Revisited: Comparison of two techniques to establish maximum acceptable forces of dynamic pushing for male industrial workers

The purpose of this experiment was to replicate a previous psychophysical experiment [Ciriello, V.M., McGorry, R.W., Martin, S.E., Bezverkny, I.B., 1999b. Maximum acceptable forces of dynamic pushing: comparison of two techniques. Ergonomics 42, 32–39] which investigated maximum acceptable initial and sustained forces while performing a 7.6 m pushing task at a frequency of 1 min⁻¹ on a magnetic particle brake treadmill versus pushing on a high-inertia pushcart. Fourteen male industrial workers performed both a 40-min treadmill pushing task and a 2-h pushcart task, with a unique water loading system, in the context of a larger experiment. During pushing, the subjects were asked to select a workload they could sustain for 8 h without “straining themselves or without becoming unusually tired, weakened, overheated or out of breath.” The results revealed that similar to the previous study maximum acceptable sustained forces of pushing determined on the high inertia cart were significantly higher (21%) than the forces determined from the magnetic particle brake treadmill. These results were countered by an 18% decrease in maximum acceptable forces for the criterion magnetic particle brake treadmill task, perhaps due to secular changes in the industrial population. Based on the present findings, it is concluded that the existing pushing data [Snook, S.H., Ciriello, V.M., 1991. The design of manual tasks: revised tables of maximum acceptable weights and forces. Ergonomics 34, 1197–1213] still provides an accurate estimate of maximal acceptable forces for this pushing distance and frequency.

Relevance to industry

Jobs are often redesigned to eliminate lifting and to include carts for transporting loads. Our database on maximum acceptable forces of pushing on a magnetic particle braked treadmill has been used as a tool to design manual handling tasks. This article links the existing database with actual cart pushing.     

The effects of container size, frequency and extended horizontal reach on maximum acceptable weights of lifting for female industrial workers

In the development of our present manual materials handling (MMH) guidelines (Snook, S.H., Ciriello, V.M., 1991. The design of manual tasks: revised tables of maximum acceptable weights and forces. Ergonomics 34, 1197-1213), the assumption was made that the effects of frequency on maximum acceptable weights (MAWs) of lifting with a large box (hand distance, 38 cm from chest) were similar to that of lifting with a small box (hand distance, 17 cm from chest). The first purpose of the present experiment was to investigate this assumption with female industrial workers. The second purpose was to study the effects of extended horizontal reach lifting (hand distance, 44.6 cm from chest) on MAWs as a confirmation of the results of a previous studies on this variable with males (Ciriello, V.M., Snook, S.H., Hughes, G.J., 1993. Further studies of psychophysically determined maximum acceptable weights and forces. Hum. Factors 35(1), 175-186; Ciriello, V.M., 2003. The effects of box size, frequency, and extended horizontal reach on maximum acceptable weights of lifting. Int. J. Ind. Ergon. 32, 115-120). Lastly, we studied the effects of high frequency (20 lifts/min) on MAWs of lifting. Ten female industrial workers performed 15 variations of lifting using our psychophysical methodology whereby the subjects were asked to select a workload they could sustain for 8h without "straining themselves or without becoming unusually tired weakened, overheated or out of breath". The results confirmed that MAWs of lifting with the large box was significantly effected by frequency. The frequency factor pattern in this study was similar to the frequency pattern from a previous study using the small box (Ciriello, V.M., Snook, S.H., 1983. A study of size distance height, and frequency effects on manual handling tasks. Hum. Factors 25(5), 473-483) for all fast frequencies down to one lift every 2 min with deviations of 7%, 15%, and 13% for the one lift every 5 and 30 min tasks and the one lift in 8h task, respectively. The effects of lifting with an extended horizontal reach decreased MAW 22% and 18% for the mid and center lift and the effects of the 20 lifts/min frequency resulted in a MAW that was 47% of a 1 lift/min MAW. Incorporating these results in future guidelines should improve the design of MMH tasks for female workers.     

Secular changes in psychophysically determined maximum acceptable weights and forces over 20 years for male industrial workers

The objective of this study was the development and validation of an integrated measure-assessment approach (driving performance and psychophysiological indicators) for the assessment of driving demands of rural road segments as a starting point for design. With 31 student test drivers and a selection of six study roads, the reactivity of psychophysiological parameters was evaluated based on a general model of cognitive-energetic effort regulation according to Hockey (1993). The road curvature change rate was introduced as the independent variable, which served as a criterion of objective road difficulty. Based on a reliability analysis, the longitudinal and cross-sectional stability, especially for heart rate (HR) and blink rate (BR) measures, is sufficiently high. Both these psychophysiological variables and speed vary as a function of the curvature change rate of the rural road segments. The speed parameter differentiates very strongly the different curvature change rates. Among the psychophysiological indicators, changes in the blink rate almost exactly mirror the level of the curvature change rate owing to the fact that the BR decreases almost steadily with increasing curvature change rate. Cardiovascular parameters, such as heart rate (HR) and heart rate variability (HRV), and skin conductance response (SCR) also vary in relation to driving difficulty of road segments, but at levels of intermediate curvature other additional road characteristics may also influence these measures.     

Effects of carrying methods and box handles on two-person team carrying capacity for females

This study used a psychophysical approach to examine the effects of carrying methods and the presence or absence of box handles on the maximum acceptable weight carried and resulting responses (heart rate and rating of perceived exertion) in a two-person carrying task. After training, 16 female subjects performed a two-person carrying task at knuckle height for an 8-h work period. Each subject performed 4 different carrying combinations two times. The independent variables were carrying methods (parallel and tandem walking) and box handles (with and without handles). For comparison with two-person carrying, the subjects also performed one-person carrying. The results showed that the maximum acceptable weight carried (MAWC), heart rate (HR), and rating of perceived exertion (RPE) were significantly affected by the presence of box handles. However, the subjects' MAWC, HR, and RPE values were not significantly influenced by the carrying methods. The test-retest reliability of the psychophysical approach was 0.945. The carrying efficiency of two-person carrying was 96.2% of the one-person carrying method. In general, the use of box with handles allows the subjects to carry a higher MAWC (with lower HR and RPE) compared to carrying boxes without handles.     

Review paper A comparative study of methods for establishing load handling capabilities

There has been much effort in recent years to quantify manual handling capabilities. Four main techniques have been used to this end; biomechanical modelling; the measurement of intra-abdominal pressure; psychophysics; and metabolic/physiological criteria. The aim of this study was to compare quantitatively the data produced from the first three techniques. The comparisons were limited to bimanual, sagittal plane lifting, which of all manual handling activities has been studied the most comprehensively, except that pushing and pulling data were compared from the psychophysics and intra-abdominal pressure (‘force limits’) databases. It was found that the data from ‘force limits’ proposed weights for bimanual lifting in the sagittal plane are lower than those reported to be psychophysically acceptable except for lifting close to and around the shoulder. The closest agreement between the databases was for lifting from an origin above knuckle height. The ‘force limits’ data were found to propose weights of lift which are at a minimum when lifting with a freestyle posture from the floor whereas the psychophysical technique proposes weights which are at a maximum when lifting from the floor. The psychophysical data were found to generate compressive forces at L5/S1 according to a static sagittal plane biomechanical model about 10% in excess of the NIOSH action limit (NIOSH 1981) when lifting from the floor, although over other lifting ranges the compressive forces were less than the NIOSH action limit. Lifting the (force limits) weights generated compressive forces which were on average 55% less than the AL (range 45 to 60%) when lifting in an erect posture. The data for pushing according to the psychophysical and ‘force limits’ database showed good agreement, but for pulling the ‘force limits’ weights were considerably greater than those selected psych ophysically. The implications of these findings are discussed.     

Rating of acceptable loads in manual sorting of postal parcels

The psychophysical test, the rating of acceptable load (RAL) were used to assess acceptable weights for dynamic lifting in postal workers engaged in sorting parcels. The standard test (RAL_St) and a work-simulating test (RAL_W) were administered to 103 volunteers: all experienced male sorters. In the RAL_St, subjects selected the weight which would be acceptable for lifting in a box with handles from table to floor and back to the table once every 5 min for the working day. For the RAL_w, the box was without handles and the weight was chosen to be acceptable for transfer 4-6 times/min from a table to the parcel container and back to the table. Both tests were made during normal working hours at postal sorting centres. The overall means for RAL_St and RAL_w were 16·4 kg and 9·4 kg respectively (p < 0·001): both being substantially higher than the average parcel weight of 4 kg. The RAL_St and RAL_w tests proved to be repetitive and sensitive for differentiating the effects of load and task variables in actual manual materials handling. Thus they appear to be applicable to the evaluation of manual materials handling problems.     

The evaluation of smaller plasterboards on productivity, work demands and workload in construction workers

Manual handling of plasterboards in order to construct interior building walls is a risk factor for musculoskeletal complaints. Unfortunately, mechanical lifting aids to reduce the physical workload are impractical for this task. Therefore, the effect of smaller plasterboards on productivity, work demands and workload was evaluated in an exploratory study among experienced construction workers (n=4-8) at the worksite. The dimensions and weight of the conventional and smaller plasterboards (PB) were: PB120 (2440 x 1200 x 15 mm; 33 kg) and PB90 (2440 x 900 x 12.5 mm; 20 kg), respectively. Productivity was defined as meters of plasterboard mounted. Work demands were assessed by means of real time observations of tasks and activities. Workload was determined using continuous heart rate monitoring and subjective judgments of perceived workload. Productivity and total work time per working day did not differ between PB120 and PB90. Duration of mounting (29% increase) and anchoring (26% increase) were longer for PB90 than PB120. Duration of lifting, carrying and turning over plasterboards, and percentage of heart rate reserve showed no difference between PB120 and PB90. A majority of the workers preferred PB90. For the last two reasons and because PB90 weighs approximately 40% less than PB120, PB90 seems preferable. The workload in both conditions, however, was considered high.     

Cart pushing: The effects of magnitude and direction of the exerted push force, and of trunk inclination on low back loading

The primary objective of the present study was to quantify the relative effect of the magnitude and direction of the exerted push force and of trunk inclination on the mechanical load at the low back using a regression analysis for correlated data. In addition, we explored the effects of handle height and type of pushing activity (standing or walking) on the magnitude and direction of exerted forces, trunk inclination, and low back loading when pushing a four-wheeled cart on a treadmill. An experimental setup was designed in which nine participants pushed a four-wheeled cart on a treadmill. Kinematics and reaction forces on the hand were measured to calculate the net moment at the L5–S1 intervertebral disc. Results show that the magnitude and direction of the exerted push force and the trunk inclination significantly and independently affect low back load. It is concluded that for the ergonomic evaluation of pushing tasks, the inclination of the trunk should be considered, in addition to the magnitude and direction of exerted forces.

Relevance to industry

Pushing carts is a common activity for a considerable part of the workforce and has been associated with musculoskeletal complaints. This paper shows that not only the magnitude of exerted forces determines the low back load but also the direction of the exerted forces and the inclination of the trunk should be considered for ergonomic evaluation.     

Psychophysical basis for maximum pushing and pulling forces: A review and recommendations

The objective of this paper was to perform a comprehensive review of psychophysically determined maximum acceptable pushing and pulling forces. Factors affecting pushing and pulling forces are identified and discussed. Recent studies show a significant decrease (compared to previous studies) in maximum acceptable forces for males but not for females when pushing and pulling on a treadmill. A comparison of pushing and pulling forces measured using a high inertia cart with those measured on a treadmill shows that the pushing and pulling forces using high inertia cart are higher for males but are about the same for females. It is concluded that the recommendations of Snook and Ciriello (1991) for pushing and pulling forces are still valid and provide reasonable recommendations for ergonomics practitioners. Regression equations as a function of handle height, frequency of exertion and pushing/pulling distance are provided to estimate maximum initial and sustained forces for pushing and pulling acceptable to 75% male and female workers.     

Acceptable workloads for three common mining materials

A series of psychophysical lifting studies was conducted to establish maximum acceptable weights of lift (MAWL) for three supply items commonly handled in underground coal mines (rock dust bags, ventilation stopping blocks, and crib blocks). Each study utilized 12 subjects, all of whom had considerable experience working in underground coal mines. Effects of lifting in four postures (standing, stooping under a 1·5m ceiling, stooping under a l·2m ceiling, and kneeling) were investigated together with four lifting conditions (combinations of lifting symmetry and lifting height). The frequency of lifting was set at four per min, and the task duration was 15?min. Posture significantly affected the MAWL for the rock dust bag (standing MAWL was 7% greater than restricted postures and kneeling MAWL was 6·4% less than stooped); however, posture interacted with lifting conditions for both of the other materials. Physiological costs were found to be significantly greater in the stooped postures compared with kneeling for all materials. Other contrasts (standing versus restricted postures, stooping under 1·5?m ceiling versus stooping under l·2?m ceiling) did not exhibit significantly different levels of energy expenditure. Energy expenditure was significantly affected by vertical lifting height; however, the plane of lifting had little influence on metabolic cost. Recommended acceptable workloads for the three materials are 20·0?kg for the rock dust bag, 16·5?kg for the ventilation stopping block, and 14·7?kg for the crib block. These results suggest that miners are often required to lift supplies that are substantially heavier than psychophysically acceptable lifting limits.     

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.     

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.     

Anthropometric,muscle strength,and spinal mobility characteristics as predictors in the rating of acceptable loads in parcel sorting

The rating of acceptable load (RAL) attained with a standard test (RAL_st) and a work-simulating test (RAL_w) for postal parcel sorting was related to anthropometric, muscle strength, and spinal mobility characteristics of 18 male sorters. The subjects comprised a subsample of 103 experienced male sorters who carried out the RAL tests at postal sorting centres. The dynamic hand-grip endurance correlated significantly (p=0·036) to the RAL_st results. Correspondingly, there was a significant correlation ( p=0·044) between the ratio of maximal isometric strength of trunk extension to body weight and the RAL_w. The dynamic hand-grip endurance predicted 26% of the variation in the RAL_st; in the RAL_w the maximal isometric strength of trunk flexion to body weight ratio predicted 24%. The subjects who rated heavier weights for RAL_st, tended to have a better trunk mobility. The dynamic endurance of hand-grip muscles, trunk strength, and spinal flexibility seemed to be the most powerful predictors for the psychophysically assessed ‘acceptable loads’ in experienced workers performing manual materials handling tasks.     

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).     

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.     

A target-based population approach for determining the risk of injury associated with manual pushing and pulling

A new procedure for determining the risk of injury associated with manual pushing and pulling was developed based upon characteristics of the user population (i.e. age, gender and stature) and task requirements (i.e. working height, task frequency and travel distance). The procedure has been integrated into international (ISO, 2004) and European (CEN, 2004) standards for determining recommended force limits for pushing and pulling that can be adapted to suit the user population. These limits consider the muscular strength of the intended target population, as well as the compressive loads on the lumbar spine. Examples are provided to demonstrate variability of the proposed ‘safety’ limits for different task scenarios.

Relevance to industry

The manual handling of physical loads are known risk factors associated with work-related musculoskeletal disorders (WMSD). These disorders are common throughout the industry and may incur considerable costs to both the employer and the employee. The new risk rating procedure enables pushing and pulling tasks to be more closely aligned to the capabilities of the user population and, therefore, has an important role to play in helping to reduce the suffering and costs associated with these disorders.     

Multiple criteria decision-making for the resolution of conflicting ergonomic knowledge in manual materials handling

The ergonomic design of manual materials handling tasks typically utilizes one or more of three approaches; biomechanical, physiological, and psychophysical. Unfortunately, a comprehensive design is rarely obtained because of the difficulty of resolving the conflicting guidelines and criteria for each of the three approaches. This paper describes a methodology utilizing the multiple criteria decision-making (MCDM) process for resolving this conflict. This approach calculates the ratio of the contribution from each type of stress to an overall stress level as determined by the unacceptability of this stress to the user. An example is presented to demonstrate this technique.     

A survey of the optimal handle position for boxes with different sizes and manual handling positions

Handles on objects are very important for enhancing the safety and efficiency of manual handling for people who use them. In this study, four different prototype boxes with auxiliary handles were designed to determine the optimal handle position of a box based on the evaluated user preferences and body part discomfort (BPD). Twenty male students participated in the experiment. Likert-5 point summated rating was applied to evaluate user preferences for the provided boxes with handles in upper, middle, and lower positions, in four different sizes and manual handling positions. Ten additional subjects were asked to indicate their BPD on a body chart after performing a similar experiment. The results show that the subjects preferred the upper part of the handle on a small box regardless of handling position; while the mid to upper parts of the handle on a big box were preferred for handling above the waist height. BPD also indicated that an upper handle was less stressful for a relatively smaller box than a big one; and mid to upper handles were less comfortable for a big box. The optimal handle positions depending on box size and handling position were suggested based on the results of the evaluation. It is thus recommended that a box provides a handle according to its relevant position, depending on size and manual handling condition, to reduce the musculoskeletal stress and in turn to increase user satisfaction.     

Comparison of prediction models for the compression force on the lumbosacral disc

The main objective of this research was to compare three representative methods of predicting the compressive forces on the lumbosacral disc: LP-based model, double LP-based model, and EMG-assisted model. Two subjects simulated lifting tasks that are frequently performed in the refractories industry of Korea, in which vertical and lateral distances, and weight of load were varied. To calculate the L5/ SI compressive forces, EMG signals from six trunk muscles were measured, and postural data and locations of load were recorded using the Motion Analysis System. The EMG-assisted model was shown to reflect well all three factors considered here, whereas the compressive forces from the two LP-based models were only significantly affected by weight of load. In addition, low lifting index (LI) values were observed for relatively high L5/S1 compressive forces from the EMG-assisted model, suggesting that the 1991 NIOSH lifting equations may not fully evaluate the risk of dynamic asymmetric lifting tasks.