Lost Time Incident: Manual Handling, Back Injury

DIA-AW- 201103 Shell Aviation February 2011

Target audience for this alert

 Into plane Operators and Airport Staff

What happened
An operator felt a pain in his back (lumbar spine) after lifting the
ladder (used for refuelling an A-320 aircraft) onto the carrier station
located at the rear of the refuelling vehicle It was his sixth refuelling of
the day and the last prior to the lunch break. On his returning to the
depot / rest rooms, he did not report the incident. On completion of the
break period, he resumed his normal duties thinking the pain was only
a temporary mild discomfit.
By the end the shift, the pain had become more severe and he
brought this to the attention of his supervisor. He was subsequently
taken to a local doctor who prescribed pain relief medication and time
off for recuperation.
The manual handling event involved lifting the 19 Kgm ladder by
holding onto one end of the ladder (as shown in the diagram right
above) up to the horizontal level and then moving forward and sliding
the other end of the ladder onto the support cage located about 50
cms off the ground. The lifting created additional stress onto the back
as the load is position well away from the body.

Why it happened

 Ergonomic analysis of various tasks at the airport had been conducted in 2006, but due to a
misunderstanding of the information within the report it had resulted in a lack appreciation of the risks
involved with this particular task. Consequently no mitigation action plan existed nor implemented for risk
reduction.
 Some operators had developed their own work practice of rolling the ladder into position near the vehicle
support bar, turning the ladder on its side, and then hooking it onto the carry cage. The lifting then into roll
on position only involved part of the ladder’s weight being manual supported (see photo lower right). Thus
reducing the load considerable. Not all operators were aware of this method nor was it included in the
training material.

Goal Zero: Zero injuries, Zero fatalities

Disclaimer: This document is made available for information only and on the condition that (i) it may not be relied upon by anyone, in the conduct of their own operations or otherwise; (ii) neither the
[Shell] company issuing this document nor any other person or company concerned with furnishing information or data used herein (A) is liable for its accuracy or completeness, or for any advice
given in or any omission from this document, or for any consequences whatsoever resulting directly or indirectly from any use made of this document by any person, even if there was a failure to
exercise reasonable care on the part of the issuing company or any other person or company as aforesaid; or (B) make any claim, representation or warranty, express or implied, that acting in
accordance with this document will produce any particular results with regard to the subject matter contained herein or satisfy the requirements of any applicable federal, state or local laws and
regulations; and (iii) nothing in this document constitutes technical advice, if such advice is required it should be sought from a qualified professional adviser.
Lessons learned
The importance of ensuring all manual handling tasks and risks are effectively assessed so as to identify
methods of Manual handling consistent with the techniques that reduce risk, ie reduce loads, operated in power
zone, reduce / eliminate twisting of the spine.

Action required
Airport refuelling manager are to hold a Manual handling toolbox meeting to discuss this incident. Ask team to
identify any potential risks activities that may have been overlooked in the recent Manual Handling Safety Day.
Share best practices within the group applicable to these tasks and / or Manual handling concerns raised.

Further information

Contact Latin America Regional HSSE Manager Sergio.Masid@shell.com or Rod.Lowther@shell.com if further

details are required.

Goal Zero: Zero injuries, Zero fatalities

Disclaimer: This document is made available for information only and on the condition that (i) it may not be relied upon by anyone, in the conduct of their own operations or otherwise; (ii) neither the
[Shell] company issuing this document nor any other person or company concerned with furnishing information or data used herein (A) is liable for its accuracy or completeness, or for any advice
given in or any omission from this document, or for any consequences whatsoever resulting directly or indirectly from any use made of this document by any person, even if there was a failure to
exercise reasonable care on the part of the issuing company or any other person or company as aforesaid; or (B) make any claim, representation or warranty, express or implied, that acting in
accordance with this document will produce any particular results with regard to the subject matter contained herein or satisfy the requirements of any applicable federal, state or local laws and
regulations; and (iii) nothing in this document constitutes technical advice, if such advice is required it should be sought from a qualified professional adviser.