Mechanical and manual handling: what do the regulations say?

Whether manual or mechanical, handling operations require the implementation of specific preventive measures. In this article, you'll find everything you need to know about regulations governing the prevention of risks associated with handling loads.

What is load handling?

There are two types of load handling: manual and mechanical.

Manual handling is defined as the transport or support of a load requiring the physical effort of one or more workers(Article R4541-2 C.Trav.).

ℹ Please note : Since October^1, 2017, manual handling of loads no longer entitles you to the benefits of the Compte Professionnel de Prévention (C2P) (Article L4163-1 C.Trav.).

Similarly, mechanical handling is defined as load-handling operations performed using work equipment (lifting accessory or lifting machine).

Examples of work equipment for lifting loads: pallet truck, forklift, electric hoist, mechanical stacker, crane, etc.

What are the challenges of mechanical and manual handling?

Whether in construction, agriculture or industry, the use of manual and mechanical handling is essential in many sectors.

| According to the Direction de l'animation, de la recherche, des études et des statistiques (DARES), 29.3% of employees perform at least two hours of manual handling per week.

Whether mechanical or manual, these handling operations often present risks for workers.

In the case of manual handling, workers are particularly exposed to occupational illnesses such as tendonitis and low back pain.

| In practice, low back pain is the cause of 20% of workplace accidents, half of which are caused by manual handling of loads (Haute Autorité de Santé (HAS) 2019, Assurance maladie 2017).

In the case of mechanical handling, workers are particularly exposed to risks associated with the use of lifting accessories and machines. In fact, the use of such equipment can be the cause of workplace accidents such as collisions, crushing, bumping, etc.

What are the regulatory requirements for mechanical and manual handling?

When workers carry out manual handling operations that involve risks, particularly of a back or lumbar nature, the employer must implement a prevention program(Article R4541-1 C.Trav.).

This approach is based on the general principles of risk prevention(Article L4121-2 C.Trav.).

Avoiding risks

In order to limit or avoid the need for manual handling of loads, the employer must give priority to the provision of mechanical equipment that enables loads to be lifted(Article R4541-3 C.Trav.).

However, the use of such equipment also requires a specific prevention approach.

| This approach is based on the general principles of risk prevention, and mainly concerns the layout of workplaces and the conformity of equipment and its use.

Assessing occupational risks

To assess the risks to which workers are exposed during manual handling operations, the employer must define precisely(Article R4541-6 C.Trav.) :

• load characteristics (weight, dimensions, gripping point, etc.) ;
• characteristics of the physical effort required (nature of movement, posture, etc.);
• characteristics of the working environment (distance to be covered, nature of the ground, presence of obstacles, temperature, etc.);
• activity requirements (handling time, work rhythm, etc.);
• the worker's individual risk factors (age, gender, physical condition, etc.).

When using a lifting accessory or machine, the employer must also assess the risks to workers in the vicinity, as well as to the operator.

His main task is to analyze the working environment in which the equipment is used, particularly with regard to the risk of falling loads and the consequences for traffic flow within the company:

• Workplaces must be wide enough for the use of work equipment, particularly with regard to equipment movements(Article R4323-8 C.Trav.);
• where mobile lifting equipment is used, appropriate traffic rules must be established and complied with (Article R4323-51 C.Trav.).

🔎 Focus : Traffic lanes for mobile work equipment must be wide enough for safe use at the speed specified in the instruction manual, and free of any obstacles (Article R4323-50 C.Trav.).

Implement risk prevention measures

Manual handling

As we have seen, the use of a mechanical aid or lifting machine makes it possible to limit or avoid manual handling(Article R4541-5 C.Trav.). It is therefore a preventive measure to be favored in this area.

Nevertheless, when manual handling cannot be avoided, the employer must act on the organization of work to limit physical effort and reduce the risk incurred during these operations(Article R4541-4 C.Trav.).

Examples of preventive measures:

• reduce the weight and size of loads to be carried ;
• carry out manual handling operations with two workers;
• reduce the duration of manual handling (turnover, change of task, etc.);
• sort loads by weight and size ;
• Reduce distances to be covered;
• ...

🔎 Focus : As far as possible, the employer must ensure that workers receive information on the weight of the load and the position of its center of gravity (Article R4541-7 C.Trav.).

Mechanical handling

When workers use work equipment for lifting loads, certain rules and preventive measures must be put in place.

The operator of a lifting device must be able to see and follow its movements with his eyes(Article R4323-41 C.Trav.). When this is not possible, a maneuvering leader must guide the operator by communicating with him.

Furthermore, lifting accessories and equipment must be appropriate for the work to be carried out(Article R4321-1 C.Trav.).

With this in mind, they must be chosen according to(Article R4323-47 C.Trav.) :

• the nature of the loads (weight, dimensions, etc.);
• and gripping points;
• slinging methods ;
• ...

⚠️ Caution : Dismountable or mobile work equipment used for lifting loads must be properly stabilized during use (Article R4323-29 C.Trav.).

When using lifting work equipment, the employer must take the necessary measures to avoid risks:

• (Article R4323-44 C.Trav.) ;
• tipping, overturning, moving or sliding of work equipment(Article R4323-39 C.Trav.) ;
• (Article R4323-34 C.Trav.) ;
• ...

⚠️Attention: It is compulsory to maintain work equipment in a state of compliance (Article R4322-1 C.Trav.). Lifting equipment must undergo periodic inspections (Article 23, Arrêté du^1er mars 2004) :

● every 12 months;

● every 6 months (lifting equipment listed in II and III of article 20 of the decree of March^1, 2004 (e.g.: forklifts) and lifting equipment, powered by energy other than human force employed directly, used for the transport of people or to move a workstation in elevation) ;

● every 3 months (lifting equipment, powered by direct human intervention, used to move a workstation in elevation).

Worker training

Workers who carry out manual handling of loads in their workstations must receive specific training which includes(Article R4541-8 C.Trav.) :

• gestures and postures to adopt, as well as a practical exercise;
• information on the risks they run if these operations are not carried out correctly.

ℹ Please note : This training must be repeated renewed in the event of the creation or modification of a workstation exposing the employee to new risks (Article R4141-15 C.Trav.).

When using work equipment used for lifting loads, workers must also receive appropriate training(Article R4323-55 C.Trav.).

| They must also have received instructions and conditions for using work equipment(Article R4323-1 C.Trav.).

🔎 Focus : Certain load-lifting equipment (e.g. self-propelled industrial trucks) may only be operated by workers who have been granted a driving authorization issued by the employer (Article R4323-56 C.Trav.).

Medical follow-up

The manual handling of loads and the operation of work equipment used for lifting loads are subject to the worker's medical fitness.

| This medical aptitude is observed during the information and prevention visit (VIP) with a health professional. This visit must be carried out within three months of starting work(Article R4624-10 C.Trav.).

| For jobs requiring driving authorization, an aptitude test must be carried out before the employee is assigned to the position, as part of the individual health monitoring process.

What are the main handling prohibitions?

Regulations prohibit certain manual and mechanical handlingpractices in order to avoid situations that could be dangerous for workers.

Manual handling

The maximum weight of a load for manual handling is 105 kilograms (kg). In addition, a worker must not be required to carry loads in excess of 55 kg on a regular basis unless he/she has been recognized as fit by the occupational physician(Article R4541-9 C.Trav.).

In addition, certain categories of workers benefit from more favourable working conditions because of their personal characteristics:

• women must not carry loads weighing more than 25 kg or transport loads using a wheelbarrow weighing more than 40 kg, including the wheelbarrow(Article R4541-9 C.Trav.);
• pregnant women are not allowed to use hand trucks to carry loads(Article D4152-12 C.Trav.);
• young workers may not carry loads exceeding 20% of their body weight, unless they have been recognized as fit by the occupational physician(Article R4153-52 C.Trav.).

Mechanical handling

Here are the main prohibitions concerning mechanical handling:

• except for tests or trials, it is forbidden to lift a load whose weight exceeds that marked on the equipment or on the load plate(Article R4323-33 C.Trav.) ;
• it is forbidden to leave suspended loads unattended unless access to the danger zone is prevented and the load has been hooked up and is held securely(Article R4323-44 C.Trav.) ;
• no load may be left suspended on the hook of a stationary piece of lifting equipment(Article R4323-35 C.Trav.).
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