ErgoAlert: Work smarter, not harder

by Rebecca Douglas

You wouldn’t expect a sander with a worn belt to last long or a leaky air compressor to run your pneumatic tools effectively. But you probably wouldn’t think twice about lugging an overloaded toolbox across a jobsite or craning around a framing beam to hammer a nail.

For some reason, we’re often more willing to strain and misuse our own bodies than any other piece of machinery or tool we own. Trouble is, human wear is much harder and more painful to repair; and jobsites are loaded with hazards that cause it.

The physical demands and working conditions on typical construction sites prompted one researcher to call the industry “a problem in ergonomics.” More recent studies have revealed the most common ergonomic problems for construction workers. 

They are (in order of risk):
• working in the same position for long periods of time;
• awkward bending or twisting of the back;
• working in awkward or cramped positions;
• working when injured or hurt;
• handling heavy materials and equipment.

Loren Wolf, president of MusculoSkeletal Injury Controls in Chicago, Illinois, focuses on improper handling of heavy materials. Her formal training as a physical therapist combines well  with her family’s business in building materials and ready-mix concrete, making the ergonomics in construction a natural for her.

Too much material handling
“Look at where and when you’re bringing materials on-site,” recommends Wolf. “They’re often double- and triple-handled before they’re even used. Each time they’re handled, workers are at risk.”

To make supplies easier to handle, she recommends using empty pallets or upside-down milk crates to raise materials and equipment off the ground. “That way, workers aren’t bending down so far to lift them,” she explains.

Another of Wolf’s “ergonomic causes” is the gang box. Her beef with the boxes: There’s almost always too much in them, and they’re rarely loaded correctly.

Wolf suggests moving large pieces of equipment that don’t have handles in separate tubs or crates with handles. She also recommends packing heavy, bulky items such as chain so it falls so workers aren’t lifting too much weight from an extended reach.

Wolf shares proper lifting techniques and other ergonomic tips on jobsite visits. During these visits, Wolf stresses how workers can protect themselves from the three most common causes of muscle pains and strains: bending, twisting, and reaching.

Reaching is the most common and detrimental cause. “Your center of gravity is critical,” she says, “Get close to your work when lifting, pulling, pushing, pounding or applying force.” She also suggests workers change the work to minimize any bending or twisting motions, especially if a heavy load is involved.

Subcontractor strategies
Another important ergonomic risk — working in the same position for long periods of time — is a particular problem for specialty workers such as carpet layers and cement finishers. “When workers don’t take time out to change position, they deprive their extremities of oxygen-rich blood,” explains Kate Perry Janney, head of rehabilitation at Shore Memorial Hospital in Somers Point, New Jersey.

To prevent the damage and soreness this can cause, Janney recommends taking short breaks and stretching in the opposite direction in which you’ve been working. Tile layers, for instance, should arch their backs and look up toward the ceiling to stretch tight muscles.

“A smooth stretch, held for about 10 seconds, can do wonders,” she says. “When you release the stretch, you’re healing your muscles and tendons by pumping fresh, oxygen-rich blood into them.” Repeat this ten-second stretch three to five times periodically throughout the day and you’ll help prevent muscle aches and other damage in less than one minute.

Rethink work
Researcher Kai Li uncovered other simple ways to prevent injuries caused by awkward bending or twisting. After analyzing nearly 3,000 working postures recorded at construction sites, Li suggests concrete workers can do themselves a favor by assembling plywood forms on sawhorses rather than squatting or kneeling to assemble them. Li also recommends the forms be cleaned and dried periodically to reduce the handling weight.

Bricklayers, he found, can reduce strain by placing bricks and buckets of mortar directly in front of their work instead of to the side. He also recommends lifting tables or adjustable scaffolding to help bricklayers maintain proper work height.

Li’s studies also found that wire-tying hooks worked better than pliers in reducing repetitive wrist motions. Unfortunately, not all ergonomic factors are so easy to control. “Cold temperatures present physiological complications,” says Wolf. “But it’s just not reasonable or feasible to expect contractors to enclose and heat entire jobsites. Extra clothes can restrict workers’ range of motion, and gloves can compromise their grip. Finding the right solution can sometimes be very complex.”

When it comes to improving job site ergonomics, there’s plenty of room at the table. Wolf urges contractors to purchase tools and equipment that do the job effectively and are engineered with the “human interface” in mind as well. When comparing backhoes or front-end loaders, for example, horsepower and bucket capacity are important. But also look at the cab: Are controls within easy, natural reach? Does the seat attenuate vibration for the operator?

Wolf is encouraged by the increasing number of ergonomic tools available, but she cautions contractors to shop carefully. “Some live up to the claims in their ads, some don’t,” she warns.

She recently evaluated a tool designed to eliminate the extended time workers spent bent at the waist while tying rebar. “It allowed them to stand up, but it was too short, so they were still hunched over,” she says. “Just because a tool is labeled ‘ergonomic’ doesn’t mean it really is. You have to take a hard look at how it will be used.”

Supervisors can help the cause by including ergonomic tips in morning job talks. Reminders about body positioning and lifting techniques should rank right up there with the importance of safety glasses and wearing fall protection harnesses. Some foremen have even instituted mandatory warm-up sessions, a move applauded by Wolf and other ergonomic specialists.

“Athletes don’t start work without stretching, but construction workers do it all the time. The muscles involved with swinging a hammer and throwing a football are actually very similar,” says Wolf.

Take personal responsibility
Personal accountability plays a major role in preventing premature wear. “It’s the employer’s responsibility to provide a safe working environment, but it’s the employees’ responsibility to use their bodies safely within that environment,” says Janney.

Even the most cutting-edge pistol-grip tool is an ergonomic problem when used on a horizontal surface above chest height. It results in “chicken-wing elbows” that can stress shoulder and back muscles. “Many construction workers think it’s normal to go home from work absolutely exhausted or wake up the next morning with a sore back,” notes Janney. “The truth is, their bodies are sending them messages. Fatigue and pain aren’t symptoms that should be ignored. They can easily develop into chronic conditions that are much more difficult to treat. Ask anyone who has suffered with a painful herniated disc.”

Failing to treat standard strains and other aches can also start a dangerous domino effect. “When one area of the body is injured or compromised, another usually compensates and it’s placed at increased risk, too,” explains Janney. “That’s why it’s important to have a medical professional perform a thorough evaluation.”

Instead of reaching from a ladder to hang that last piece of drywall, move the ladder. And by all means, drop the macho act. Some materials are just too heavy to carry alone. Mechanical lifts, hoists, carts and dollies are widely recognized as grossly under-used.

Wolf suggests looking at lifting and other everyday duties through “ergo eyes.” “Even though you’ve done something a million times, there’s often a better way to do it,” she says. “Ergonomic improvements save wear and tear on your body and they usually make the job go easier and faster, too.”

Published in the July/August 2002 issue of Contractor Tools and Supplies magazine.

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