Acceptable weights and physiological costs of performing combined manual handling tasks in restricted postures

Eight healthy, male underground coal miners (mean age=36·9 yrs±4·5 SD) participated in a study examining psychophysical acceptable weights and physiological costs of performing combined lifting and lowering tasks in restricted headroom conditions. Independent variables included posture (stooping or kneeling on two knees), task symmetry (symmetric or asymmetric), and vertical lift distance (35 cm or 60cm). All tasks were 10min in duration and were performed under a 1·22 m ceiling to restrict the subject's posture. Subjects were required to raise and lower a lifting box every 10 s, and asked to adjust the box weight to the maximum amount they could handle without undue strain or fatigue. During the final 5 min of each test, data were collected to determine the energy expenditure requirements of the task. Results of this study demonstrated that psychophysical lifting capacity averaged 11·3% lower when kneeling as compared to stooping. Subjects selected 3·5% more weight in asymmetric tasks, and lifted 5·0% less weight to the 60 cm shelf compared to the 35 cm shelf. Heart rate was not significantly affected by posture, but was increased an average of 4 beats/min in asymmetric conditions, and by 3·5 beats/min while lifting/lowering to/from the high shelf. Oxygen uptake was increased by 9% when stooped, by 10% when lifting/lowering asymmetrically, and by 8·2% when performing the task to the high shelf. Results of this study indicate that, wherever possible, materials that must be lifted manually in low-seam coal mines be designed in accordance with the decreased lifting capacity exhibited in the kneeling posture.     

Static and dynamic lifting strength at different reach distances in symmetrica] and asymmetrical planes

Postural and therefore biomechanical standardization in strength testing has not been rigorously and consistently applied. To develop a quantitative relationship between strength and posture (body position, symmetry, and reach) 30 normal subjects (18 male and 12 females) were required to stoop and squat lift or exert in the relevant posture against a standardized instrumented handle. The isometric lifting efforts and isokinetic lifts were studied. The isokinetic lifts were done at a linear velocity of 50cm/s of the hand displacement from the floor to the knuckle heights of the respective subjects in stoop and squat postures. The isometric stoop lifting efforts were exerted in two standardized postures: (a) with 60° hip flexion; and (b) with 90° hip flexion. The isometric squat lifting efforts were also exerted in two standardized postures: (a) with 90° knee flexion; and (b) with 135° knee flexion. All isometric lifting efforts and isokinetic lifts were performed at half, three-quarters, and full horizontal reach in sagitally symmetrical, 30° left lateral, and 60° left lateral planes. Isometric stoop and squat lifting efforts were also measured in self-selected optimal postures. These 56 conditions were tested in random order. The analysis of variance revealed that the gender, the mode of lifting, the postural asymmetry and reach of lifting affected the strength significantly (p<0·0001). Most two-way and three-way interactions were significant (p<0·01). Of 108 prediction regression equations, 103 were significant with up to 90% of the variation explained by anthropometric variables and sagittal plane strength. The reach affected the strength most profoundly followed by postural asymmetry and the mode of lifting.     

Effectiveness of an on-body lifting aid at reducing low back physical demands during an automotive assembly task: Assessment of EMG response and user acceptability

The purpose of this study was to investigate the effectiveness and user acceptability of a Personal Lift-Assist Device (PLAD) at an automotive manufacturing facility, with operators who perform an on-line assembly process requiring forward bending and static holding. Surface EMG data were collected at six sites on the low back and abdomen, and an accelerometer was used to measure trunk inclination. Use of the PLAD significantly reduced the thoracic and lumbar erector spinae activity and EMG-predicted compression at the 10th, 50th, and 90th APDF percentile levels (p ≤ 0.05), without significantly increasing rectus abdominus activity or trunk flexion. Similarly, ratings of perceived exertion were found to be significantly lower when wearing the PLAD (p = 0.006). Subjective opinions were positive, with 8/10 subjects indicating they would wear the device everyday. With slight changes, workers felt that the PLAD could be beneficial at reducing forces and discomfort in similar industrial or manual materials handling tasks that place excessive physical demands on the low back.     

Test-retest reliability of isometric and isoinertial testing in symmetric and asymmetric lifting

The aim of this study was to evaluate test-retest reliability of a dynamometer in measuring lifting strength or force parameters under several combinations of ergonomic factors. Thirteen healthy participants were tested on peak force (PF), related variables and isometric strength (IS) twice, at intervals of 3 months. Correlation coefficients for all parameters in the sagittal plane were 0.60–0.85. Coefficients of variations (CVs) of methodology error for PF in the sagittal plane were 6.2–6.9%. Correlation coefficients and CVs for IS at 90° to the lateral plane were 0.51– 0.54 and 16.6–17.9%, respectively. In paired t-tests of the parameters under all conditions, there was no significant difference between test and retest. In the test and retest, ratings of perceived exertions for the low back and the right arm in isometric lifting were significantly higher than those in dynamic lifting. It was concluded that the test-retest reliability of dynamic forces in the dynamometer was high. The peak force in the sagittal plane was considered reliable. In isometric lifting, isometric strength in the sagittal plane seemed reliable, while that at right angles to the lateral plane was considered to be less reliable.     

Psychophysical modelling for combined manual materials-handling activities

Most psychophysical studies in manual materials handling (MMH)are involved only with single MMH activities, i.e. lifting, lowering, carrying, holding, pushing or pulling. Very little research has been reported on the determination of operator capacities for combinations of MMH activities (e.g. lifting a box, then carrying the box, or carrying a box, then lowering the box). These kinds of combined activities are prevalent in industry and in our daily lives. The objective of this study was to utilize the psychophysical approach to examine the effects of combinations of lifting, carrying and lowering activities. Twelve male students served as subjects for the study. The capacities that were determined as the maximum acceptable workloads for a 1-h work period for four individual MMH activities—lifting from floor to knuckle height (LFK), lifting from knuckle to shoulder height (LKS), lowering from knuckle to floor height (LOW) and carrying for 3·4 m (C) —and three combined MMH activities—LFK + C, LFK + C + LKS and LFK + C + LOW—were determined psychophysically under three frequency conditions: one time maximum, one handling per minute and six handlings per minute. Combined MMH capacities models were developed using the following three methods: a limiting individual MMH capacity, isoinertial 1·83-m maximum strength and fuzzy-set theory. The advantages and disadvantages of different models were discussed.     

Physiological and biomechanical responses to a prolonged repetitive asymmetric lifting activity

This study investigated the effects of a prolonged repetitive asymmetric lifting task on behavioural adaptations during repetitive lifting activity, measures of tissue oxygenation and spine kinematics. Seventeen volunteers repeatedly lifted a box, normalised to 15% of the participant's maximum lifting strength, at the rate of 10 lifts/min for a period of 60 min. The lifts originated in front of the participants at ankle level and terminated on their left side at waist level. Overall, perceived workload increased during the repetitive lifting task. Erector spinae oxygenation levels, assessed using near-infrared spectroscopy, decreased significantly over time. Behavioural changes observed during the repetitive lifting task included increases in the amount of forward bending, the extension velocity and the lateral bending velocity, and a reduced lateral bending moment on the spine. These changes, with the exception of the reduced lateral bending moment, are associated with increased risk of low back disorder.     

Muscular and centre of pressure response to sudden release of load in symmetric and asymmetric stoop lifting tasks

Sudden changes in load during asymmetric lifting may be associated with a particularly high risk of loss of balance and spinal injury. Centre of pressure (COP) motions and electromyographic responses of trunk and lower limb muscles were studied in 10 normal male volunteers during sudden release of 20, 40, 60 and 80N stoop lifting loads in symmetric and asymmetric postures. Similar overall COP responses and muscular response strategies to sudden release of load were seen in both postures, although the asymmetric posture showed a larger medio-lateral COP displacements and greater co-contraction asymmetries. While sudden release of load in asymmetric stoop lifting does not seem to involve a greater risk of fall than symmetric lifting, the muscular response results in more complex and asymmetric loading of the trunk, indicating greater localised segmental loading and therefore increased risk of tissue injury.     

Physiological effects of back belt wearing during asymmetric lifting

This study investigated the effect of wearing a back belt on subjects' heart rate, oxygen consumption, systolic and diastolic blood pressure, and respiratory frequency during asymmetric repetitive lifting. Thirty subjects with materials-handling experience utilized three different belts (ten subjects per belt). Subjects completed six 30-min lifting sessions--three while wearing a belt and three without. Data analyses were conducted on the second, third, and fourth lifting periods. A 9.4 kg box, without handles, was lifted 3 times/min, starting at 10 cm above the floor, ending at 79 cm, with a 60 degree twist to the right. Data analysis indicates that belt-wearing did not have a significant effect on the overall mean values for heart rate, systolic and diastolic blood pressure, and respiratory frequency. Belt-wearing had a significant effect on the overall mean oxygen consumption of the subjects.     

A cross-validation of the NIOSH limits for manual lifting

The psychophysical, biomechanical, and physiological criteria used in establishing the NIOSH limits for manual lifting were cross-validated against the data published by different researchers in the subject literature. Assessment of the 1991 NIOSH lifting equation indicated that: (1) NIOSH-based limits are significantly different from the psychophysical limits in the (i) low and high frequencies of lift, and (ii) small and large horizontal distances; (2) NIOSH limits are highly correlated with the data of Snook and Ciriello (1991) in the low frequency range, with the Recommended Weight Limit (RWL) protecting about 85% of the female population and 95% of the male population; (3) the 3·4 kN limit for compression on the lumbosacral joint cannot protect the majority of the worker population on the basis of damage load concept; and (4) energy expenditure limits used in development of the RWL index can be sustained by 57 to 99% of worker population when compared to the physiological limits based on previous fatigue studies. Results of the cross-validation for psychophysical criterion confirmed the validity of assumptions made in the 1991 NIOSH revised lifting equation. However, the results of cross-validation for the biomechanical and physiological criteria were not in total agreement with the 1991 NIOSH model     

Quantification of back motion during asymmetric lifting

The objective of this study was to determine how trunk motion characteristics (in all three planes of the trunk) change as a free dynamic lifting task becomes more asymmetric. Trunk motion characteristics included range of motion, velocity (peak and average), and acceleration. Previous studies have shown that trunk motion characteristics affect trunk strength as well as the action of. the trunk musculature. These trunk motion characteristics were quantified as a function of seven task asymmetries and three task weights. The experimental task required the subject to lift materials in positions commonly seen in the workplace. The range of motion, peak velocity, average velocity, and peak acceleration in each plane of the body were documented during the tasks. Generally, trunk motion characteristics in all three planes increased with an increase in task asymmetry. However, with an increase in task weight all the sagittal plane parameters and one transverse plane parameter decreased. Models were constructed to predict trunk motion characteristics given a task asymmetry and weight. When these motion components were compared to dynamic strength estimates from previous studies it was found that dynamic asymmetric lifts could reduce available strength up to 21% of maximum static strength. The results provide new insight into factors associated with the risk of developing low back disorders.     

External L5–S1 joint moments when lifting wire mesh screen used to prevent rock falls in underground mines

Bolting large sheets of wire mesh screen (WMS) to the roof of underground mines prevents injuries due to rock falls. However, WMS can be heavy and awkward to lift and transport, and may result in significant spinal loading. Accordingly, six male subjects (mean age = 45.8 years + 7.5 SD) were recruited to lift WMS in a laboratory investigation of the biomechanical demands. Biomechanical modeling was used to estimate external moments about L5–S1 for sixteen lifting tasks, using two sizes of WMS. Full-size WMS involved a two-person lift, while half-size WMS involved a one-person lift. Lifts were performed under 168 cm and 213 cm vertical space. Restriction in vertical space increased the maximum L5–S1 extensor moment from 254 to 274 Nm and right lateral bending moment from 195 to 251 Nm. Lifting full sheets of screen (as opposed to half sheets) resulted in an average 33 Nm increase in L5–S1 extensor moment. The L5–S1 extensor moment was increased by an average of 44 Nm (18%) when lifting screens positioned flat on the floor compared to an upright position.

Relevance to industry

Large flexible materials are commonly lifted in industrial work environments, and may involve the efforts of two or more workers. The current study examines the low back loading associated with lifting large flexible screens and presents recommendations to reduce spine loading.     

A national cross-sectional study in the Danish wood and furniture industry on working postures and manual materials handling

Musculoskeletal disorders constitute a major problem in the wood and furniture industry and identification of risk factors is needed urgently. Therefore, exposures to different work tasks and variation in the job were recorded based on an observation survey in combination with an interview among 281 employees working in wood working and painting departments. A questionnaire survey confirmed high frequencies of symptoms from the musculoskeletal system: The one-year prevalence of symptoms from the low back was 42% and symptoms from the neck/shoulder was 40%. The exposure was evaluated based on: (1) classification of work tasks, (2) work cycle time, (3) manual materials handling, (4) working postures, and (5) variation in die job. Among the employees 47% performed feeding or clearing of machines, 35% performed wood working or painting materials, and 18% performed various other operations. Among the employees 20% had no variation in their job while 44% had little variation. Manual materials handling of 375 different burdens was observed, which most often occurred during feeding or clearing of machines. The weight of burdens lifted was 0·5-87·0 kg, where 2% had a weight of more than 50 kg. Among the lifting conditions 30% were evaluated as implying a risk of injury. An additional risk factor was the high total tonnage lifted per day, which was estimated to range from 132 kg to 58 800 kg. Working postures implied a risk of injury due to prolonged forward and lateral flexions of the neck, which was seen most frequently during wood working or painting materials. These data substantiate the finding that work tasks mainly during feeding or clearing of machines imply a risk of injury to the low back and a risk of injury to the neck and shoulder area mainly during wood working or painting materials. Optimal strategies for job redesign may be worked out by using these data in order to prevent occupational musculoskeletal disorders.     

Prediction accuracy in estimating joint angle trajectories using a video posture coding method for sagittal lifting tasks

This study investigated prediction accuracy of a video posture coding method for lifting joint trajectory estimation. From three filming angles, the coder selected four key snapshots, identified joint angles and then a prediction program estimated the joint trajectories over the course of a lift. Results revealed a limited range of differences of joint angles (elbow, shoulder, hip, knee, ankle) between the manual coding method and the electromagnetic motion tracking system approach. Lifting range significantly affected estimate accuracy for all joints and camcorder filming angle had a significant effect on all joints but the hip. Joint trajectory predictions were more accurate for knuckle-to-shoulder lifts than for floor-to-shoulder or floor-to-knuckle lifts with average root mean square errors (RMSE) of 8.65°, 11.15° and 11.93°, respectively. Accuracy was also greater for the filming angles orthogonal to the participant's sagittal plane (RMSE = 9.97°) as compared to filming angles of 45° (RMSE = 11.01°) or 135° (10.71°). The effects of lifting speed and loading conditions were minimal. To further increase prediction accuracy, improved prediction algorithms and/or better posture matching methods should be investigated.

Statement of Relevance: Observation and classification of postures are common steps in risk assessment of manual materials handling tasks. The ability to accurately predict lifting patterns through video coding can provide ergonomists with greater resolution in characterising or assessing the lifting tasks than evaluation based solely on sampling with a single lifting posture event.     

Manual materials handling capabilities in non-standard postures

Research efforts to establish manual materials handling (MMH) capabilities of individuals and populations have been conducted for many years. Most of the previous efforts have explored ‘standard postures’, utilizing two-handed, symmetric, sagittal plane MMH using unrestricted postures. Recognizing that many industrial MMH activities do not utilize ‘standard postures’, recent research projects have explored psychophysicaly determined MMH capacities in a variety of non-standard postures. Among the non-standard postures examined were: twisting while lifting or lowering, lifting and lowering from lying, sitting, kneeling, and squatting positions, and carrying loads under conditions of constricted ceiling heights. This paper presents the results of a series of previous research efforts at Texas Tech University. The results are presented in the form of population capabilities of both males and females for 99 MMH tasks using ‘non-standard postures’. The data tables contain means and standard deviations of the data, as well as percentile distributions for the subject populations. Sample sizes for the experimental populations ranged from 45 to 50 subjects of each sex in the first three experiments to 20 subjects of each sex in the fourth set of experiments.     

Evaluation of team lifting on work demands,workload and workers' evaluation: An observational field study

The objective of this study was to assess differences in work demands, energetic workload and workers’ discomfort and physical effort in two regularly observable workdays in ironwork; one where loads up to 50 kg were handled with two persons manually (T50) and one where loads up to 100 kg were handled manually with four persons (T100). Differences between these typical workdays were assessed with an observational within-subject field study of 10 ironworkers. No significant differences were found for work demands, energetic workload or discomfort between T50 and T100 workdays. During team lifts, load mass exceeded 25 kg per person in 57% (T50 workday) and 68% (T100 workday) of the lifts. Seven ironworkers rated team lifting with two persons as less physically demanding compared with lifting with four persons. When loads heavier than 25 kg are lifted manually with a team, regulations of the maximum mass weight are frequently violated.     

Psychophysically determined symmetric and asymmetric lifting capacity of Chinese males for one hour's work shifts

A laboratory experiment was conducted to determine the effects of asymmetric lifting on psychophysically determined maximum acceptable weight of lift (MAWL) and the resulting heart rate, oxygen uptake and rating of perceived exertion. Thirteen male college students were recruited as participants. Each participant performed 12 different lifting tasks involving three lifting frequencies (one-time maximum, 1 and 4 lifts/min) and four twisting angles (including the sagittal plane and three different angles of asymmetry, i.e., 0, 30, 60, and 90°) from the floor to a 76 cm high pallet for one hour's work shift using a free-style lifting technique. The results showed that: (1) The MAWLs were significantly lower for asymmetric lifting than for symmetric lifting in the sagittal plane. The MAWL decreased with an increase in the angle of asymmetry, however, the heart rate, oxygen uptake and RPE remained unchanged; (2) Lifting frequency had no significant effect on the percentage decrease in MAWL from the sagittal plane values. Correction factors of 4, 9, and 13% for MAWL at 0, 30, 60, and 90°of asymmetric lifting, respectively, are recommended; (3) Both the physiological costs (heart rate and oxygen uptake) and rating of perceived exertion increased with an increase in lifting frequency though maximum acceptable weight of lift decreased. The most stressed body parts were the lower back and the arm; and (4) The percentage decrease in MAWL with twisting angle for the Chinese participants was somewhat lower than those of the Occidental participants. In addition, even though there was a decrease in MAWL, heart rate and RPE increased with an increase in the angle of a symmetric lifting for the Occidental participants, it was different from that of the Chinese participants.

Relevance to industry

It is generally believed that asymmetric lifting involving torso twisting is more harmful to back spine than symmetric lifting. However, the previous studies were conducted in Europe and North America, and the data were obtained from the Caucasian populations. This work, therefore, aims to investigate the influence of asymmetric lifting on the lifting capacity of the Chinese participants, and to compare the differences with the Occidental populations.     

Maximum acceptable weights and maximum voluntary isometric strengths for asymmetric lifting

A laboratory study was conducted to determine the effects of asymmetric lifting on psychophysically determined maximum acceptable weights and maximum voluntary isometric strengths. Thirteen male college students lifted three different boxes in the sagittal plane and at three different angles of asymmetry (30,60 and 90°) from floor to an 81-cm high table using a free-style lifting technique. For each lifting task, the maximum voluntary isometric strength was measured at the origin of lift.

The maximum acceptable weights and the static strengths for asymmetric lifting were significantly lower than those for symmetric lifting in the sagittal plane for three box sizes (P<0·01). The decrease in maximum acceptable weight and static strength from the sagittal plane values increased with an increase in the angle of asymmetry (P < 0·01). Box size had no significant effect (P≥ 0·05) on the percentage decrease in maximum acceptable weight or voluntary isometric strength from the sagittal plane values. Correction factors of 7,15 and 22% for maximum acceptable weights and 12, 21 and 31% for static strength at 30, 60 and 90% of asymmetric lifting are recommended. Lastly, in the absence of epidemiological data, a comparison of maximum acceptable weight and static strength in the sagittal plane with the NIOSH guidelines for action and maximum permissible limits indicates that the guidelines may be conservative.     

Manual materials handling in mining: the effect of rod heights and foot positions when lifting "in-the-hole" drill rods

There is a paucity of studies focusing on the lifting of rods or long awkward heavy objects. In-the-hole (ITH) drilling is a heavy repetitive mining task, which has been identified as having a relatively high incidence and severity rate of musculoskeletal injuries. The purpose of this study was to examine how the load experienced by ITH drill operators changed when lifting a vertical drilling rod (1.61 m, 35 kg) using two rod heights and four different foot positions. In addition, a symmetrical lift with a lifting index (LI) of 1.4 also served as a comparison to determine possible risk of low back injury. Eleven experienced ITH drill operators participated in the study. Each subject was required to lift a vertical drilling rod until the upper body was in an erect posture using four different foot positions (0°=subject facing the rod, 45°=subject oblique to the rod, 90°=subject right side to the rod and freestyle). In addition, two rod height conditions were studied where the base of the vertical rod was supported either (1) at ground level (height of rod CG=0.83 m) or (2) on a 20 cm rack (height of rod CG=1.03 m). Finally, each subject lifted a 21.5 kg box in the sagittal plane, which corresponded to an LI of 1.4 in the NIOSH lifting equation. Reflective markers were placed on the subjects, and three video cameras and one force plate were used to record the forces and the motion of the subjects’ segments. Two surface electrodes were applied on the right and the left erector spinae (ES) at the level of L3. Back loading was defined by the level of the peak moments, the mechanical work and erector spinae muscle activity (EMG). It was found that the vertical height of the rod had the most significant impact on back loading, while the effect of the initial foot positioning relative to the rod was limited by the technique adopted by the drillers. Moreover, it was found that some of the subjects used techniques less strenuous for the back than others. Finally, the asymmetrical lifting component was found to be the most negative aspect of lifting an ITH drill rod compared to a standard symmetrical lift (NIOSH).     

Modification of an EMG-assisted biomechanical model for pushing and pulling

Pushing and pulling tasks using carts and material handling devices have become more prevalent in occupational environments in an attempt to reduce the musculoskeletal risks associated with lifting. However, little change in low back disorder rates have been noted as tasks change from lifting to pushing and pulling indicating that we do not understand the mechanics of pushing and pulling well. Biomechanical assessments of pushing and pulling tasks using person-specific biologically assisted models offer a means to help understand how the spine is loaded under pushing and pulling conditions. However, critical components of these models must be adjusted so that they are sensitive to the different physiologic responses in the torso muscles expected during pushing and pulling compared to lifting tasks.The objective of this study was to modify an electromyography (EMG)-assisted biomechanical model designed to evaluate lifting tasks so that it can better represent the biomechanical forces expected during pushing and pulling tasks. Several key modifications were made. Based upon a literature review, changes in muscle cross-sectional area and muscle origins and insertions were made to better represent the geometry of the torso muscles. It was also necessary to adjust the length–force and velocity–force muscle relationships. Empirically derived length–force and velocity–force relationships were developed to independently represent the flexor and extensor musculature. These modifications were then systematically incorporated into the model.The model was exercised over several pushing and pulling conditions to assess the effect of these modifications on its ability to predict externally measured spinal moments. Results indicated that the alterations made to the preexisting EMG-assisted model resulted in acceptable model performance for pushing, pulling, and lifting activities.

Relevance to industry

The use of carts and material handling devices has become increasingly prevalent in industry, though little research has been done to examine the body's response. The modifications made to the biomechanical model would enable its use in the evaluation and design of material handling devices and pushing and pulling tasks.     

Biomechanical evaluation of heavy tool-handling in two age groups of firemen

The biomechanical load of a rescue-clearing task (lifting a power saw from the floor up to the ceiling level) was evaluated with six older (47 ± 5 years) and seven younger firemen (32 ± 2 years). The mean dynamic compressive force at the L5/SI disc was 5998?N for the older subjects and 6392?N for the younger subjects. The peak torques for the back and knee extensions were about equal for the two groups of the subjects. The younger subjects had a significantly higher movement speed in the knee extension than the older subjects (89.1 ± 25.7 vs. 35.3±11.5°/, p<0.001). The results showed that lifting a power saw produced a high load on the musculoskeletal system, and that the load was not influenced by age.