MAC Assessment (Lifting)
HSE Manual Handling Assessment Charts: INDG383(rev3) lifting operations
Assessment Details
MAC Methodology Guide
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- Green (0): Low risk. Consider exposure for vulnerable workers.
- Amber (varies): Medium risk. Examine the task closely.
- Red (varies): High risk. Prompt action needed.
- Purple (10): Unacceptable. May represent serious risk and must be improved.
Individual color bands drive action. Target Red and Purple factors first. Look to reduce Red factors to Amber, and Amber to Green.
Per HSE: "The total scores do not relate to specific action levels." The total is for prioritising which tasks need attention first when comparing lifting operations. The Low / Medium / High / Unacceptable bands shown here (≤4 / 5–12 / 13–19 / 20+) are practitioner-added thresholds for triage, not HSE-published action levels.
- Assess worst case for every factor: Score the most demanding posture, heaviest load, and worst floor condition seen, not the average. Include both the pick-up and put-down if they differ.
- The MAC is a screening tool: It may not be a "suitable and sufficient" full risk assessment on its own. A full L23 assessment is needed for lifts above 12 per minute, seated handling, carrying on the shoulder, and where Schedule 1 factors apply (sudden movement, unstable/unpredictable loads, hot, sharp, or otherwise hazardous loads).
- Individual Red/Purple bands: Even a low total score warrants action if any single factor scores Red or Purple. Address the colour bands, not just the total number.
A. Load Weight / Frequency Matrix
The MAC load score is not linear. It is a matrix intersection of weight band and lift frequency, returning Green (0), Amber (4), Red (6), or Purple (10). A 24 kg load lifted continuously (>5/min) scores Purple (10). Use the heaviest load lifted at that frequency; if frequency varies with weight, assess the worst combination separately.
B. Hand Distance from Lower Back
Measured horizontally from the lower back to the hands at the point of maximum stress, typically when the load is furthest from the body. Close = hands near the torso throughout (0). Moderate = arms angled away (3). Far = arms fully outstretched, e.g. reaching across a conveyor or deep into a container (6). This factor has the highest possible score of any single B/C factor.
C. Vertical Lift Zone
Score for the worst vertical hand position during the lift. Ideal zone (knee to elbow height) is Green (0). Floor-to-knee or elbow-to-head height is Amber (1). At floor level or above head height is Red (3). For lifts spanning multiple zones, score the worst starting or finishing position.
D. Torso Twisting and Bending
Observe the torso during the lift. The highest-risk moment is typically when the load is heaviest and furthest away. Straight = no twist or bend (0). Slight = twists OR bends to one side (1). Severe = twists AND bends simultaneously (2). Twisting is almost always caused by the pick-up and put-down locations not being in front of the worker. Repositioning the work is the fix.
E. Postural Constraints
Environmental restrictions that prevent the worker from adopting a safe posture. None = worker is unhindered (0). Restricted = posture is constrained but the worker remains upright, e.g. working in a narrow aisle (1). Severe = worker is forced to bend or lean due to low ceilings, confined spaces, or working inside a container (3).
F, G, H. Grip, Floor, Environment
F (Grip): Good (0) = cutouts or solid handles. Reasonable (1) = hook grip or fingers clamped under the load. Poor (2) = no handles, bulky, or pinch grip only. G (Floor): Good (0) = dry, clean, flat. Reasonable (1) = damp, minor debris, or minor damage. Poor (2) = slippery/wet, much debris, soft, or unstable. H (Environment): score the number of adverse factors (extremes of temperature, strong air movement, extreme lighting) present simultaneously.
- ▸Screening tool, not a full assessment: The MAC identifies high-risk manual handling for prioritisation. On its own it may not be a suitable and sufficient assessment under the Manual Handling Operations Regulations. A full L23 assessment is needed where Schedule 1 factors apply (sudden movement, unstable or unpredictable loads, hot, sharp, or otherwise hazardous loads).
- ▸Lifting, carrying, and team handling only: The MAC does not cover pushing or pulling (use RAPP), seated handling, one-handed lifting, lifts above 12 per minute, or carrying on the shoulder over long distances. Those tasks need a different tool or a full assessment.
- ▸Total score has no action level: Per HSE, the total scores do not relate to specific action levels. The Low, Medium, and High bands here are practitioner triage thresholds, not HSE-published levels. Act on individual Red and Purple factors regardless of the total.
- ▸Does not account for the individual: The MAC assumes a capable worker and does not adjust for age, health, pregnancy, disability, or training. Individual capability and psychosocial factors must be weighed separately.
- ▸Subjective banding: Posture, distance, and floor bands rely on visual judgement without measured angles or weights. Different assessors can reach different bands, so score the worst case and calibrate.
- ▸Snapshot of one uniform task: The MAC screens a single lifting task observed once. Where load weights vary across a shift (parcel sorting, order picking), use the HSE V-MAC spreadsheet for cumulative daily exposure.
Target Red and Purple factors first; they expose the most workers to injury. Reduce Red factors to Amber and Amber to Green, then re-score to confirm the improvement. The controls below run from most to least effective.
- 1.Eliminate the lift: Can handling be avoided? Use mechanical aids (hoists, vacuum lifts, conveyors, scissor lifts) or deliver loads directly to the point of use.
- 2.Reduce the load: Lighten or split loads, shrink package sizes, or lower the weight per lift to drop the load and frequency band, which is the only factor that can score Purple.
- 3.Reposition the work: Bring the load close to the body, store it between knee and elbow height, and place pick-up and put-down points in front of the worker to remove twisting. This targets the highest-scoring factors (B distance, C zone, D twist).
- 4.Improve the load and grip: Add handles or cut-outs and make loads stable and predictable to raise the grip band and reduce sudden movement.
- 5.Improve the environment: Repair and clean floors, provide adequate lighting and temperature, and clear space so the worker can stand upright and move freely.
- 6.Organisation and training: Cut lift frequency through rotation and breaks, use team handling where needed, and train workers in technique and when to ask for help. Re-score after changes to confirm the risk has dropped.
This calculator screens a single uniform lifting task. When load weights vary significantly across a shift (e.g. parcel sorting, order picking), use the HSE V-MAC spreadsheet to model cumulative daily load exposure. Export baseline MAC scores into the V-MAC workbook to generate a weighted daily exposure result.
Load Weight & Frequency
Section A score is the HSE matrix intersection of weight and frequency, returning 0 (Green), 4 (Amber), 6 (Red), or 10 (Purple).
Posture & Biomechanics
Work Environment & Load
MAC Total Score
Task Prioritisation Index
Compare against other tasks. Focus interventions on those with the highest total scores.