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 laboratory’s 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: *Circle as appropriate

Task description: Handling of gas Is an assessment needed?
cylinder. (e.g. is there risk for injury?)
Load weight: 60 Kg
Carrying distance: 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
Assessor’s name: S.J
Section B Detailed Risk Assessment for Manual Handling of Gas Cylinders
Questions to consider
Do the tasks involve:
-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?
The loads to be moved:
-Does it lack good handholds?
-Is it unstable/ unpredictable?
-Is vision over it restricted?
If yes, tick level of Problems occurring from the task Possible remedial action
risk e.g. changes to be made to
load, task, environment
Low Medium High
9 Wheels difficult to move, not well aligned. Review procedures for
Weight supported on arms to balance cylinder maintenance of trolley.
9 on trolley and maintain it in position, high force
required.
9
9 .
9
9 Long distance: from 3rd floor to loading bay Review suitability of
situated on ground floor, shoulder and arms mechanical equipment.
9 muscles under considerable strain
9
9
Due to its shape and absence of handle on
cylinders, and inclined position, initial large Possibility of using two staffs
9 force needed to push trolley. to perform task.
when loading and unloading cylinder on trolley,
9 risk of unpredictable movement high
Thin and long shape made it unstable
9
Question to consider
If trolleys used, are they:
-Unsuitable for the type of
load?
-Unsuitable for the floor
surface/ work environment?
-Difficult to steer?
-Easily damaged or defective?
-Without brake or difficult to
stop?
-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?
If yes, tick level of Problems occurring from the task Possible remedial
risk action
Low Medium High
9 Unsuitable trolley for a 65 Kg cylinder, Consult manufacturer to find
technician has to support trolley handle which alternative model of trolley.
put excessive strain on shoulder, forearms and
9 wrists.
9 Very difficult to steer and to hold handle of Assess design of handles and
trolley to prevent cylinder from falling. ensure handle height are
9 Difficult to balance cylinder on trolley. appropriate.
9
9
Maintenance of trolley needed i.e. lubrication, Arrange for plan preventive
cleaning of wheels. maintenance of trolleys.
Questions to consider
Do the tasks involve:
-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?
If yes, tick level of Problems occurring from the Possible remedial
risk task action
Low Medium High
Large constraint on posture while Review suitability of trolley.
holding the trolley and trying to prevent Provide facilities (chain) to
9 load from falling. secure trolley in lift.
9 Hard to open doors while holding
9 trolley.
Confined space: transport cylinder in
9 lift.
9
9 Presence of uneven surface: Problems
9 occur when engaging the two-wheeled Report problem to lift
9 trolley in lift (lift floor sometime not at engineer.
9 same levelled).
Person need to be strong to be able to Review suitability of trolley
9 hold weight of cylinder on trolley. Hard
9 to get the right equilibrium.
9 Would pose risk to person with
physical disability. Provide task-specific
9
Training needed. training.
Questions to consider Yes/ Problems occurring Possible remedial
No from the task action

Other factors to consider

Equipment

-Is movement or posture hindered by clothing or personal protective Tricky to manoeuvre Find alternative types of
equipment? Yes cylinder with gloves, gloves.
dexterity decreased
-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? Review maintenance
Yes Wheels not aligned properly procedures.
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? No

-Do workers feel that there is poor communication between managers

and employees (e.g. not involved in risk assessments of tasks)?
No
-Are there sudden changes in workload, without mechanism to deal with
the change?
No