country! However, consider the work of furniture removal workers; clearly, setting a weight limit of 15kg would put them out of business. The answer is as Jane alludes to. Implementing intelligent planning of task, load, environment and individual capability linked to thorough training and feedback of problems encountered does it for me.

If I read the original post correctly it asks about filling totes and what would be an acceptable weight? Just as a thought the 25 KG weight guidance (male) from the HSE is basically suggesting that an average male can lift a weight of 25 KG, at arms length, using proper techniques and would not be at risk of injury, this is general terms notwithstanding individual sucseptability, age, fitness etc.. So although many people have suggested here RA is key and the weight may not be important, I'm not sure if this is helpful in answering the question. For example if you are manufacturing products or filling boxes for people outwith your organisation to lift then they should where possible be manufactured/filled to within the guidance weight set by the HSE. Hopefully if the guidance has been complied with it would be seen as you upholding your duty if a person was injured. Hence the reason why when I recently brought a flat pack product (child's bed) it came in three boxes all within the 25 KG guidance limit, previously it would have been one or two heavy box/s. In my view weight is important and the guidance has a purpose.