GUIDANCE NOTE 3 SAFE CYLINDER HANDLING AND THE APPLICATION OF THE MANUAL HANDLING OPERATIONS REGULATIONS TO GAS CYLINDERS REVISION 3: 2016

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1 GUIDANCE NOTE 3 SAFE CYLINDER HANDLING AND THE APPLICATION OF THE MANUAL HANDLING OPERATIONS REGULATIONS TO GAS CYLINDERS REVISION 3: 2016

2 GUIDANCE NOTE 3 SAFE CYLINDER HANDLING AND THE APPLICATION OF THE MANUAL HANDLING OPERATIONS REGULATIONS TO GAS CYLINDERS REVISION 3: 2016 Copyright 2016 by British Compressed Gases Association. First printed All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopy, without permission from the publisher: BRITISH COMPRESSED GASES ASSOCIATION Registered office: 4a Mallard Way, Pride Park, Derby, UK. DE24 8GX Company Number: 71798, England Website: ISSN

3 PREFACE The British Compressed Gases Association (BCGA) was established in l971, formed out of the British Acetylene Association, which existed since l901. BCGA members include gas producers, suppliers of gas handling equipment and users operating in the compressed gas field. The main objectives of the Association are to further technology, to enhance safe practice, and to prioritise environmental protection in the supply and use of industrial, food and medical gases, and we produce a host of publications to this end. BCGA also provides advice and makes representations on behalf of its Members to regulatory bodies, including the UK Government. Policy is determined by a Council elected from Member Companies, with detailed technical studies being undertaken by a Technical Committee and its specialist Sub-Committees appointed for this purpose. BCGA makes strenuous efforts to ensure the accuracy and current relevance of its publications, which are intended for use by technically competent persons. However this does not remove the need for technical and managerial judgement in practical situations. Nor do they confer any immunity or exemption from relevant legal requirements, including by-laws. For the assistance of users, references are given, either in the text or Appendices, to publications such as British, European and International Standards and Codes of Practice, and current legislation that may be applicable but no representation or warranty can be given that these references are complete or current. BCGA publications are reviewed, and revised if necessary, at fiveyearly intervals, or sooner where the need is recognised. Readers are advised to check the Association s website to ensure that the copy in their possession is the current version. This document has been prepared by BCGA Technical Sub- Committee 6. This document replaces BCGA Guidance Note 3, Revision 2: It was approved for publication at BCGA Technical Committee 154. This document was first published on 13/07/2016. For comments on this document contact the Association via the website

4 CONTENTS Section Page TERMINOLOGY AND DEFINITIONS 1 1. INTRODUCTION 2 2. SCOPE 3 3. MANUAL HANDLING OPERATIONS REGULATIONS 3 4. AVOID MANUAL HANDLING OF GAS CYLINDERS 4 5. ASSESSMENT OF HANDLING GAS CYLINDERS Cylinder weight Cylinder size / shape The work environment 7 6. CONTROL MEASURES TO REDUCE THE RISK OF INJURY Mechanical handling equipment Trolleys Personal Protective Equipment TRAINING SAFE CYLINDER HANDLING Typical injuries Cylinder handling techniques REFERENCES * 16 APPENDICES: Appendix 1 Illustrated examples of good and bad practice 18 Appendix 2 Appendix 3 Appendix 4 Worked Example 1 Model Risk Assessment Moving cylinders by hand Worked Example 2 Model Risk Assessment Moving cylinders by churning Worked Example 3 Model Risk Assessment Moving cylinders by trolley * Throughout this publication the numbers in brackets refer to references in Section 9. Documents referenced are the edition current at the time of publication, unless otherwise stated.

5 TERMINOLOGY AND DEFINITIONS Gas cylinder May Shall Should For the purposes of this document includes all cylinders containing a compressed, dissolved and liquefied gas. Indicates an option available to the user of this Guidance Note. Indicates a mandatory requirement for compliance with this Guidance Note and may also indicate a mandatory requirement within UK law. Indicates a preferred requirement but is not mandatory for compliance with this Guidance Note. 1

6 GUIDANCE NOTE 3 SAFE CYLINDER HANDLING AND THE APPLICATION OF THE MANUAL HANDLING OPERATIONS REGULATIONS TO GAS CYLINDERS 1. INTRODUCTION This Guidance Note provides a short summary of the duties of employers and employees under the Manual Handling Operations Regulations (1) as amended by the Health and Safety (Miscellaneous Amendments) Regulations (5) with regard to the handling of gas cylinders by users. The Health and Safety Executive (HSE) provide guidance on the Manual Handling Operations Regulations (1) within HSE L23 (7), Manual Handling. Manual Handling Operations Regulations 1992 (as amended). Guidance on Regulations. Additional information can be found in the HSE Research Report 228 (15), Review of the risks associated with pushing and pulling heavy loads. Manual handling covers a wide variety of tasks including lifting, lowering, pushing, pulling and carrying, and specifically for gas cylinders movement by churning. If any of these tasks are not carried out safely then there is a risk of injury. Work related manual handling injuries can have serious implications for the employer too as they may have to bear substantial costs, for example for retraining, wages, overtime and civil liability. Musculoskeletal disorders Manual handling is one of the most common causes of injury at work and causes over a third of all workplace injuries which include work related Musculoskeletal Disorders (MSDs) such as upper and lower limb pain / disorders, joint and repetitive strain injuries. MSDs affect muscles, joints, tendons and other parts of the musculoskeletal system. Risk factors that can contribute to the onset of some types of MSD include: Repetitive and heavy lifting; Bending and twisting; Repeating an action too frequently; Uncomfortable working position; Exerting too much force; Working too long without breaks; Adverse working environment (e.g. hot, cold). When a number of such risk factors are present, the risk is usually greater. 2

7 Gas cylinders can be awkward objects to handle safely. This Guidance Note has been prepared by producers and distributors of cylinder gases and cylinder manufacturers for the benefit of all users. The purpose of this guidance is: To provide a basis for good practice when handling cylinders; The implementation of the Manual Handling Operations Regulations (1) relating to gas cylinders; To give specific guidance to personnel involved in handling cylinders, as well as their employer. The Manual Handling Operations Regulations (1) were introduced predominantly to reduce the number and severity of back and other injuries such as those to hands, arms and feet, suffered in industry as a result of manual handling operations by: Avoiding the need for potentially hazardous manual handling, so far as is reasonably practicable; Identifying potential hazards through structured assessment; Subsequent risk reduction. 2. SCOPE To define the principles of safe practice for handling gas cylinders at work. Although this Guidance Note encourages the use of mechanical handling equipment, it does not incorporate specific guidance on their use or maintenance, which should be obtained from the equipment manufacturers. Refer to the Provision and Use of Work Equipment Regulations (2) and the Lifting Operations and Lifting Equipment Regulations (3). For additional guidance on handling Liquid Petroleum Gas (LPG) Cylinders refer to the UKLPG. 3. MANUAL HANDLING OPERATIONS REGULATIONS Employers have a legal obligation under the Manual Handling Operations Regulations (1) to make a sufficient and suitable assessment of the risk to employees from the manual handling of loads. The Manual Handling Operations Regulations (1) set out a hierarchy of measures to reduce the risks from manual handling. Employers should: Avoid hazardous manual handling operations so far as is reasonably practicable, refer to Section 4; 3

8 Assess the risk in any hazardous manual handling operations that cannot be avoided, refer to Section 5; and Reduce the risk of injury so far as is reasonably practicable, refer to Section AVOID MANUAL HANDLING OF GAS CYLINDERS Avoid manual handling operations so far as is reasonably practicable, by redesigning the task to avoid moving the gas cylinder by hand. Options to achieve this include: Use of a palletised process, where cylinders remain in a pallet. Introducing the use of cylinder bundles. Installing a bulk tank. Installing a gas generator. 5. ASSESSMENT OF HANDLING GAS CYLINDERS Carry out a risk assessment to identify where there may be a risk of injury from any hazardous manual handling operations that cannot be avoided. NOTE: You may need to conduct risk assessments for other activities alongside the requirement for a Manual Handling Operations Regulations (1) risk assessment. HSE has developed a range of tools to help employers analyse lifting, carrying and team handling (the MAC tool and the V-MAC tool), repetitive upper limb tasks (the ART tool) and pushing and pulling (the RAPP tool). Depending on the task, more than one tool may be used, for example, you may need to pick up a cylinder (lifting), carry it to a workstation (carrying), then carry out a variety of tasks on the cylinder requiring regular movement (repetitive movements). There is detailed information on each of these tools on the HSE website. HSE Guidance L23 (7) provides guidance on carrying out a manual handling assessment and includes examples of Manual Handling Checklists that may be used as a basis for assessment. HSE INDG 143 (10), Manual handling at work. A brief guide, provides simplified guidance for carrying out a manual handling assessment. BCGA TIS 17 (23), Model risk assessment for the manual handling of gas cylinders, has been developed based on this guidance, as a model risk assessment specifically for manual handling activities associated with gas cylinders. Carry out a preliminary assessment to establish if the activity is low risk. Information is available in HSE L23 (7) or as detailed in BCGA TIS 17 (23), use the Risk Assessment Filter. If the activity is confirmed as low risk a more thorough risk assessment is not necessary, record the assessment. 4

9 If the preliminary assessment indicates that the activity involves an increased risk from manual handling then a thorough risk assessment is required. When conducting a risk assessment some of the typical factors to be considered include: The task Consider why gas cylinders are being used and whether there is a suitable alternative. Determine how the cylinders are being handled, how frequently and over what distance. Gas suppliers provide cylinders in a variety of sizes. Where practical, one simple method of reducing the risk when manual handling is to use smaller cylinders. The individual Consider the individual s physical capability to handle a gas cylinder. Have the individuals who are handling gas cylinders got the necessary information, instruction and training for handling gas cylinders? Refer to Section 7. The load Gas cylinders vary in weight, size and shape. These variations can give rise to potential handling hazards, a number of which are expanded on in Section 5.1 and Section 5.2. The environment Consider the location where the cylinder is being handled and the ambient weather conditions that may exist (not just on the day of the assessment), refer to Section 5.3. Case studies of good and bad practice when manually handling gas cylinders are illustrated in Appendix 1. Appendixes 2 to 4 provide worked examples of risk assessments carried out using these case studies, which use the templates for risk assessments within BCGA TIS 17 (23). The assessment may be carried out by managers, supervisors and operatives with knowledge of the regulations and experience in manual handling operations. Employees representatives should be consulted and involved in the risk assessment process. Employers having five or more employees shall document the risk assessment. Records of each assessment shall be kept and be subject to regular review. All risk assessments shall be reviewed: When there is reason to suspect that it is no longer valid. When any significant changes are made or new information comes to light (e.g. following an accident or injury involving manual handling operations). Periodically to take account of small changes in work practices which will eventually have a cumulative effect. 5

10 5.1 Cylinder weight Cylinders range from small lecture bottles, which are of low risk potential if handled correctly, to banks of large cylinders (bundles), manifolded together, that can only be handled with appropriate mechanical handling equipment. The weight of cylinders can be obtained from the gas supplier. Work instructions should provide information on the weight of cylinders to be handled. The weight of a cylinder depends on several factors, including its capacity, construction, the material of construction and the weight of product contained. As an example some typical weights for steel cylinders are displayed in Table 1. Type of cylinder Product Approximate weight full (kg) Small Oxygen 20 (10 Litre) Carbon Dioxide 23 Acetylene 19 LPG (approx. 7 kg) 17 Medium Oxygen 58 (30 Litre) Carbon Dioxide 60 Acetylene 59 LPG (approx. 19 kg) 45 Large Oxygen 80 (50 Litre) Carbon Dioxide 99 Acetylene 93 LPG (approx. 47 kg) 95 < 10 Litre < 10 Table 1: Typical weights for some common gas cylinders It is important that there is a method available to distinguish between full and nominally empty cylinders containing liquefied gases due to the movement of the liquid inside the cylinder which may affect the cylinder centre of gravity. Some gas cylinders have a valve guard fitted, a check should be made with the gas supplier to determine if this is suitable for manual handling and / or lifting. However, it is recommended that cylinders are secured into, and moved in a purpose-built trolley whenever practicable, refer to Section Cylinder size / shape Cylinders of various heights and diameters are used. Gas cylinders typically have a large height to diameter ratio and a high centre of gravity which may render them unstable on ground that is not level. On unsuitable or uneven surfaces freestanding cylinders may topple over causing adjacent cylinders to topple. Cylinder handlers can be at risk of injury if attempting to stop a falling cylinder or coming into contact with a falling cylinder. 6

11 WARNING: Do not attempt to catch a falling cylinder; get out of the way! Some typical sizes for steel cylinders are illustrated in the Table 2. There is a risk of injury from incorrectly lifting a fallen cylinder to restore it to the vertical, refer to Section 8. Gas cylinders containing a liquefied gas have a larger base diameter with a low height to diameter ratio and low centre of gravity and are relatively stable. Handlers should, however, be aware that when moving gas cylinders containing a liquefied gas from the vertical position the centre of gravity will alter and may affect the stability of the cylinder. NOTE: Some gas cylinders have a rounded base profile. This style is typical of older designs, the majority of modern cylinders utilise a flat base profile. Round base profiles are more likely to be used in multiple cylinder packs or banks where the mountings and frame make the cylinders stable. If you have a single cylinder with a rounded base profile, take extra care when handling and when returning to a store, as necessary contact your gas supplier for additional advice. Table 2: Typical sizes for some common gas cylinders (cm) 5.3 The work environment Consider the suitability of the work environment and the route of travel. Be aware of the hazards of uneven, sloping, slippery and vibrating surfaces as well as loose debris. As necessary clear the route of travel of objects which will impede the journey, and arrange for barriers, doors etc. to be opened whilst moving through them. Are different handling techniques required for day and night operations? adequate lighting? Is there Consider how to handle cylinders in a range of potential weather conditions, e.g. rain, snow, high winds etc. Wet cylinders may be slippery. Extra care will be required when handling them. NOTE: On completion of any handling task involving a gas cylinder, the cylinder should be stowed in an appropriate stowage or a dedicated gas cylinder store. Refer to BCGA CP 44 (20), The storage of gas cylinders. 7

12 6. CONTROL MEASURES TO REDUCE THE RISK OF INJURY Control measures should be implemented when handling cylinders. So far as is reasonably practicable, avoid manual handling operations, refer to Section 4. Use mechanical handling equipment, refer to Section 6.1. Ensure all personnel involved with manual handling cylinders have the appropriate information, instruction and training, refer to Section 7. Use a handling trolley, designed for moving gas cylinders, refer to Section 6.2. When conducting manual handling activities always wear the correct Personal Protective Equipment (PPE), refer to Section 6.3. Always ensure gas cylinders are secured when not being moved. 6.1 Mechanical handling equipment HSE provide specific guidance for transport in the workplace, refer to the HSE website: HSE HSG 136 (9), A guide to workplace transport safety, and HSE INDG 199 (12), Workplace transport safety. A brief guide Vehicles Vehicles used for the carriage of gas cylinders should be of a suitable design. When off-loading gas cylinders appropriate means should be used, e.g. a fork lift truck for palletised cylinders. In addition to these hazards, where cylinders are transported on vehicles not specifically designed for carriage of cylinders there is a significant risk of injury during loading and unloading operations, particularly if it is necessary to handle cylinders in an awkward fashion or in a confined space. This activity may require a specific risk assessment Forklift trucks Forklift trucks are often used to carry cylinders secured in pallets. Your cylinder supplier may be able to provide pallets to facilitate the movement of cylinders from storage to the point of use Cranes For hoisting, either a purpose-made cradle, a twin-rope sling or a bandage sling should be used. Magnet hoists, single ropes or chain slings shall not be used. ALWAYS check that cylinders in pallets and storage cages are stable and straighten any leaning cylinders before releasing the restraining strap or chain and ALWAYS GET HELP TO DO THIS. 8

13 The European Industrial Gases Association (EIGA) provide advice on transporting gas cylinders using a crane within EIGA Safety Information 25 (19), Crane transport of cylinder packages Cylinder pallets Always check that cylinders in pallets are stable before releasing strap or chain. Remember if cylinders in a pallet are leaning or unstable GET HELP before removing the restraining straps. Never load cylinders into a pallet that has defective restraining straps or chains or severely distorted bases. Ensure that the base is clear of debris. Never hide round-bottomed or unstable cylinders in the middle of a pallet. 6.2 Trolleys Wherever practicable, suitable trolleys should be used to move small quantities of cylinders. Two-wheeled trolleys, adapted to secure the cylinders whilst they are being moved, are the most versatile as they will assist the movement of cylinders over uneven ground and over kerbs. They can also be easily stowed on a vehicle to facilitate handling of cylinders during delivery operations. NOTE: Whilst two-wheeled trolleys are very common, three or four wheel trolleys are available. These have the benefit that the operative does not support any weight. BS 2718 (16), Specification for gas cylinder trolleys, provides a specification for the design of gas cylinder trolleys. HSE INDG 398 (14), Making the best use of lifting and handling aids, provides advice on lifting and handling aids. Manual handling risk assessments should consider the following aspects of using a trolley: (i) Securing straps. Straps or chains to ensure that the cylinders cannot fall from the trolley must be fitted and used at all times. (ii) Handle design. Handles should be such that: Two-handed operation is required and so designed to avoid trapping / knocking of hands and elbows. They should protrude far enough from the back of the trolley to prevent the operator knocking their shins against the back of the trolley. The height of the handles with respect to the operator is appropriate. A height of 950 mm will be suitable for most people. 9

14 (iii) Wheels. Larger wheels of at least 200 mm are recommended for cylinder trolleys. They have a lower rolling resistance than smaller wheels and will be less affected by uneven floor surfaces. The trolley wheels should be sufficiently far apart so that the stability of the trolley / load is not impaired. (iv) The load height. Does the operator have to twist around the load to see the direction of travel? (v) The trolley / load width. With respect to the narrowest point of the travel route; there should be sufficient space to manoeuvre the trolley easily through any doorways / narrow openings to avoid trapping the hands. (vi) Force. The force required to move the trolley / load. Refer to Table 3. Consideration should be given to the provision of brakes, which will facilitate loading and unloading of the cylinders or where there may be sloping surfaces. (vii) Other people in the workplace. If the trolley is being used to carry heavy loads consideration must be given to how easy it will be to stop the load to prevent collisions. (viii) Maintenance. Regular maintenance, particularly of the wheels and bearings, will ensure that the forces required to push and pull the cylinders are kept to a minimum. Other factors to consider are tread wear, corrosion and a check of the cylinder securing mechanism (straps / chains etc.). (ix) Pre-use check. Always carry out an inspection of the trolley before use to ensure it is suitable and serviceable for the task to be undertaken. Guideline figure for stopping or starting a load * Men 20 kg (about 200 N) Women 15 kg (about 150 N) Guideline figure for keeping a load in motion * 10 kg (about 100 N) 7 kg (about 70 N) * These guideline figures trigger the need for a detailed risk assessment. Table 3: The force required to move the trolley / load 6.3 Personal Protection Equipment The minimum recommended Personal Protective Equipment (PPE) requirements for personnel involved with the handling of gas cylinders includes: Foot protection. Safety boots / shoes, footwear with metatarsal protection is recommended. 10

15 Hand protection. Use gloves of an appropriate design for handling cylinders. Eye protection. In certain locations, or site conditions, other additional PPE may be obligatory, e.g. hard hats, ear defenders, high-visibility clothing. All PPE is to be kept free of oil and grease. Contaminated PPE is to be replaced. The work activity risk assessment will determine the requirement for the use of hazard controls, including PPE. PPE may only be considered as a control to achieve an acceptable level of residual risk after other levels of control have been addressed. Where PPE is required a PPE Assessment is to be carried out. PPE is to be provided as required by the Personal Protective Equipment Regulations (4). The PPE shall be selected for a particular task and location and shall be appropriate and chosen to effectively reduce the overall risk. Thus there are different PPE requirements for differing products, different tasks and possibly different personnel. Due regard is to be given to the requirements of the Control of Substances Hazardous to Health Regulations (6), any relevant equipment publications, manufacturers information and the product Safety Data Sheet. HSE L25 (8), Personal Protective Equipment at Work, provides guidance on the Personal Protective Equipment Regulations (4). EIGA Document 136 (18), Selection of personal protective equipment, provides guidance for selecting and using PPE at work. 7. TRAINING All personnel who are required to handle gas cylinders shall receive suitable information and instruction regarding the hazards associated with gas cylinders and the gases being stored within them, and provided with the necessary skills and knowledge to carry out their job safely. It is the duty of the employer to ensure their persons are adequately trained and to establish competency. It is recommended that a training programme is carried out under a formalised system where an acceptable level of competency has to be achieved. Records shall be kept of the training provided and the competence level achieved. The training programme shall make provision for periodic re-training. Recommendations for the training of personnel are described in EIGA Document 23 (17), Safety training of employees. BCGA GN 23 (20), Identifying gas safety training requirements in the workplace, provides information on the topics that should be covered when considering gases safety training. Specific information on the knowledge and training for manual handling is also given in HSE L23 (7). Training shall not, however, be seen as the means of accepting a high-risk activity. Effective training should complement a safe system of work and the continual development of techniques and equipment to reduce the risk of injury. Training should be reviewed and/or up-dated following: A related accident or incident. 11

16 The receipt of gases which have not previously been used on site. Changes to guidance or information previously provided. The appointment of new and / or transferred employees. For compressed gas cylinders the information provided to the employees should include: Weight. Advice on stability. Position of hand holds and attachment points. Safe use of lifting devices and other mechanical aids. The importance of good housekeeping. How to identify unstable / unsafe cylinder loads. The necessary protective equipment for each activity. Appropriate techniques for handling cylinders, including how to churn, dolly or roll cylinders vertically. Not turning your back on a potentially unstable cylinder or attempting to catch a falling cylinder. For the employees handling cylinders, advice must be given in the basic requirements of the regulations and instructions on basic handling techniques, i.e. basic lifting practice, positioning of feet and hands, smooth non-jerking motion and taking account of environmental conditions. Short, concise, written work instructions are often useful guidance to employees to remind them of the safe handling techniques. It may be necessary for work instructions to clearly identify and prohibit certain manual handling activities that have given rise to accidents and personal injury in the past. Advice and information on training for customers and third parties, offered by suppliers, can be of benefit in reducing accidents in the gas user industries. 8. SAFE CYLINDER HANDLING Cylinders should be moved on a hard flat surface, handling can be hazardous, particularly on unsuitable surfaces. If cylinders are handled horizontally, the risk of injury is increased because of the need to bend, stoop and to lift cylinders, with the additional potential of trapping fingers. 12

17 On completion of the move the cylinder should be left in a secure position. For information on gas cylinder stores refer to BCGA CP 44 (20). Where gas cylinders are being supplied to customers, appropriate advice should be provided. BCGA provide information in BCGA TIS 12 (22), Handle gas cylinders safely. Information for customers handling gas cylinders. 8.1 Typical injuries Experience has shown that there are a range of typical injuries that can occur when handling gas cylinders. The causes of hand injuries are: Failure to wear stout gloves which may greatly reduce the probability of cuts and abrasions. Trying to straighten cylinders or cylinders that are leaning in strapped pallets. Trapping the hand between individual cylinders or contact with other stationary objects. This can include: o Not being fully in control of the movement of the cylinder, for example, by attempting to complete a task to quickly. o Movement of cylinders which are wet, which can be slippery and therefore more difficult to handle. NOTE: Where cylinders are identified as damaged they should not be used. They should be identified as damaged, returned to the store and be segregated from other gas cylinders, and the gas supplier advised. The types of injury resulting from people trapping their hands are shown in Figure 1. Broken bones Dislocated fingers Cuts Bruises Figure 1: Possible hand injuries The causes of lower limb and torso injuries are: A cylinder falling which contacts the body. 13

18 Dropping a cylinder during a movement. Failure to wear safety footwear with toe protection (footwear fitted with metatarsal protection is recommended). Unexpected movement of a cylinder, or the disturbance of adjacent cylinders, when unsecured. Attempting to prevent a cylinder from falling. Never attempt to catch a falling cylinder; get out of the way! The types of injury resulting from falling cylinders are shown in Figure 2. Leg injuries Broken toes Broken metatarsal bones Injured chest 8.2 Cylinder handling techniques Figure 2: Possible injuries from falling cylinders How to raise the cylinders from the horizontal Cylinders should be stored upright. If cylinders need to be lifted by hand from a horizontal position, avoid injury by using correct lifting methods, refer to Figure 3. Foot position: hip width apart with one slightly in front of the other, astride the valve end of the cylinder. Bend the knees to lower your body. This will enable your thigh muscles to do most of the lifting. Once your grip is established, look forward, which encourages good body posture. Ensure that the valve guard is secure then take a firm grip using both hands. Only lift using the valve guard if it has been designed for this purpose, otherwise grip the cylinder neck. Keep your back straight throughout its length (this does not mean it has to be vertical). Doing this will help to reduce strain on the back. 14

19 Lift decisively with a smooth non-jerking motion. It is done initially by straightening the legs then following through with the arms at the same time walking forward until the cylinder is upright. Figure 3: Raising a cylinder from the horizontal Moving cylinders by hand A recommended method to move a cylinder over short distances is by churning, refer to Figure 4. The churning method requires the use of both hands. One supports the cylinder whilst the other rotates the cylinder (away from the body). It requires the cylinder to be tilted slightly (again away from the body). The method takes some practice (ideally with empty, quite light cylinders such as aluminium alloy ones) and should only be attempted on a firm, even surface. Churning should only be used for short distances (up to 5 metres). For longer distances or uneven or slippery surfaces, trolleys or mechanical aids should be used. Figure 4: Churning a cylinder Cylinders should not be dragged or rolled horizontally along the ground since this may damage or even open the valve and will damage identifying marks and symbols. Cylinders should not be moved with the valve open and should not be transported with the regulators and hoses attached, unless on a purposely designed trolley or carrier. Cylinders should not be used as work-supports or rollers. 9. REFERENCES Document Number Title 1. SI 1992 No The Manual Handling Operations Regulations 1992 (as amended). 2. SI 1992 No Provision and Use of Work Equipment Regulations (PUWER). 3. SI 1998 No Lifting Operations and Lifting Equipment Regulations (LOLER). 4. SI 2002 No Personal Protective Equipment Regulations

20 Document Number Title 5. SI 2002 No Health and Safety (Miscellaneous Amendments) Regulations SI 2002 No Control of Substances Hazardous to Health Regulations 2002 (COSHH). 7. HSE L23 Manual Handling. Manual Handling Operations Regulations 1992 (as amended). Guidance on Regulations. 8. HSE L25 Personal Protective Equipment at Work. 9. HSE HSG 136 A guide to workplace transport safety. 10. HSE INDG 143 Manual handling at work. A brief guide. 11. HSE INDG 163 Risk assessment. A brief guide to controlling risks in the workplace. 12. HSE INDG 199 Workplace transport safety. A brief guide. 13. HSE INDG 383 Manual Handling Assessment Charts (the MAC tool). 14. HSE INDG 398 Making the best use of lifting and handling aids. 15. HSE Research Report 228 Review of the risks associated with pushing and pulling heavy loads. 16. BS 2718 Specification for gas cylinder trolleys. 17. EIGA IGC Document EIGA IGC Document EIGA Safety Information BCGA Code of Practice BCGA Guidance Note 23 Safety training of employees. Selection of personal protective equipment. Crane transport of cylinder packages. The storage of gas cylinders. Identifying gas safety training requirements in the workplace. 22. BCGA TIS 12 Handle gas cylinders safely. Information for customers handling gas cylinders. 23. BCGA TIS 17 Model risk assessment for the manual handling of gas cylinders. 16

21 Further information can be obtained from: UK Legislation Health and Safety Executive British Standards Institute (BSI) European Industrial Gases Association (EIGA) British Compressed Gases Association (BCGA) The UK LPG trade association (UKLPG)

22 ILLUSTRATED EXAMPLES OF GOOD AND BAD PRACTICE APPENDIX 1 Sheet 1 of 12 These two Case Studies and their associated illustrations display examples of good and bad practice whilst manually handling gas cylinders. They may provide guidance to an assessor when carrying out a risk assessment, refer to BCGA TIS 17 (23). Appendixes 2, 3 and 4 provide worked examples of completed risk assessments based on these Case Studies. Case Study 1 The activity is to move a 20 L cylinder from Point A to Point B. Figure A1-1 The work area. The pictures in Figures A1-2 (a to f) observe the activity being undertaken without the necessary control measures. Figure A1-2a The cylinder is being lifted by placing one hand under the base. This is causing the operative to stoop and twist. 18

23 APPENDIX 1 Sheet 2 of 12 Figure A1-2b The route has not been cleared and pallets are creating an obstacle. Figure A1-2c The operative is stooping, twisting and stretching to move the cylinder to the other side of the pallets. 19

24 APPENDIX 1 Sheet 3 of 12 Figure A1-2d Inadequate PPE is in use, only safety shoes are worn. Using this method to carry the cylinder increases the likelihood of it being dropped. Figure A1-2e Another obstacle is causing the operative to stretch to reach the destination stillage. 20

25 APPENDIX 1 Sheet 4 of 12 Figure A1-2f The securing bars have not been used to secure the cylinders in the stillage The pictures in Figures A1-3 (a to e) observe the activity being undertaken with the necessary control measures implemented. Figure A1-3a The route has been cleared and the securing bar is removed from the destination stillage prior to commencing the operation. 21

26 APPENDIX 1 Sheet 5 of 12 Figure A1-3b The cylinder is churned down the ramp, preventing the need for stooping or twisting. Figure A1-3c The route is cleared of obstacles and the cylinder is churned to the destination stillage. Churning instead of carrying reduces the risk of musculoskeletal injury and reduces the likelihood of the cylinder being dropped. Additional PPE is also worn (gloves, safety glasses, high visibility clothing). 22

27 APPENDIX 1 Sheet 6 of 12 Figure A1-3d The cylinder is placed in the destination stillage. Figure A1-3e The securing bar is replaced on the stillage. 23

28 APPENDIX 1 Sheet 7 of 12 Case Study 2 The activity is to move a 50 L cylinder from an external position (Point A) to an internal position (Point B). Point A Point B Figure A1-4 The work area. The pictures in Figures A1-5 (a to g) observe the activity being undertaken without the necessary control measures. Figure A1-5a The cylinder weight is being supported and guided by the operative whilst pivoting on its base. This is causing the operative to take some of the weight of the cylinder with his right arm. The physical capability of the operative relates directly to his / her ability to maintain direct control of the cylinder whilst churning. Inadequate PPE is in use, only safety shoes are worn. 24

29 APPENDIX 1 Sheet 8 of 12 Figure A1-5b The route has not been cleared. The door has not been secured in an open position. In addition, there is a slope with a potentially slippery uneven surface. The operative is taking increasing amount of the cylinder weight as he is standing below the level of the cylinder. He will need to negotiate stepping up while supporting the cylinder, increasing the risk of dropping the cylinder and injuring himself. Figure A1-5c The operative is twisting and stretching to open the door, whilst supporting the weight of the cylinder on a slope. In addition, there is a risk of someone exiting the door, which could lead to the cylinder being dropped. 25

30 APPENDIX 1 Sheet 9 of 12 Figure A1-5d The complicated task of using his foot to keep the door open whilst moving the cylinder into the building increases the likelihood of a slip or of dropping the cylinder. Figure A1-5e The operative is taking increasing amounts of the weight of the cylinder on his right side as he enters the building. The cylinder base is wet; as it moves over the threshold it could slip. There is also a danger that as the door closes he may lose his balance and drop the cylinder. The closed cage door poses an additional obstacle. 26

31 APPENDIX 1 Sheet 10 of 12 Figure A1-5f The operative has to negotiate a doorway. This leads to twisting and stretching to open the door, whilst supporting the weight of the cylinder. Figure A1-5g The operative has to churn the cylinder the length of the building. Over this distance the task is physically and mentally demanding. In addition to tiredness, other potential obstacles, such as pallets, personnel and the forklift increase the likelihood of injury and the cylinder being dropped. 27

32 APPENDIX 1 Sheet 11 of 12 The pictures in Figure A1-6 (a to d) observe the activity being undertaken with the necessary control measures implemented. Figure A1-6a The operative is wearing appropriate PPE. The cylinder is secured onto an appropriate cylinder trolley. The entrance door has been secured in an open position, prior to commencing the move, allowing unrestricted access. Figure A1-6b The operative negotiates the doorway without the risk of twisting, slipping or losing control and dropping the cylinder. Although the operative is taking some of the weight it is close to the body; at any time the operative can place the trolley upright to rest (for example, to open or close doors). 28

33 APPENDIX 1 Sheet 12 of 12 Figure A1-6c The cage doorway can either be opened by a colleague or propped open during the operation. The door can be closed by the operative / colleague prior to continuing the activity. Figure A1-6d The cylinder can be safely transported to the delivery point. At any time the trolley can be placed securely upright. The trolley allows the operative to negotiate obstacles while maintaining control of the cylinder. 29

34 WORKED EXAMPLE 1 MODEL RISK ASSESSMENT MOVING CYLINDERS BY HAND APPENDIX 2 Sheet 1 of 3 Model Risk Assessment for moving cylinders by hand (lifting and carrying) Activity name: Carrying gas cylinders by hand Personnel involved: B Smith; R Jones; L Williams Activity description: Moving cylinders between storage stillages (Point A to B) [Refer to Figure A1-1] Do they undertake other handling tasks: Yes Load weight: Approximately 15 kg Assessment date: September 2015 Frequency of activity: 10 + times per day per operative Review date: March 2015 Carrying distance 5 to 10 m Assessed by: D Roberts Location: Cylinder preparation area Reviewed by: Overall assessment of the risk of injury (Complete tables below prior to making overall assessment) Recommended control measures 1) Remove or reduce the need for carrying cylinders by introducing the use of mechanical handling aids e.g. palletisation and use of Fork Lift Truck or hoists. Discussed with employee safety representative: Yes Low / Medium / High Existing control measures 2) Remove or reduce the need for carrying cylinders by introducing the use of trolleys or hand lift trucks. 3) Reduce handling distances e.g. from storage to loading point. 4) Review ergonomics to remove or reduce the need for stretching or twisting. 5) Review work areas to eliminate or reduce defects e.g. uneven floors, trapping hazards, confined spaces, steps, slopes or ramps. 6) Provide information to personnel involved on weights of the cylinders. 7) Avoid handling damaged or wet cylinders or those with dirt on the bottom. 8) Provide training to personnel involved on safe handling techniques and safe use of lifting devices. There are no steps in the cylinder preparation area and the floor is in good condition. 9) Introduce PPE as required e.g. protective footwear, safety glasses and gloves. All operatives wear protective footwear at all times. 10) Ensure securing chains or straps are available for securing cylinders after handling. Cylinder stillages are all fitted with securing bars to prevent cylinders from falling over. 30

35 Questions to consider: Does the task involve: ~ Holding cylinders away from the body? ~ Twisting? ~ Stooping? ~ Reaching upwards? ~ Large vertical movements? ~ Long carrying distances? ~ Unpredictable movement of cylinders? If yes, tick the appropriate level of risk Low Medium High Problems occurring from the task (make notes in this column in preparation for the remedial action to be taken) Obstacles on the route mean that the cylinder is held away from the body. [Figure A1-2a] Obstacles on the route and the technique used result in twisting. [Figure A1-2b] The technique used (picking up the cylinder with one hand at the base) results in stooping. [Figure A1-2a] APPENDIX 2 Sheet 2 of 3 Possible remedial action (e.g. changes that need to be made to the task, load, working environment etc. and who needs to be involved in implementation) The route should be cleared prior to the cylinder being moved. The route should be cleared prior to the cylinder being moved. The risk would be reduced if the cylinder is churned or moved by trolley. The risk would be reduced if the cylinder is churned or moved by trolley. ~ Repetitive cylinder handling? Routine manual handling operation. All personnel to receive appropriate training. ~ Insufficient rest or recovery? ~ A work rate imposed by a process? Are the cylinders: ~ Heavy? ~ Bulky / unwieldy? ~ Difficult to grasp? ~Unstable / unpredictable e.g. wet cylinders? ~ Intrinsically harmful e.g. toxic at high pressure? In the working environment are there: ~ Constraints on posture? ~ Poor, slippery or uneven floors? ~ Variations in levels e.g. steps, slopes? Cylinder weight is approximately 15 kg and there is stooping, twisting and stretching involved. Some cylinders contain gases at high pressure and may have toxic contents. The stillage at Point A has a small ramp. [Figure A1-3b] The risk would be reduced if the cylinder is churned or moved by trolley. The route should be cleared prior to the cylinder being moved. The contents and pressure of the cylinder would present a much lower risk if the cylinder was churned or moved by trolley as it is less likely to be dropped. This ramp would present a much lower risk if the cylinder was churned as the base remains in contact with the floor at all times. 31

36 ~ Hot / cold / humid conditions? ~ Strong air movements? ~ Inadequate lighting conditions? APPENDIX 2 Sheet 3 of 3 ~ Obstacles on the travel route e.g. doors? Pallets etc. obstructing route. Route should be cleared before starting movement. Consider individual capability. Does the job: ~ Require particular strength, height or other capability? ~ Pose an increased risk to those with a health problem or a physical or learning difficulty? Individual person capability. Cylinders can be heavy. Refer to BCGA GN 3, Table 1. Physical effort required to move cylinders would increase risk of injury to operatives with health issues. ~ Pose an increased risk to those who are preganant? Yes, although there are currently no female operatives who are preganant. ~ Call for special information / training? Specialist training is required to move cylinders safely. Other factors to consider: ~ Is movement or posture hindered by clothing, personal protective equipment (PPE) or the cylinder? ~ Is PPE required? If so, is the correct / suitable PPE being worn? ~ Are there sudden changes in workload or seasonal changes? Are cylinder accesssories e.g. valve guard, cap etc. suitable to be used for lifting? ~ Is the end point prepared to receive the cylinder? ACTION PLAN Remedial steps that should be taken (in priority order) Advise operative that this size of cylinder can be awkward to carry. Recommend movement by trolley or churning in future. All operatives to undergo manual handling training to include information on safe cylinder moving techniques (churning, use of trolleys, ensuring route is kept clear). Securing bars on stillages shall be used at all times. Provide gloves. Where the route or action plan requires other PPE provide appropriate PPE, including gloves, safety glasses, and high visibility clothing to all operatives and ensure it is worn. Review workplace to ensure minimum number of cylinder movements required over the shortest distance possible. Additional references: No Yes No No protection provided for hands or eyes. [Figure A1-2d] The risk would be reduced if the cylinder is churned or moved by trolley. This requires less strength as the full weight of the cylinder does not need to be supported. The risk would be reduced if the cylinder is churned or moved by trolley. This requires less strength as the full weight of the cylinder does not need to be supported. Requires review if any female operatives advise that they are preganant. Training required for all operatives. Ensure PPE, as determined by the PPE Risk Assesment, is provided and worn. Person responsible for implementing controls Target implementation date Completed? Line manager to discuss with all Immediately Yes operatives. Line manager. Within 3 months Booked 22/10/2015 Line manager to discuss with all Immediately Yes operatives. Line manager. October 2015 Yes Line manager. November 2015 No BCGA GN3, Safe cylinder handling and the application of the manual handling operations regulations to gas cylinders; BCGA TIS12, Handle Gas cylinders safely; HSE L23, Manual handling operations regulations. Guidance on regulations; HSE INDG 383, Manual Handling Assessment Charts (MAC); HSE INDG 163, Risk assessment. 32

37 WORKED EXAMPLE 2 MODEL RISK ASSESSMENT MOVING CYLINDERS BY CHURNING APPENDIX 3 Sheet 1 of 3 Model Risk Assessment for moving cylinders by hand (churning)) Activity name: Moving gas cylinders by churning Personnel involved: H Roddy; I Constable; J Broughton Activity description: Moving cylinders from outside to inside Do they undertake other handling tasks: Yes Load weight: 90 kg large cylinder Assessment date: 1 September 2015 Frequency of activity: 2 + times daily Review date: March 2015 Carrying distance 30 m Assessed by: I Sadler Location: Storage facility Reviewed by: Discussed with employee safety representative: Yes Overall assessment of the risk of injury (Complete tables below prior to making overall assessment) Recommended control measures 1) Only use the churning method for short distances (less than 5 m). If distances are greater than this use mechanical handling aids e.g. palletisation and use of Fork Lift Truck, hoists, hand trolleys or hand lift trucks. 2) Only use the churning method on firm, even, non-slippery surfaces. 3) Reduce handling distances e.g. from storage to loading point. 4) Review ergonomics to remove or reduce the need for stretching or twisting. 5) Review work areas to eliminate or reduce defects e.g. uneven floors, trapping hazards, confined spaces, steps, slopes or ramps. 6) Provide information to personnel involved on weights of the cylinders. 7) Avoid handling damaged or wet cylinders or those with dirt on the bottom. 8) Provide training to personnel involved on safe handling techniques and safe use of lifting devices. Low / Medium / High Existing control measures There are no steps in the cylinder preparation area and the floor is in good condition. 9) Introduce PPE as required e.g. protective footwear, safety glasses and gloves. All operatives wear protective footwear at all times. 10) Ensure securing chains or straps are available for securing cylinders after handling. Cylinder stillages are all fitted with securing bars to prevent cylinders from falling over. 33

38 Questions to consider: Does the task involve: If yes, tick the appropriate level of risk Low Medium High Problems occurring from the task (make notes in this column in preparation for the remedial action to be taken) APPENDIX 3 Sheet 2 of 3 Possible remedial action (e.g. changes that need to be made to the task, load, working environment etc. and who needs to be involved in implementation) ~ Holding cylinders away from the body? The operative has to hold a proportion of the Use of an appropriate cylinder trolley would reduce ~ Twisting? weight throughout the task he can only rest if the risk. A trolley ensures that the cylinder is secure he stops & stands the cylinder upright. He needs at all times, it can be stood upright whilst the ~ Stooping? to be physically able to hold the weight during operative opens doorways to clear access. Consider ~ Reaching upwards? ~ Large vertical movements? complicated moves (opening & holding doors open whilst churning cylinder). Negotiating the doorways involves twisting while taking weight of cylinder on one side of his body. 3 or 4 wheel trolleys so that the operative does not support any weight at all. ~ Long churning distances e.g. > 5m? Distance greater than 5m. The cylinder should be moved by trolley. ~ Unpredictable movement of cylinders? ~ Repetitive cylinder handling? ~ Insufficient rest or recovery? ~ A work rate imposed by a process? ~ A change in direction of travel? Are the cylinders: ~ Heavy? ~ Bulky / unwieldy? ~ Difficult to grasp? ~Unstable / unpredictable e.g. wet cylinders? ~ Intrinsically harmful e.g. toxic at high pressure? In the working environment are there: ~ Constraints on posture? Need to pass through entrance door. Cylinder weight is approximately 90 kg. A significant proportion of which is being held by the operative. His physical capacity needs to match the load he is expected to lift. The likelihood of dropping the cylinder increases with decreased capability of operative. Cylinder is tall, narrow and heavy. The cylinder is being lifted and churned on the edge of its base and has the potential to slip. Cylinder is moved from an external location. Cylinder maybe wet and therefore slippery. Some cylinders contain gases at high pressure and may have toxic contents. The route should be cleared prior to the cylinder being moved. Use of an appropriate cylinder trolley ensures that the operative is in direct control of the cylinder. The cylinder is secured by cylinder restraints into the trolley. The operative is holding less weight and can place trolley upright so he can rest. The cylinder would present a lower risk if it was moved by trolley. The cylinder would present a lower risk if it was moved by trolley. There is a lower risk from the contents and pressure if the cylinder is moved by trolley. ~ Poor, slippery or uneven floors? Externally the ground may be wet and slippery. The cylinder should be moved by trolley. ~ Variations in levels e.g. steps, slopes? The entrance to the building has a ramp. The ramp incorporates a metal plate. This ramp presents a greater risk when wet. In wet conditions the cylinder should be moved by trolley. 34

39 APPENDIX 3 Sheet 3 of 3 ~ Hot / cold / humid conditions? Possible. Cylinders are stored externally. Take weather conditions into account prior to a move. ~ Strong air movements? ~ Inadequate lighting conditions? ~ Obstacles on the travel route e.g. doors? Consider individual capability. Does the job: ~ Require particular strength, height or other capability? ~ Pose an increased risk to those with a health problem or a physical or learning difficulty? Necessary to travel through the doorway and change direction on the inside. Particular strength is needed to balance cylinder. Physical effort required to move cylinders would increase risk of injury to operatives with health issues. ~ Pose an increased risk to those who are preganant? Yes, although there are currently no female operatives who are preganant. ~ Call for special information / training? Specialist training is required to move cylinders safely. Other factors to consider: ~ Is movement or posture hindered by clothing, personal protective equipment (PPE) or the cylinder? ~ Is PPE required? If so, is the correct / suitable PPE being worn? ~ Are there sudden changes in workload or seasonal changes? ~ Are cylinder accessories e.g. valve guard, cap etc. suitable to be used for churning? ~ Is the end point prepared to receive the cylinder? ACTION PLAN Remedial steps that should be taken (in priority order) Cylinders of this size or larger shall not be carried. They are to be moved by trolley or churning in future. All operatives to undergo manual handling training to include information on safe cylinder moving techniques (churning, use of trolleys, ensuring route is kept clear). Securing bars on stillages shall be used at all times. Provide gloves, safety glasses, and high visibility clothing to all operatives and ensure it is worn as appropriate. Review workplace to ensure minimum number of cylinder movements required over the shortest distance possible. Additional references: No No Yes Only protective footwer is being worn. Changes in weather conditions, rain, snow, ice etc. will increase the risk when churning. The route should be cleared prior to the cylinder being moved. The cylinder should be churned or moved by trolley. This requires less strength as the full weight of the cylinder does not need to be supported. The cylinders should be moved by trolley. This requires less strength as the full weight of the cylinder does not need to be supported. Requires review if any female operatives advise that they are preganant. Training required for all operatives. Consider use of protective gloves, safety glasses and high visibility clothing. Ensure PPE, as determined by the PPE Risk Assesment, is provided and worn. Take weather conditions into account prior to a move. Person responsible for implementing controls Target implementation date Completed? Production Manager to discuss Immediately Yes with all operatives. Production Manager. October 2015 Booked 22/10/2015 Production Manager to discuss Immediately Yes with all operatives. Production Manager. October 2015 Yes Production Manager. November 2015 No BCGA GN3, Safe cylinder handling and the application of the manual handling operations regulations to gas cylinders; BCGA TIS12, Handle Gas cylinders safely; HSE L23, Manual handling operations regulations. Guidance on regulations; HSE INDG 383, Manual Handling Assessment Charts (MAC); HSE INDG 163, Risk assessment. 35

40 WORKED EXAMPLE 3 MODEL RISK ASSESSMENT MOVING CYLINDERS BY TROLLEY APPENDIX 4 Sheet 1 of 4 Model Risk Assessment for moving cylinders by trolley Activity name: Moving gas cylinders by trolley Personnel involved: H Roddy; I Constable; J Broughton Activity description: Moving cylinders from outside to inside Do they undertake other handling tasks: Yes Load weight: 90 kg large cylinder Assessment date: 1 September 2015 Frequency of activity: 2+ times daily Review date: March Carrying distance 30 m Assessed by: I Sadler Location: Storage facility Reviewed by: Discussed with employee safety representative: Yes Overall assessment of the risk of injury (Complete tables below prior to making overall assessment) Recommended control measures 1) Reduce handling distances e.g. from storage to loading point. Low / Medium / High Existing control measures 2) Review work area and travel route to eliminate or reduce defects e.g. uneven floors. A ramp is in place to at the building entrance to allow easier manoeuvring whilst using the trolley. 3) Provide training to personnel involved on safe handling techniques. Practical and theoretical training is provided to all personnel required to handle cylinders in trolleys. 4) Ensure trolley is suitable for the weight of the cylinder. Cylinder trolleys are purchased in line with an approved specification. 5) Ensure trolleys have a restraining chain. Cylinder trolleys are purchased with a chain. 6) Ensure checks are made of the trolley prior to using it. 7) Implement a maintenance programme for all cylinder trolleys. 8) Provide information to personnel involved on weights of the cylinders. 9) Introduce PPE as required e.g. protective footwear, safety glasses and gloves. Safety footwear is mandatory at all times whilst on site. 36

41 APPENDIX 4 Sheet 2 of 4 Questions to consider: Does the task involve: If yes, tick the appropriate level of risk Low Medium High Problems occurring from the task (make notes in this column in preparation for the remedial action to be taken) Possible remedial action (e.g. changes that need to be made to the task, load, working environment etc. and who needs to be involved in implementation) ~ Transporting cylinder on trolley away from the body? ~ Twisting? ~ Stooping? ~ Reaching upwards? ~ Large vertical movements? ~ Travel over long distances? ~ Unpredictable movement of cylinders? ~ Repetitive cylinder handling? ~ Insufficient rest or recovery? ~ A work rate imposed by a process? Are the cylinders: ~ Heavy? ~ Bulky / unwieldy? ~ Difficult to grasp? ~Unstable / unpredictable e.g. wet cylinders? ~ Intrinsically harmful e.g. toxic at high pressure? The operative has to hold a proportion of the weight throughout the task Storage location is outside of the building resulting in the need to transport the cylinder on the trolley for >30 metres. Cylinders could move on the trolley if not restrained. Transporting large cylinders in trolleys requires pushing and pulling which could place undue pressure on the lower back and upper limbs. Large cylinder on a trolley could become unwieldly in transit. Some cylinders contain gases at high pressure and may have toxic contents. Consider 3 or 4 wheel trolleys so that the operative does not support any weight at all. Consider whether the building can be restructured to allow the transportation of cylinders by pallet and FLT, or, if this cannot be achieved, review the layout of the yard and consider how travel distance can be minimised Ensure security chain is correctly fitted and used. Ensure that the manual handling training course includes techniques for pushing and pulling rather than just the traditional lifting and carrying techniques. All trolleys have a security chain when purchased. Train employees on how to carry out a pre-use check. Implement a maintenance programme to ensure chains remain fit for purpose. Ensure cylinders are restrained in the trolley using security chains. 37

42 APPENDIX 4 Sheet 3 of 4 In the working environment are there: ~ Constraints on posture? ~ Poor, slippery or uneven floors? ~ Variations in levels e.g. steps, slopes? ~ Hot / cold / humid conditions? ~ Strong air movements? ~ Inadequate lighting conditions? ~ Obstacles on the travel route e.g. doors? Consider individual capability. Does the job: Floors could become worn over time resulting in an uneven surface along the route. Outdoor surfaces could be slippery in wintery conditions (snow/ice). There is a ramp at the building entrance however this aids trolley movement into and out of the building. Inadequate lighting in the yard area could lead to inadequate visibility during reduced light hours e.g. winter time and night shift. Doors are present at the entrance to the building however these can be kept open with a wedge. Obstacles could become present on the route e.g. debris. ~ Require particular strength, height or other Cylinder use requires less strength than carrying capability? cylinders. ~ Pose an increased risk to those with a health problem Although the trolley is the preferred method to or a physical or learning difficulty? move the large cylinders there may still be an increased risk of injury to operatives with preexisting medical conditions when pushing the trolley up the ramp into the building. ~ Pose an increased risk to those who are preganant? Yes, although there are currently no female operatives who are preganant. ~ Call for special information / training? Specialist training is required to move cylinders safely. Other factors to consider: ~ Is movement or posture hindered by clothing, personal protective equipment (PPE) or the cylinder? ~ Is PPE required? If so, is the correct / suitable PPE being worn? ~ Are there sudden changes in workload or seasonal changes? No Yes Yes Changes in weather conditions, rain, snow, ice etc. will increase the risk of slipping. Implement a workplace inspection programme to ensure all primary routes used for transporting cylinders in trolleys are frequently checked. Provide materials for melting the snow/ice or grit the area. Consider whether the building can be restructured to allow the transportation of cylinders by pallet and FLT. Review the lighting assessment for the yard. Ensure maintenance of the external lights are scheduled as part of the site maintenance programme. Ensure that employees using trolleys to handle cylinders are trained in dynamic risk assessment techniques to enable them to recognise hazards that could arise as a result of the changing environment en route. N/A. Consider whether the building can be restructured to allow the transportation of cylinders by pallet and FLT. Requires review if any female operatives advise that they are preganant. Training in manual handling techniques is required for all operatives. The training must cover push and pulling. Take weather conditions into account prior to a move. 38

43 APPENDIX 4 Sheet 4 of 4 ~ Pre-use inspection and routine maintenance carried See Action Plan. No out on the trolley? ~ Is the trollley being used to move more than one cylinder at a time? No ~ Is the end point prepared to receive the cylinder? Yes ACTION PLAN Remedial steps that should be taken (in priority order) Person responsible for implementing controls Target implementation date Consider whether the building can be restructured to allow the transportation of cylinders by pallet and Site manager with operatives. 1 month FLT or Review the layout of the yard and consider how travel distance can be minimised. Review the lighting assessment for the yard. Site manager with operatives. 1 month Completed? Ensure maintenance of the external lights are scheduled as part of the site maintenance programme. Maintenance Manager. 1 month Implement a workplace inspection programme to ensure all primary routes used for transporting cylinders Line Manager. 1 month in trolleys are frequently checked. Train employees on how to carry out a pre-use check. Line Manager. 1 month Consider the design of the trolley. The use of a 3 or 4 wheel trolley would mean that the operative does Safety Advisor. 3 months not support any weight at all. Implement a maintenance programme to ensure chains remain fit for purpose. Maintenance Manager. 1 month Training in manual handling techniques is required for all operatives. The training must cover push and Safety Advisor. 3 months pulling. Ensure that employees handling cylinders using trolleys are trained in dynamic risk assessment techniques Safety Advisor. 6 months to enable them to recognise hazards that could arise as a result of the changing environment en route. Provide materials for melting the snow/ice or grit the area. Site Manager. As part of winterisation programme. Additional references: BCGA GN3, Safe cylinder handling and the application of the manual handling operations regulations to gas cylinders; BCGA TIS12, Handle Gas cylinders safely; HSE L23, Manual handling operations regulations. Guidance on regulations; HSE INDG 383, Manual Handling Assessment Charts (MAC); HSE INDG 163, Risk assessment. 39

44 British Compressed Gases Association