RAPP Assessment (Wheeled)
Risk Assessment of Pushing and Pulling for wheeled equipment
Assessment Details
RAPP Methodology Guide (INDG478)
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- Green: Low risk. Optimal conditions.
- Amber: Medium risk. Examine closely and monitor.
- Red: High risk. Prompt action/controls needed.
- Purple: Unacceptable risk. Stop task immediately.
- Note: If any individual factor is Red, the overall result is always Red, regardless of the total score. Similarly, any Purple factor immediately makes the result Unacceptable. Always eliminate Red and Purple factors first.
- ▸Score the worst case: Watch the full operation and band the worst posture, surface, and obstacle seen on the trip, not the average or the moment at rest. HSE's RAPP guidance is explicit about scoring the worst case.
- ▸Initial force is the hardest: Getting a load moving takes far more force than keeping it moving, so observe the start of the push or pull, not just steady travel.
- ▸Score subjective postures conservatively: The line between Reasonable (Amber) and Poor (Red) bending, leaning, or twisting is hard to judge without measured angles. When in doubt, score the higher band.
- ▸Assess each equipment type and load separately: If different trolleys or loads are used, run a separate assessment for each, and assess the combined weight when more than one loaded unit is moved at once.
- ▸Total score is for comparison only: Use it to rank tasks and check whether changes helped, not as an action threshold. The colour bands decide what needs attention.
A-1 Load Weight
The total weight moved (equipment plus load). Pick the equipment class first: small (1 to 2 wheels, worker bears some load, e.g. sack truck), medium (3+ fixed wheels or castors, e.g. roll cage), or large (steerable or on rails, e.g. pallet truck). Each class has its own weight bands. If the load exceeds the equipment's rated capacity it is Purple (Unacceptable) and carries no score. Assess the heaviest load likely, and the combined weight if more than one unit is moved at once.
A-2 Posture
The hands and body during the operation. Green: torso upright and untwisted, hands between hip and shoulder height. Amber: body inclined into the exertion, or torso bent or twisted, or hands below hip height. Red: body severely inclined, squatting, kneeling or pushing with the back, a severe bend or twist, or hands above shoulder or behind the body. Observe during the actual push or pull, not at rest.
A-3 Hand Grip
How securely the hands contact the equipment. Green: handles or handholds giving a comfortable power grip (pull) or full-hand contact (push). Amber: handholds allow only a partial grip (fingers clamped at 90 degrees) or partial contact. Red: no handles, or the contact is uncomfortable. If the task involves both pushing and pulling, assess both.
A-4 Work Pattern
How repetitive the task is and whether the worker controls the pace. Green: not repetitive (fewer than 5 transfers per minute) and the worker sets the pace. Amber: repetitive, but rest or recovery is available through breaks or job rotation. Red: repetitive with no breaks and no job rotation.
A-5 Travel Distance
The distance of a single trip, start to finish. Green: 10 m (33 ft) or less. Amber: between 10 m and 30 m (33 to 100 ft). Red: more than 30 m (100 ft). For repetitive work use the average of at least five trips; otherwise use the longest trip.
A-6 Condition of Equipment
The maintenance regime and the state of the wheels, bearings, and brakes. Green: planned preventive maintenance, good repair, wheels running freely. Amber: maintenance only when problems arise, or reasonable repair. Red: no planned maintenance system, or poor repair.
A-7 Floor Surface
The route surface at its worst point. Green: dry, clean, level, firm, and undamaged. Amber: damp or some debris, or a gradient of 3 to 5 degrees, or reasonably firm (carpet), or minor damage. Red: wet or debris in several areas, or a slope over 5 degrees, or soft or unstable underfoot, or severe damage. For outdoor work, weather changes the score.
A-8 Obstacles Along the Route
Trailing cables, raised edges, ramps, steps, narrow or closed doors, confined spaces, bends, and corners. Count each obstacle type once. Green: none. Amber: one obstacle type, but no steps or steep ramps. Red: any steps, any steep ramp (over 5 degrees), or two or more obstacle types.
A-9 Other Factors
Anything else raising risk: an unstable load, a load blocking the worker's view, sharp or hot surfaces, poor lighting, extreme heat, cold or humidity, gusts of wind, or restrictive PPE. Green: none present. Amber: one present. Red: two or more present.
- Individual factors: Pregnant workers, those returning from injury, or workers with existing musculoskeletal conditions may need a lower threshold for intervention regardless of the score.
- New workers: Those unfamiliar with the task or equipment need closer supervision and may fatigue faster, so consider scoring more conservatively.
- Ask the worker: They will often identify the hardest part of the task (e.g. getting it started, a particular corner). This is where risk is highest.
- ▸Whole-body pushing and pulling only: RAPP covers manual push and pull tasks using whole-body effort. It is not for upper-limb-only work (levers, buttons, conveyor loads), lower-limb-only work (pedals), or powered handling equipment. Use HSG60 for upper-limb tasks.
- ▸Not a full risk assessment on its own: RAPP screens and prioritises; it does not replace a full assessment under the Manual Handling Operations Regulations. Always weigh individual capability and psychosocial factors alongside the score.
- ▸Total score has no action threshold: The total is for comparison and tracking only. It does not map to an action level, and a task can be high risk on a single Red factor while carrying a modest total. Act on Red and Purple bands regardless of the total.
- ▸Subjective banding: Posture, floor, and obstacle bands rely on field judgement without measured angles or forces. Different assessors can land on different bands, so train and calibrate, and score the worst case when unsure.
- ▸Snapshot of observed practice: A score reflects what was seen during one assessment. It does not capture day-to-day variation, fatigue across a shift, or differences between workers, so observe enough trips to be representative.
- ▸No force measurement: RAPP infers risk from task and equipment factors rather than measured push or pull forces. Where forces are borderline or disputed, a direct force-gauge reading gives firmer evidence.
Tackle Red and Purple factors first; they expose a significant share of workers to injury. Eliminate or reduce the Red bands, then the Amber ones, and re-score after each change to confirm the risk has dropped. The control hierarchy below runs from most to least effective.
- 1. Eliminate: Can the load be delivered directly to point of use? Can conveyor, chute, or gravity assist remove the push/pull entirely?
- 2. Reduce the load: Split loads into smaller batches, reduce fill levels, or use lighter containers.
- 3. Better equipment: Upgrade to larger-diameter wheels, pneumatic tyres, or powered assistance (e.g. electric tugger). Ensure regular maintenance schedule.
- 4. Improve the route: Level or repair floor surfaces, add ramps to replace steps, widen doorways, create dedicated push/pull lanes.
- 5. Work organisation: Introduce job rotation, enforce rest breaks, limit continuous pushing distance, and ensure adequate staffing levels.
- 6. Training: Ensure workers know correct starting technique (initial force is always highest), how to steer safely, and when to ask for help.
Equipment & Load
Spin each wheel by hand. Dragging, wobble, or flat spots indicate poor condition. Ask about the maintenance programme.
Posture, Grip & Pattern
Observe during the actual push/pull, not at rest. Score for the worst posture seen during the operation.
This factor scores grip quality only. Hand height is captured under A-2 Posture. Wet/oily handles or ill-fitting gloves push toward a worse band.
Repetitive = 5 or more transfers per minute. Informal recovery (e.g. doing other tasks between loads) counts as a break.
Environment & Route
Measure start to finish for one trip, not total shift distance. For repetitive operations, average over at least five trips.
Walk the entire route and score for the worst section. A 5° slope is roughly 1 in 11.
Count each obstacle type only once regardless of how often it appears. Types include: trailing cables, raised edges, narrow/closed doors, screens, confined spaces, corners.
Count how many of the factors below are present and score accordingly.
Check each of the following:
RAPP Total Score
Task Prioritization Index
Per HSE guidance, total scores are for comparison and prioritisation only. They do not relate to specific action levels. The colour bands determine which factors need attention.
Conditions are optimal. Minimal risk of injury.