A weighty issue tha energy firms must get to grips with
Energy workers face being banned from flights if they breach a new mandated weight limit, warns Natalie Walker
Energy industry companies have been given less than a year to get heavier staff down to a new mandated weight for offshore flights – or risk having their workers banned from travelling.
New mandates have been introduced by UK offshore trade body Offshore Energies UK (OEUK), which caps the seasonally clothed weight of staff flying out to offshore platforms at 124.7kg (which includes a 0.7kg safety margin) in order to ensure they can be winched to safety by a helicopter if necessary.
The move comes after research by OEUK found the average weight of offshore workers had risen by nearly 10kg since 2008, with as many as 2,200 workers (around 5 per cent of the offshore workforce) currently thought to be over the new limit.
But it could leave hundreds of workers facing a race to get their weight down in time for the November 2026 deadline, and those unable to do so would be banned from being able to do their jobs offshore, leaving their employment at risk.
Companies will need to carefully adhere to the new policy given the strict limit on medical certification. Failing to comply puts them at risk of not being able to deploy their staff offshore, so supporting staff and ensuring they are under the cut-off will benefit everyone involved and save unnecessary losses.
The policy has been put in place after consultation and research with helicopter and offshore providers and HM Coastguard, with an introductory phase designed to raise awareness of the problem running until January 31.
After that a transition phase will run from February 1 until the end of October, during which time workers over the limit will have six months to cut weight to a level where, including their clothing for the helicopter flight out, they are under 124kg.
After November 1 anyone who fails weight tests at their medical or mobilisation will not be able to travel offshore and will not get an OEUK medical certificate. Those who are marginally under will have their offshore certification reduced, with those between 120.1kg and 124kg at medical examination being certified for up to three months, and those between 115kg and 120kg getting a reduced-duration medical certificate for up to six months.
OEUK said this was to encourage weight loss among workers at the top end of the limits. Energy industry workers body, Step Change in Safety, will be providing healthy living information to members, with offshore industry businesses encouraged to provide weight loss support for staff.
The worst-case scenario is that workers who do not meet the new limits may be unable to work offshore. However, this could lead to claims of unfair dismissal, disability discrimination, and even indirect sex discrimination, as men are statistically more likely to be affected.
Employers can reduce these risks by offering practical support, engaging with employees about their individual circumstances, and clearly explaining the health and safety rationale behind the policy.
Beyond legal considerations, the bigger challenge is retaining skilled workers who are hard to replace. Helping as many employees as possible to meet safe weight limits will be a significant priority for offshore employers in 2026.
Natalie Walker, Senior Associate specialising in litigation and regulatory law at Pinsent Masons
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