Guidance for Manual Handling of Gas Cylinder

The Manual Handling Operations Regulations 1992 (updated 1998) came

into force in January 1993. The purpose of the regulations is to reduce the
risk of injury from manual handling operations.
To comply with these regulations, the Imperial College as an employer
must identify all manual handling operations undertaken by its employees
and appoint a competent person to assess the risks involved in the manual
handling activities.

It is imperative to carry out a risk assessment on manual handling of gas

cylinders which is a high risk activity. Cylinders are extremely heavy due
to the fact that they are made of metal and have to withstand high
pressure. They are also unstable when unsupported because of their long,
thin shape.
Over 30% of the accidents reported to the Health and Safety Executive
under RIDDOR 1995 (Reporting of Injuries, Diseases and Dangerous
Occurrences Regulations) were caused by manual handling activities. To
reduce these risks staffs that operate mechanical aids, such as cylinder
trolleys must be fully trained in their use and the use of correct body
mechanics for pushing and pulling.

The Imperial College has an Occupational Health Unit which provides

advice and, general training on manual handling to staff. Staff suffering
from manual handling injuries must report it to the Occupational Health
Unit using the accident form which can be obtain from the College
website (Safety Unit).

Risk Assessment
1. Identify hazards associated with manual handling of gas cylinders
The impact from falling cylinders can cause explosion resulting in
injuries from flying parts. Manual handling of cylinders involving wrong
postures can caused severe health problems such as disc injuries, sprains
and strains when muscles are stretched. Fractures can be caused by
crushing body parts under the heavy load of the cylinder.

2. Identify people at risk

The risk assessment must identity everyone who is at risk for the hazards
involved in handling gas cylinders: People directly involved in
performing the tasks (technicians, post graduates students), and people
who might be in the vicinity when there is an accident such as
contractors, cleaners, maintenance workers, students, and visitors.
Persons at risk must be identified to devise adequate control measures
which must give priority to protecting the whole workplace instead of
concentrating on individual measures such as use of protective personal
equipment.

3. Evaluation of existing control

Adequate control measures involved carrying out a risk assessment under
the Manual Handling Operation Regulation 1992 (amended 1998) and
taking the following point into account:
- Mass and dimension of the gas cylinders (safety data sheet from
supplier).
- Establish gripping points before doing the lift such as valve guard.
- Use of suitable PPE: lab coat, safety spectacles/goggles, safety shoes.
-Use of ergonomically designed mechanical aids e.g. cylinder trolley.
- Perform the task by two staff.

4. Record the finding

The finding of the risk assessment must be recorded and communicated
to all staff involved in the manual handling of gas cylinders.
The risk assessment must be reviewed when there is any change in the
task (longer carrying distance) or personnel (untrained staff) involved.

Techniques for Safe Manual Handling of Gas Cylinders

Loading Gas Cylinder on trolley

Wear steel toe capped shoes and industrial quality gloves

Undo securing bars on trolley and slide it near the cylinder
Unhook chain from rack and place palm of hand on top of cylinder
neck, get a firm grip
Tilt cylinder slightly forward so it rests on the rim of the base and
use the other hand to rotate cylinder milk churning it from rack to
trolley

Pushing trolley and unloading gas cylinder

Fasten securing bars on the trolley

Place one foot on the axle and tilt the trolley back so it balances
comfortably on the wheels
Keeping back straight, push trolley and set it down in front of the
laboratory bench
Remove cylinder from trolley, milk churning it into its new
position and clamp it securely to the bench using chains, or straps.

Training

Training is an important way of achieving competence and contributes to

the laboratorys health and safety culture at all levels. All employees must
be given the following training:

1. General training on Manual Handling as part of induction training

which should outline all the relevant health and safety issues associated
with manual handling operations.

2. Task specific training identified by suitable risk assessment of all

manual handling tasks performed by staff. Thus employees involved with
handling of gas cylinders must receive specific manual handling training,
as well as refresher training, including some practical session in the
course to demonstrate to staff how to perform the manual handling task
e.g. proper manual handling technique to load and propel a cylinder
trolley.

The objectives of this manual handling guidance is to assist the staff

involved with manual handling of gas cylinders to reduce the number of
manual handling injuries by providing practical advice to reduce the risks
associated with handling of cylinders.
Safe manual handling techniques when put into practice will help reduce
sickness and absenteeism, lower healthcare costs, insurance premiums
and compensation claims and improve productivity of the technical staff
of the Imperial College.

An example of Risk Assessment carried out on the Manual

Handling of Gas Cylinder
Manual Handling of loads: Assessment checklist
Section A Preliminary:
Task description: Handling of gas
cylinder.
Load weight: 60 Kg
Carrying distance:

*Circle as appropriate
Is an assessment needed?
(e.g. is there risk for injury?)
Yes/ No

Assessment discussed with

employees/safety representatives: Yes

If Yes continue. If No assessment need go no further.

Operations covered by this assessment
Gas cylinder from ground floor lifted and
placed on trolley which is manoeuvred
into lift, then pushed into lab, unloaded
and placed near lab bench.
Locations: Loading bay to Laboratory on
3rd floor.
Personnel involved: Lab Technician
Date of assessment: January 06

Section B See detailed analysis

Section C Overall assessment of the risk of injury? Low/ Med/ High
Section D- Remedial action to be taken
Remedial steps that should be taken, in order of priority:
1. Provide ergonomically designed cylinder trolley.
2. Task specific training for technicians.
3. Wear suitable PPE
4. Obtain help when doing the task
5. Always keep a spare oxygen cylinder in the lab.
Date by which action should be taken: January 06
Date for reassessment: July 06
Assessors name: S.J

Section B Detailed Risk Assessment for Manual Handling of Gas Cylinders

Questions to consider

If yes, tick level of

risk

Do the tasks involve:

Low

-High initial force to get load

moving?
-High forces to keep load in
motion?
-Sudden movements to start
stop or manoeuvre the load?
-Twisting/manoeuvring of the
load into position or around
obstacles?
-One-handed operations?
-The hand below the waist or
above shoulder height?
-Movement at high speed?
-Movement over long
distances?
-Repetitive pushing/ pulling?

Medium

High
9
9

Possible remedial action

e.g. changes to be made to
load, task, environment

Wheels difficult to move, not well aligned.

Weight supported on arms to balance cylinder
on trolley and maintain it in position, high force
required.

Review procedures for

maintenance of trolley.

9
9

Long distance: from 3rd floor to loading bay

situated on ground floor, shoulder and arms
muscles under considerable strain

9
9

Review suitability of
mechanical equipment.

9
9

The loads to be moved:

-Does it lack good handholds?

-Is it unstable/ unpredictable?

-Is vision over it restricted?

Problems occurring from the task

Due to its shape and absence of handle on

cylinders, and inclined position, initial large
Possibility of using two staffs
force needed to push trolley.
to perform task.
when loading and unloading cylinder on trolley,
risk of unpredictable movement high
Thin and long shape made it unstable

Question to consider
If trolleys used, are they:

If yes, tick level of

risk
Low

Medium

-Unsuitable for the type of

load?
-Unsuitable for the floor
surface/ work environment?

Possible remedial
action

Unsuitable trolley for a 65 Kg cylinder,

technician has to support trolley handle which
put excessive strain on shoulder, forearms and
wrists.

Consult manufacturer to find

alternative model of trolley.

Very difficult to steer and to hold handle of

trolley to prevent cylinder from falling.
Difficult to balance cylinder on trolley.

Assess design of handles and

ensure handle height are
appropriate.

Maintenance of trolley needed i.e. lubrication,

cleaning of wheels.

Arrange for plan preventive

maintenance of trolleys.

High

-Difficult to steer?
9

-Easily damaged or defective?

-Without brake or difficult to
stop?

Problems occurring from the task

-With brakes, but the brakes

are poor/ineffective?
-Without a planned inspection
and maintenance regime based
on a frequency that keeps
them in working order?

Questions to consider

If yes, tick level of

risk

Do the tasks involve:

Low

-Consider the work environment: are

there:
-Constraints on posture
-Confined spaces/ narrow doorways?
-Surfaces or edges to cause
cuts/abrasions/burns to hand or body
-Rutted/damaged/slippery floors?
-Ramps/slopes/uneven surface?
-Trapping or tripping hazards?
-Hot/cold/humid conditions?
-Strong air movement?
-Poor lighting conditions?
Consider individual capability-does the
job:
-Require unusual capability?
-Pose a risk to those with a health
problem or physical/learning disability
-Pose a risk to pregnant women?
-Call for special information/training?

Medium

Problems occurring from the

task

Possible remedial
action

High

9
9
9
9
9
9
9
9
9

9
9
9
9

Large constraint on posture while

Review suitability of trolley.
holding the trolley and trying to prevent Provide facilities (chain) to
load from falling.
secure trolley in lift.
Hard to open doors while holding
trolley.
Confined space: transport cylinder in
lift.
Presence of uneven surface: Problems
occur when engaging the two-wheeled
trolley in lift (lift floor sometime not at
same levelled).

Report problem to lift

engineer.

Person need to be strong to be able to

Review suitability of trolley
hold weight of cylinder on trolley. Hard
to get the right equilibrium.
Would pose risk to person with
physical disability.
Training needed.

Provide task-specific
training.

Questions to consider

Yes/
No

Problems occurring
from the task

Possible remedial
action

Yes

Tricky to manoeuvre
cylinder with gloves,
dexterity decreased

Find alternative types of

gloves.

Wheels not aligned properly

Review maintenance
procedures.

Other factors to consider

Equipment
-Is movement or posture hindered by clothing or personal protective
equipment?
-Is there an absence of correct/suitable PPE being worn?
No
-Are trolleys/floor surfaces poorly maintained/ cleaned/ repaired?
No
-Is there a lack of regular maintenance procedures for the equipment?
Yes
Work Organisation(Psychological factors)
-Do workers feel that there has been a lack of consideration given to the
planning and scheduling of tasks/ rest breaks?
-Do workers feel that there is poor communication between managers
and employees (e.g. not involved in risk assessments of tasks)?
-Are there sudden changes in workload, without mechanism to deal with
the change?

No

No

No