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GUIDANCE NOTE 3
SAFE CYLINDER HANDLING AND THE
APPLICATION OF THE MANUAL
HANDLING OPERATIONS
REGULATIONS TO GAS CYLINDERS
REVISION 3: 2016
BCGA GN 3 – Revision 3
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 1993. 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:
www.bcga.co.uk
ISSN 0260 - 4809
BCGA GN 3 – Revision 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 five-
yearly 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: 2010. 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 www.bcga.co.uk.
BCGA GN 3 – Revision 3
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 4
5.1 Cylinder weight 6
5.2 Cylinder size / shape 6
5.3 The work environment
7
6. CONTROL MEASURES TO REDUCE THE RISK OF INJURY 8
6.1 Mechanical handling equipment 8
6.2 Trolleys 9
6.3 Personal Protective Equipment
10
7. TRAINING
11
8. SAFE CYLINDER HANDLING 12
8.1 Typical injuries 13
8.2 Cylinder handling techniques
14
9. REFERENCES *
16
APPENDICES:
Appendix 1 Illustrated examples of good and bad practice
18
Appendix 2 Worked Example 1 – Model Risk Assessment – Moving cylinders
by hand
30
Appendix 3 Worked Example 2 – Model Risk Assessment – Moving cylinders
by churning
33
Appendix 4 Worked Example 3 – Model Risk Assessment – Moving cylinders
by trolley
36
* 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.
1 BCGA GN 3 – Revision 3
TERMINOLOGY AND DEFINITIONS
Gas cylinder For the purposes of this document includes all cylinders containing a
compressed, dissolved and liquefied gas.
May Indicates an option available to the user of this Guidance Note.
Shall Indicates a mandatory requirement for compliance with this
Guidance Note and may also indicate a mandatory requirement
within UK law.
Should Indicates a preferred requirement but is not mandatory for
compliance with this Guidance Note.
2 BCGA GN 3 – Revision 3
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.
3 BCGA GN 3 – Revision 3
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;
4 BCGA GN 3 – Revision 3
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 6.
4. 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.
5 BCGA GN 3 – Revision 3
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.
6 BCGA GN 3 – Revision 3
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
(10 Litre)
Oxygen 20
Carbon Dioxide 23
Acetylene 19
LPG (approx. 7 kg) 17
Medium
(30 Litre)
Oxygen 58
Carbon Dioxide 60
Acetylene 59
LPG (approx. 19 kg) 45
Large
(50 Litre)
Oxygen 80
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 6.2.
5.2 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.
7 BCGA GN 3 – Revision 3
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? Is there
adequate lighting?
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.
8 BCGA GN 3 – Revision 3
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:
www.hse.gov.uk/workplacetransport, HSE HSG 136 (9), A guide to workplace transport
safety, and HSE INDG 199 (12), Workplace transport safety. A brief guide.
6.1.1 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.
6.1.2 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.
6.1.3 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.
9 BCGA GN 3 – Revision 3
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.
6.1.4 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.
10 BCGA GN 3 – Revision 3
(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.
Men Women
Guideline figure for
stopping or starting a load *
20 kg
(about 200 N)
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.
11 BCGA GN 3 – Revision 3
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.
12 BCGA GN 3 – Revision 3
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.
13 BCGA GN 3 – Revision 3
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.
14 BCGA GN 3 – Revision 3
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
Figure 2: Possible injuries from falling cylinders
8.2 Cylinder handling techniques
8.2.1 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.
15 BCGA GN 3 – Revision 3
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
8.2.2 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. 2793 The Manual Handling Operations Regulations 1992 (as
amended).
2. SI 1992 No. 2932 Provision and Use of Work Equipment Regulations (PUWER).
3. SI 1998 No. 2307 Lifting Operations and Lifting Equipment Regulations
(LOLER).
4. SI 2002 No. 1144
Personal Protective Equipment Regulations 2002.
16 BCGA GN 3 – Revision 3
Document Number Title
5. SI 2002 No. 2174
Health and Safety (Miscellaneous Amendments) Regulations
2002.
6. SI 2002 No. 2677 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 23
Safety training of employees.
18. EIGA IGC
Document 136
Selection of personal protective equipment.
19. EIGA Safety
Information 25
Crane transport of cylinder packages.
20. BCGA Code of
Practice 44
The storage of gas cylinders.
21. BCGA Guidance
Note 23
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.
17 BCGA GN 3 – Revision 3
Further information can be obtained from:
UK Legislation
www.legislation.gov.uk
Health and Safety Executive
www.hse.gov.uk
British Standards Institute (BSI)
www.bsigroup.co.uk
European Industrial Gases Association (EIGA)
www.eiga.eu
British Compressed Gases Association (BCGA)
www.bcga.co.uk
The UK LPG trade association (UKLPG) www.uklpg.org
18 BCGA GN 3 – Revision 3
APPENDIX 1
Sheet 1 of 12
ILLUSTRATED EXAMPLES OF GOOD AND BAD PRACTICE
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.
19 BCGA GN 3 – Revision 3
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.
20 BCGA GN 3 – Revision 3
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.
21 BCGA GN 3 – Revision 3
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.
22 BCGA GN 3 – Revision 3
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).
23 BCGA GN 3 – Revision 3
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.
24 BCGA GN 3 – Revision 3
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.
25 BCGA GN 3 – Revision 3
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.
26 BCGA GN 3 – Revision 3
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.
27 BCGA GN 3 – Revision 3
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.
28 BCGA GN 3 – Revision 3
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).
29 BCGA GN 3 – Revision 3
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.
30 BCGA GN 3 – Revision 3
APPENDIX 2
Sheet 1 of 3
WORKED EXAMPLE 1 – MODEL RISK ASSESSMENT – MOVING CYLINDERS BY HAND
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:
Discussed with employee safety representative: Yes
Overall assessment of the risk of injury (Complete tables below prior to making overall assessment)
Low / Medium / High
Recommended control measures Existing 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.
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.
There are no steps in the cylinder preparation area and the floor is in good condition.
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.
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.
31 BCGA GN 3 – Revision 3
APPENDIX 2
Sheet 2 of 3
Questions to consider:
If yes, tick the appropriate level of risk 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) Low Medium High
Does the task involve:
~ Holding cylinders away from the body?
Obstacles on the route mean that the cylinder is
held away from the body. [Figure A1-2a]
The route should be cleared prior to the cylinder
being moved.
~ Twisting?
Obstacles on the route and the technique used result in twisting. [Figure A1-2b]
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.
~ Stooping?
The technique used (picking up the cylinder with one hand at the base) results in stooping.
[Figure A1-2a]
The risk would be reduced if the cylinder is churned or moved by trolley.
~ Reaching upwards?
~ Large vertical movements?
~ Long carrying distances?
~ Unpredictable movement of cylinders?
~ 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?
Cylinder weight is approximately 15 kg and there
is stooping, twisting and stretching involved.
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.
~ Bulky / unwieldy?
~ Difficult to grasp?
~Unstable / unpredictable e.g. wet cylinders?
~ Intrinsically harmful e.g. toxic at high pressure?
Some cylinders contain gases at high pressure and may have toxic contents.
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.
In the working environment are there:
~ Constraints on posture?
~ Poor, slippery or uneven floors?
~ Variations in levels e.g. steps, slopes?
The stillage at Point A has a small ramp.
[Figure A1-3b]
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.
32 BCGA GN 3 – Revision 3
APPENDIX 2
Sheet 3 of 3
~ Hot / cold / humid conditions?
~ Strong air movements?
~ Inadequate lighting conditions?
~ 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?
Individual person capability. Cylinders can be heavy. Refer to BCGA GN 3, Table 1.
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.
~ Pose an increased risk to those with a health problem or a physical or learning difficulty?
Physical effort required to move cylinders would increase risk of injury to operatives with health
issues.
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.
~ Pose an increased risk to those who are preganant?
Yes, although there are currently no female
operatives who are preganant.
Requires review if any female operatives advise that
they are preganant.
~ Call for special information / training?
Specialist training is required to move cylinders safely.
Training required for all operatives.
Other factors to consider:
~ Is movement or posture hindered by clothing, personal protective equipment (PPE) or the cylinder?
No
~ Is PPE required? If so, is the correct / suitable PPE
being worn? Yes
No protection provided for hands or eyes.
[Figure A1-2d]
Ensure PPE, as determined by the PPE Risk
Assesment, is provided and worn.
~ Are there sudden changes in workload or seasonal changes?
No
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) Person responsible for
implementing controls
Target implementation date Completed?
Advise operative that this size of cylinder can be awkward to carry. Recommend movement by trolley or
churning in future.
Line manager to discuss with all
operatives.
Immediately Yes
All operatives to undergo manual handling training to include information on safe cylinder moving
techniques (churning, use of trolleys, ensuring route is kept clear).
Line manager. Within 3 months Booked 22/10/2015
Securing bars on stillages shall be used at all times. Line manager to discuss with all
operatives.
Immediately Yes
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.
Line manager. October 2015 Yes
Review workplace to ensure minimum number of cylinder movements required over the shortest distance
possible.
Line manager. November 2015 No
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.
33 BCGA GN 3 – Revision 3
APPENDIX 3
Sheet 1 of 3
WORKED EXAMPLE 2 – MODEL RISK ASSESSMENT – MOVING CYLINDERS BY CHURNING
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)
Low / Medium / High
Recommended control measures Existing 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. There are no steps in the cylinder preparation area and the floor is in good condition.
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.
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.
34 BCGA GN 3 – Revision 3
APPENDIX 3
Sheet 2 of 3
Questions to consider:
If yes, tick the appropriate level of risk 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) Low Medium High
Does the task involve:
~ Holding cylinders away from the body? The operative has to hold a proportion of the
weight throughout the task – he can only rest if he stops & stands the cylinder upright. He needs
to be physically able to hold the weight during
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.
Use of an appropriate cylinder trolley would reduce
the risk. A trolley ensures that the cylinder is secure at all times, it can be stood upright whilst the
operative opens doorways to clear access. Consider
3 or 4 wheel trolleys so that the operative does not support any weight at all.
~ Twisting? ~ Stooping? ~ Reaching upwards?
~ Large vertical movements?
~ 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?
Need to pass through entrance door. The route should be cleared prior to the cylinder being moved.
Are the cylinders:
~ Heavy?
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.
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.
~ Bulky / unwieldy?
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.
The cylinder would present a lower risk if it was moved by trolley.
~ Difficult to grasp?
~Unstable / unpredictable e.g. wet cylinders?
Cylinder is moved from an external location.
Cylinder maybe wet and therefore slippery.
The cylinder would present a lower risk if it was
moved by trolley.
~ Intrinsically harmful e.g. toxic at high pressure?
Some cylinders contain gases at high pressure
and may have toxic contents.
There is a lower risk from the contents and pressure
if the cylinder is moved by trolley.
In the working environment are there:
~ Constraints on posture?
~ 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.
35 BCGA GN 3 – Revision 3
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?
Necessary to travel through the doorway and
change direction on the inside.
The route should be cleared prior to the cylinder
being moved.
Consider individual capability. Does the job:
~ Require particular strength, height or other
capability?
Particular strength is needed to balance cylinder. 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.
~ Pose an increased risk to those with a health problem
or a physical or learning difficulty?
Physical effort required to move cylinders would
increase risk of injury to operatives with health
issues.
The cylinders should be moved by trolley. This
requires less strength as the full weight of the
cylinder does not need to be supported.
~ Pose an increased risk to those who are preganant?
Yes, although there are currently no female
operatives who are preganant.
Requires review if any female operatives advise that
they are preganant.
~ Call for special information / training?
Specialist training is required to move cylinders
safely.
Training required for all operatives.
Other factors to consider:
~ Is movement or posture hindered by clothing, personal protective equipment (PPE) or the cylinder?
No
~ Is PPE required? If so, is the correct / suitable PPE
being worn? No
Only protective footwer is being worn. 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.
~ Are there sudden changes in workload or seasonal changes? Yes
Changes in weather conditions, rain, snow, ice etc. will increase the risk when churning.
~ 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) Person responsible for
implementing controls
Target implementation date Completed?
Cylinders of this size or larger shall not be carried. They are to be moved by trolley or churning in future. Production Manager to discuss
with all operatives.
Immediately Yes
All operatives to undergo manual handling training to include information on safe cylinder moving techniques (churning, use of trolleys, ensuring route is kept clear).
Production Manager. October 2015 Booked 22/10/2015
Securing bars on stillages shall be used at all times. Production Manager to discuss
with all operatives.
Immediately Yes
Provide gloves, safety glasses, and high visibility clothing to all operatives and ensure it is worn as appropriate.
Production Manager. October 2015 Yes
Review workplace to ensure minimum number of cylinder movements required over the shortest distance
possible.
Production Manager. November 2015 No
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.
36 BCGA GN 3 – Revision 3
APPENDIX 4
Sheet 1 of 4
WORKED EXAMPLE 3 – MODEL RISK ASSESSMENT – MOVING CYLINDERS BY TROLLEY
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)
Low / Medium / High
Recommended control measures Existing control measures
1) Reduce handling distances e.g. from storage to loading point.
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.
37 BCGA GN 3 – Revision 3
APPENDIX 4
Sheet 2 of 4
Questions to consider:
If yes, tick the appropriate level of risk 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) Low Medium High
Does the task involve:
~ Transporting cylinder on trolley away from the body?
The operative has to hold a proportion of the weight throughout the task
Consider 3 or 4 wheel trolleys so that the operative does not support any weight at all.
~ Twisting?
~ Stooping?
~ Reaching upwards?
~ Large vertical movements?
~ Travel over long distances?
Storage location is outside of the building
resulting in the need to transport the cylinder on
the trolley for >30 metres.
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
~ Unpredictable movement of cylinders?
Cylinders could move on the trolley if not restrained.
Ensure security chain is correctly fitted and used.
~ Repetitive cylinder handling?
~ Insufficient rest or recovery?
~ A work rate imposed by a process?
Are the cylinders:
~ Heavy?
Transporting large cylinders in trolleys requires
pushing and pulling which could place undue pressure on the lower back and upper limbs.
Ensure that the manual handling training course
includes techniques for pushing and pulling rather than just the traditional lifting and carrying
techniques.
~ Bulky / unwieldy?
Large cylinder on a trolley could become
unwieldly in transit.
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.
~ Difficult to grasp?
~Unstable / unpredictable e.g. wet cylinders?
~ Intrinsically harmful e.g. toxic at high pressure?
Some cylinders contain gases at high pressure
and may have toxic contents.
Ensure cylinders are restrained in the trolley using
security chains.
38 BCGA GN 3 – Revision 3
APPENDIX 4
Sheet 3 of 4 In the working environment are there:
~ Constraints on posture?
~ Poor, slippery or uneven floors?
Floors could become worn over time resulting in an uneven surface along the route.
Outdoor surfaces could be slippery in wintery
conditions (snow/ice).
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.
~ Variations in levels e.g. steps, slopes?
There is a ramp at the building entrance however this aids trolley movement into and out of the
building.
Consider whether the building can be restructured to allow the transportation of cylinders by pallet and
FLT.
~ Hot / cold / humid conditions?
~ Strong air movements?
~ Inadequate lighting conditions?
Inadequate lighting in the yard area could lead to
inadequate visibility during reduced light hours
e.g. winter time and night shift.
Review the lighting assessment for the yard.
Ensure maintenance of the external lights are
scheduled as part of the site maintenance programme.
~ Obstacles on the travel route e.g. doors?
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.
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.
Consider individual capability. Does the job:
~ Require particular strength, height or other
capability?
Cylinder use requires less strength than carrying
cylinders.
N/A.
~ Pose an increased risk to those with a health problem
or a physical or learning difficulty?
Although the trolley is the preferred method to
move the large cylinders there may still be an
increased risk of injury to operatives with pre-existing medical conditions when pushing the
trolley up the ramp into the building.
Consider whether the building can be restructured to
allow the transportation of cylinders by pallet and
FLT.
~ Pose an increased risk to those who are preganant?
Yes, although there are currently no female operatives who are preganant.
Requires review if any female operatives advise that they are preganant.
~ Call for special information / training?
Specialist training is required to move cylinders
safely.
Training in manual handling techniques is required
for all operatives. The training must cover push and
pulling.
Other factors to consider:
~ Is movement or posture hindered by clothing, personal protective equipment (PPE) or the cylinder?
No
~ Is PPE required? If so, is the correct / suitable PPE
being worn? Yes
~ Are there sudden changes in workload or seasonal changes?
Yes Changes in weather conditions, rain, snow, ice etc. will increase the risk of slipping.
Take weather conditions into account prior to a move.
39 BCGA GN 3 – Revision 3
APPENDIX 4
Sheet 4 of 4
~ Pre-use inspection and routine maintenance carried
out on the trolley? No
See Action Plan.
~ 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 Completed?
Consider whether the building can be restructured to allow the transportation of cylinders by pallet and
FLT or Review the layout of the yard and consider how travel distance can be minimised.
Site manager with operatives. 1 month
Review the lighting assessment for the yard.
Site manager with operatives. 1 month
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
in trolleys are frequently checked.
Line Manager. 1 month
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
not support any weight at all.
Safety Advisor. 3 months
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
pulling.
Safety Advisor. 3 months
Ensure that employees handling cylinders using trolleys 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.
Safety Advisor. 6 months
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.