Pushing and Pulling Loads Safely: Force Limits and Technique
Wheeling a trolley or pallet truck feels far easier than lifting — but pushing and pulling injuries are common and easily overlooked. Understanding the HSE guideline forces, and the technique behind them, keeps your team and their backs out of trouble.
Why pushing and pulling deserves attention
When a load is too heavy or awkward to lift, the sensible answer is usually to move it on wheels. But putting a load on a trolley does not make the risk disappear — it changes it. Pushing and pulling place real strain on the lower back, shoulders and arms, especially when starting a stationary load moving, stopping it again, or steering it round a tight corner.
The Manual Handling Operations Regulations 1992 (MHOR 1992) cover pushing and pulling just as they cover lifting and carrying. So the same logic applies: avoid the hazardous task where you can, assess what remains, and reduce the risk to the lowest level reasonably practicable.
HSE guideline forces
The HSE publishes guideline figures to help you judge when a pushing or pulling task may need a closer look. These are screening values, not strict legal limits — but if the force needed exceeds them, you should assess the task in more detail. The figures cover two distinct moments:
- Starting or stopping a load — getting it moving from rest, or bringing it to a halt, demands the most effort. The HSE guideline figure for this is roughly 20 kg of force (about 200 newtons) for men and 15 kg (about 150 newtons) for women.
- Keeping a load in motion — once it is rolling, far less effort is needed. The guideline for sustained movement is around 10 kg of force (about 100 newtons) for men and 7 kg (about 70 newtons) for women.
These figures assume the force is applied with the hands roughly between knuckle and shoulder height. Push or pull from too low or too high, and the safe figure drops. They also assume the load is moved no more than a short distance without a break.
The hardest moment is always the first push. If getting a load moving feels like a real struggle, that is your cue to reassess the task — not to heave harder.
Trolley and pallet-truck technique
Good equipment is only half the story; technique does the rest. Whether your team uses sack trucks, cage trolleys or manual pallet trucks, the principles are the same:
- Push, do not pull, wherever possible. Pushing lets you use your body weight and keeps the load in view.
- Keep the back straight and lean into the load with the whole body, rather than yanking with the arms alone.
- Hands at waist-to-chest height for the best leverage and least strain.
- Start gently — a smooth, steady effort beats a sudden jerk that can wrench the back.
- Take small steps and keep the load moving; stopping and restarting repeatedly multiplies the effort.
Choosing the right aid matters too. A well-maintained trolley with the correct wheels for the surface can dramatically cut the force required — our guide to manual handling aids and equipment covers how to pick the right one.
Train in Manual Handling — the right way
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Route, floor surface and visibility
Even a light load becomes dangerous on the wrong route. Before moving anything, plan the journey and remove the obstacles:
The route
Check for slopes, ramps, kerbs and steps — these dramatically increase the force needed and the risk of losing control. Where a slope is unavoidable, keep loads light and never let a trolley run away downhill.
The floor surface
Smooth, clean, level floors require far less force than rough, broken, wet or cluttered ones. Trapped grit, worn castors and damaged surfaces all add resistance and can stop a wheel dead, jolting the handler. Keep gangways clear and floors well maintained.
Visibility
The handler must be able to see over or around the load. If a trolley is stacked so high it blocks the view, it is too high — reduce the stack or use a different aid. Poor visibility at doorways and blind corners is a frequent cause of collisions and trapped fingers.
Pushing and pulling sits alongside lifting in any complete handling programme. If your team also lifts, our refresher on safe lifting technique is a natural companion to this guide.
Key takeaways
- Pushing and pulling are covered by MHOR 1992 — the risk does not vanish on wheels.
- HSE guideline forces are higher for starting and stopping than for sustained movement.
- Push rather than pull, keep the back straight and apply force at waist-to-chest height.
- Plan the route: slopes, kerbs, poor floors and blocked visibility all raise the risk.
- The right trolley and good maintenance cut the force required dramatically.
Master the forces and the technique together, and pushing and pulling becomes one of the safest ways to move a heavy load. Our £18 Manual Handling course walks your team through every step.