How to choose the right ergonomic lifting aid
Ergonomic lifting aids relieve the back where manual lifting reaches its limits. This guide shows how to select the right device by load weight and the DGUV key indicator method, which limit values apply and which design fits your task.
View lifting aidsAt what weight do you need a lifting aid?
There is no legal kilogram limit above which a lifting aid is mandatory, but there are clear guidance values. Around 25 kg for men and 15 kg for women serve as a reference for occasional lifting in a good posture. When lifting is frequent, awkward or above shoulder height, these values drop sharply.
In practice: from about 20 kg, or at a high repetition rate, a technical lifting aid should be considered. Musculoskeletal disorders are among the most common causes of sick leave and, in many operations, 40‑60 % of them trace back to manual load handling.
Matching hand trucks, trolleys and lift systems for in-plant transport.
Read the guideHow does the key indicator method guide selection?
The key indicator method (KIM) from the Federal Institute for Occupational Safety (BAuA) and the DGUV rates strain using key indicators. For lifting and carrying, load weight, posture, execution conditions and duration or frequency feed into a single risk score.
The sum of points yields a risk range. It shows whether the task is harmless or whether workplace redesign and a lifting aid are required.
Which lifting aid suits which task?
The right design depends on load, distance and environment. Vertical lifting calls for different equipment than horizontal transport or tilting drums and rolls.
- Vacuum lifters: for dense, smooth surfaces such as panels, boxes and glass, often 50 kg or more per suction pad.
- Electric pallet trucks and scissor lift tables: raise loads to an ergonomic working height and avoid deep bending.
- Manipulators and balancers: guide heavy parts almost weightlessly, ideal for frequent repetition.
- Hand trucks and trolleys: cut carrying over distance but do not relieve the initial lift.
- Drum and roll handlers: tilt and position bulky containers safely without trunk rotation.
Watch the rated capacity with a safety margin, the lift height and the floor condition. A device should cover the whole task, otherwise the load ends up being moved by hand after all.
Frequently asked questions
At what weight is a lifting aid mandatory?
There is no fixed legal limit. Reference values are around 25 kg for men and 15 kg for women. The risk assessment decides; in practice a lifting aid is recommended from about 20 kg or with frequent lifting.
What is the key indicator method?
The KIM is a procedure developed by BAuA and the DGUV that combines load weight, posture, execution conditions and frequency into a single score. The resulting risk range indicates whether and when a lifting aid is needed.
Which lifting aid reduces back strain best?
It depends on the task. Vacuum lifters and manipulators take over the lift almost entirely, while lift tables avoid deep bending. The key is that the load is not moved by hand again anyway.
Must the selection be documented?
Yes. The risk assessment and manual handling regulations require a traceable evaluation. The KIM scores and the measure chosen from them belong in the documentation.
Looking for the right lifting aid?
We help you choose by load weight and the key indicator method - from vacuum lifters and lift tables to manipulators.
Standards-based
Selection follows the DGUV key indicator method and handling regulations.
Fewer MSDs
Technical aids measurably lower spinal load.
Correctly sized
Rated capacity with a safety margin for every task.
Expert advice
Our specialists support your risk assessment.