. 53_·---
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DESIGN OF WARNINGSFOR PHYSICALTASKS:
SLIPS, TRIPS,FALLS,AND MANUAL
MATERIALSHANDLING
BoftdanaSftereftiy,DavidRodrick,andWaldemarKarwowski
Universityof Louisville
MichaelS. Wogalter
NorthCarolinaState University
ABSTRACT
11li.s chapter describes the design of warning signs in the domain of physical ergonomics. The design of effective warnings
for hazards regarding musculoskeletal injury requires knowledge about potential risk factors and injury mechanisms and
should consider the anthropometric , biomechanical , and motor
skill abilities of the target population. This information should
be integrated with the warning design process as a means of reducing costly work.place injuries. Particular emphasis is given to
hazards related to slips, trips, falls, and manual material handling
tasks . Example prototype w~
are presented . Recommendations for future research and application arc offered.
WARNINGDESIGN PRINCIPLES
AND PHYSICALERGONOMICS
Increased attention bas been given to the use of warnings in addressing hazard control in various domains, including consumer
products and work environments (Laughe ry & Hammond,
1999). According to Sanders and McCormick (1993), warnings
are the last line of defense of a three-pan hierarchy of hazard
control. Accoroing to this hierarchy, the first and best method
is to design out the hazard. The second-best method is to guard
against the hazatd. The third and last method is to use warnings . The first two methods are considered the most effective
for safety, because if one can design out or effectively control
the hazard then individuals are relatively safe without having to
do anything themselves to prevent the hazard from causing injury (or property damage). However, in many instances , it is not
possible to completely eliminate or to adequately guard against
all hazards or risks in prod uct usage or task performance. ht
those situations , warnings can play an important role as a third
line of defense against recognized hazards.
Most standards and guidelines for the warning design (e.g.,
American National Standards htstirote (ANSI), 2002; Wogalter,
Conzola , & Smith-Jackson, 2002) generally identify four main
textual components : (a) a colo red panel with a signal word and
an alert symbol (triangl e surrounding an exclamation point) to
attract attention and convey a level of hazard , (b) information
Handbook of Warntngs, Edited by Michael S. Wogaltcr, © 2006 , Lawrence Erlbaum Associates (Mahwah, NJ).
655
656 •
SHEREHIYET AL.
identifying the hazard, (c) an explanation of the potential consequences if exposed to the hazard , and ( d) directives for avoiding
the hazard. A fifth component is a graphic, such as a pictorial
symbol that may assist in conveying one or more of the other
four components. Therefore, a warning should convey the level
and nature of the hazard present in the situation, how to avoid it,
and what could happen if the hazard is not avoided. Research
(e.g., Frantz, Miller, & Lehto 1991; Laughery, Vaubel, Young.
Brelsford, & Rowe, 1993) recommends that the message text
pertaining to the hazard , consequences , and directives should
be specific and complete, but also reasonably brief. If needed,
the mechanisms of injury involved should be presented to explain the nature of the hazard, including reasons why it is important to comply with the directives (Wogalter et al., 2002).
It should also provide directives that can be accomplished expeditiously. Not only should the actions named be specific but
also they should be relatively easy to perform. People are less
like to comply if the directive is effortful and time consuming
(Wogaltcr, Allison, & McKenna, 1989 ; Wogalter ct al., 1987) .
Thus , the design of effective warnings requires knowledge
of existing standards , guidelines , and research in the domain of
risk communication. It also requires detailed knowledge about
the hazards associated with the foreseeable modes of product usage and the environments in which such usage occurs
(Frantz, Rhoades, & Lehto, 1999). 'Iypically, in the initial phases
of the design process, hazard analyses arc conducted. Several
kinds of hazard analyses (Laughery & Hammond, 1999) may be
employed , including : (a) procedures analyzing various circumstances that will or might arise and the severity and probabilities
of their occurrence (e.g., fault tree and failure mode analysis),
and (b) accident data reportS from various sources. These methods provide important opportunities to identify and understand
the hazards. With t'CSpcct to physical ergonomics, there is a
considerable body of research and evaluation (hazard analyses)
that have identified musculoskeletal hazards in various tasks and
environments .
The purpose of this chapter is to explore how warnings
might be used in physical (occupational) ergonomics. Physical ergonomics is concerned with human anatomical , anthropometric, physiological, and biomcchanical characteristics as
they relate to physical activity (Karwowski , 200 l; International
Ergonomics Association, 2004) . It concerns the study of physical task performance considering the hazards and risks involved
in work. A goal is to develop ways to eliminate or reduce known
risk f.lctors in jobs and to develop guidelines for safe task performance . Hwnan body movements arc studied in conjunction with enviroruncntal objects , considering factors such as
sequence of movements and positions. Understanding of how
these components interact and contribute to injures and accidents is a major challenge for the design of warnings in this
domain .
The Importance of Warnings in Physical Ergonomics
According to Ramsey (1989), warnings should provide instructions that targeted individuals can carry out. A weU-known
concept in the warnings literature is the cost of compliance
(Wogalter et al., 1987, 1989). If a warning instructs people to
undertake a hazard avoidance activity that is effortful and time
consuming, they will be less likely to comply relative to one that
instructs them to undertake a relatively easy and quick activity.
Thus, the prescribed avoidance actions should be as simple to
perf orm as possible . Although this may seem straightforward, it
also requires consideration of the skills, strength , and anthropometrics of the population expected to respond to the warning.
For example, some individuals may lack the necessary reaction
time , strength , arm length, marupulative skill, and other f.lctors
required by a warnlng's instruction to adequately or effectively
perform the warning 's hazard avoidance activity. Thus , a person
might not be able to comply, even though the individual understands the message and wants to avoid the hazard. Therefore,
in addition to the attentional, cognitive, and other f.lctors that
should be considered in the design of warnings, an effective
warning must also be consistent with the biomcchanical and
motor skill abilities of the target population being warned.
In view of the previous discussion , the design of effective
warnings requires consideration of the following issues:
• the potential hazards associated with products and equipment
or environments ;
• detailed information about the context and circumstances in
which an injury pathway or accident sequen ce may occur;
• knowledge about how people behave when interacting with
the product;
• foreseeable uses and misuses of the product;
• safe Wll)'S to perform a task or manipulate a product; and
• anthropometric , biomechanical, and motor skill abilities of
the target population.
Tilis chapter mainly focuses on the anthropometric, biomcchanical , and motor skills of the target population. A detailed
description of all haz.ardous situations and risk factors associated
with physical tasks is beyond the scope of this chapter . However,
a few notable examples are given, which demonstrate wherethe biomechanical-type hazard s have been weU established and
how warnings may be beneficial in reducing the risk of musculoskeletal injury.
The following sections of this chapter initially describe background into two main typeS of physical ergonomics injwies :
slips, trips, and falls (STFs), and manual material handling
(MMH) . Tilis background serves as justification for intervention
by using warnings as a method of hazard control. The final sections describe examples of warnings that might be used to decrease accidents and injuries pertaining to STFs and MMH tasks.
(STFs)
STF-related injuries and mortality arc considered a substantial
problem, with falls representing 10% of all fatal accidents in
the United States (Agnew & Suruda, 1993) and 26.9% in Japan
(Nagata, 1991). Slips and falls are the second highest source of
unintended death each year in United States (Fingerhut, Cox,
& Warner, 1998). The National Safety Cowidl (NSC; 1998)
53. WARNINGS FOR PHYSICAL TASKS
•
657
of the body is in the same direction as the slip (Chang, 200 1;
Haslam, 2001) .
The Bureau of Labor Statistics (U.S. Department of Labor,
1992) Occupational Injury and Illness Qassificatio n Sche me distinguishes betWeen three major groups of falls: falls on the same
level, falls to a lower level, and jumps to a lower level. Falls on
the same level occur when the point of contact is on the same
level or above the surface level supportin g the person. Falls to a
lower level occur when the point of cont"llct is below the level
supporting the pers on. Fmally, jwnps to a lower
of the sum.cc
level occur when a person voluntarily leaps from an elevation,
even if an attempt is made to avoid an uncontrolled fall or injury .
Tripping is less frequent than slipping , occurring when the foot
collides with an obstacle while the b ody continues in motion ,
resulting in loss of balance and a subsequent stum ble or fall
(Gauchard Ct al., 2001; Haslam, 2001) .
CAUTIONi •M:iifr!i
l
FALL
PROTECTION
FALLPROTECTION
REQUIRED
IN
REQUIRED
IN
THISAREA
THIS AREA
CAUTION
CAUTION
SLIPPERY
WHEN
WET
FIGURE 53. t . Illustration of typical SFf signs.
reported that , in 1997, there were 14,900 deaths in the United
States resulting from fall accidents. Other data show that falls
represented about 15% of all unintended deaths and 21 % of unintended injuries resulting in emergency department visits in
1995 (NSC, 1998). Among nine industries examined by Leamon
and Murphy (1995), the direct cost of occupational injuries from
slips and falls was highest of all of the accident categories for
the construction , restaurant, and clerical industries. Slips and
falls were also the second highest souoceof losses for the business sectors of manufacturing , trucking , retail and wholesale
stores, health care, food products manufacturing, and professional drivers .
Warnings intended to prevent STFs are fairly common (e.g .,
wet floor signs). Figure 53.1 shows some typical warning signs
used for STFs. However, few, if any, posted signs or labels give
the necessary risk-related information important for effective
warnings, including potential risk factors, mechanisms of injury,
and specific injury consequences, for example, bone fracture ,
back dislocation , ruptured disc , sprains, or even fatalities.
Slipperiness can be ddined as the condition underfoot that
may intetfere with travel , causing the foot to slide (Gronqvist
et al., 2001b). Slipperiness may cause injury or harmful loading of body tissues resulting from a sudden release of energy.
Slipping occurs when there is insufficient friction between
the foot and the floor , causing unintended movement between
the two surfaces . Slipperiness is a function of the coefficient
of the friction that quantifies the resistance between an object
and the surface. A fall sequence involves the following events :
(a) occurrence of imbalance (slips, trips, etc.); (b) attempt
to recover equilibrium and , in the case of failure to recover,
(c) a fall, with body impact on a surface (Gauchard, Chau, Mur,
& Perrin , 2001) . Slipping can happen during either the toe-off
or heel-strike phases of walking. The heel-strike form is usually
more difficult to recover from because the forward momentum
STF Risk Factors
Multiple interacting environmental and human factors are involved in causing slips and falls . The primary risk factor for slipping is poor grip or low friction between the footwear (foot )
and the underfoot surface (floor, pavemen t, etc.; Gronqvist
et al., 2001a, 2001b; Haslam , 2001 ; Redfern ct al., 2001) . Secondary risk factors for slipping are related to a variety of
environmental factors. These bctors include wa.lking-swface
properties, such as surface roughness, irregularities, compli ance , topography , and the properties of adjacent areas and
contaminants (Gauchard, et al., 2001 ; Gronqvist et al. , 2001a ,
2001b; Haslam , 2001 ; Leclercq, 1999a; Red.fem et al., 2001).
Unexpected changes in slipperine ss are particularl y hazardous
(Gronqvist, 2001a, 2001b). Another important environmental
factor causing falls is insufficient lighting and glare (Gauchard,
et al., 2001 ; Redfern ct al., 2001).
The pre sence of contaminants or lubricants on the contact
surface are important risk factors for occupatio n al and nonoccupational slips and falls (Gronqvist et al., 2001a , 2001 b ; Lcclercq ,
1999a; Manning, Ayers, Jones, Bruce, & Cohen, 1988; Myung &
Smith, 1997). Slip-related injuries often occur on wet, dirty, oily,
greasy , or othe r contaminated walking surfaces. Accident investigations of these slip-type falls have shown that the ground
covering is soiled in approximately 80% of the cases (Manning
ct al., 1988). liquids , strewn objects , and ice/ snow contribute
to 45%, 21%, and 15 % of the reported cases, respcctively(Man·
ning et al., 1988; Strandberg & Lanshanunar, 1981) . Individual
characteristics contributing to the slips and falls include gait,
expectation , and the capabilities of the sensory (i.e., vision,
proprioception , somatosensation, and vestibular) and the neu romuscular systems (Gauchard , et al. , 2001 ; Gronqvist et al.,
2001a , 2001b; Haslam, 2001; Leclercq, 1999a; Redfern et al.,
2001).
Falls also occur in dual-task situ ations in which locomotion
i.s a sec ondary taSk, to other tasks , such as talking, searching
through store aisles for a particular object (e .g., grocery shopping), or carrying loads (Bentley & Haslam, 200 l ; Gauchard ,
et al., 2001 ; Gronqvist et al ., 2001a, 2001b ; Myung & Smith,
1997). In the latter case, the load carriage affects the center of
658
•
SHEREHIY ET AL.
gravity and adversdy affects an individ ual's ability to maintain
their equilibrium and to recover from an imbalanc e (Bentley
& Haslam, 2001; Haslam, 2001; Myung & Smith , 1997). Pushing and pulling loads are also considered substantial risk factors
for slips and falls (Haslam, 2001; Gauchard, et al., 2001) . When
pushing and pulling , the shear forces between the feet and the
floor increase , which increase s the likelihood of the slipping .
1iipping can be caused by a permanent feature of the swfac e,
such as a raised rock or step, or by a temp orary item, such as,
trailing dectrical cable or a carpet fold (Bentley & Haslam , 2001;
Haslam, 2001).
Accidents involving the steps and stairS are another major category of falls. Imponant features of steps and st.airs include : riser
and going (tread) dimensions, design of nosing, length of flight,
nature and condition of surface material, position of handrail ,
and lighting (Cohen & Pauls, chap. 57, this volume; Haslam ,
2001). lt has been recommended that riser dimensions should
be within 117 to 183 mm, with goings between 279 and 356 mm
(Templer , 1992). Dimensional irregularities between adjoining
steps and content of the visual .field arc contributory factors
to accidents (Templer , 1992). User behaviors, which increase
the risk of falls, include rushing, carrying items, and leaving
objects on stairs. See Cohen and Pauls (chap. 57, this volume )
for more risk filctors involving the use of stairs and p edestrian
walkways .
Falls from h eights are a leading cause of serious injuries and
fatal accidents at work in the United State (Cattledge, Hendricks,
& Stanevich, 1996; Rivara & Thompson, 2000 ), United Kingdom
(Haslam, 2001), and Denmarlc (Kines, 2001), with construction
industry workers particularly at risk. Falls from heights tend to
occur in locales where there is a sudden, unexpected change
in floor levd or where there is a need to climb to a h e ight.
They include falls from or through roofs, from scaffolding, off
ladders, through windows, and from machinery. Frequently, serious fall-from-height injuries occur from relatively low elevations , suggesting that some people may not realize the extent
of the hazard involved (Kines, 2003).
STF Avoi dance
The risk of slips and falls depends on the capabilities of the
postural control system and the mental set of the individual
(Chang, 2001 ; Haslam , 2001 ; I.eclercq, 1999a, 1999b; Redfern
et al., 2001). The risk is also dependent on the subjective judgments of the user on potential slipperiness of actual floor conditions , particularly when vision is the only sensory mode affording its prediction (Chang, 200 l; Gronqvist, et al., 2001 a, 200 lb ;
Haslam, 2001). With greater perceived slipperiness , postural
control mechanisms are activated. and relevant postural adjust.ments arc taken to maintain balance and to adapt to the low
fricti on conditions. Th e adaptation actions inciude shorter steps
and increased knee flexion , which reduces the vertical acceler ation and the forward velocity of the body (Cham & Redfern ,
2002 ; Chang, 2001; Gauchard et al., 2001). Adequate adaptation
may not occur when it is not apparent that there is a change in
the slipperiness (Chang, 2001; Leclercq , 1999a, 199b; Strandberg & Lanshammar, 1981). This explains why slips are more
likely to occur where the properties of a walking surface change,
- with the likelihood disproportiatd y higher when the change
is sudden and unexpected . Therefore , methods tha t en.able bet ter detecti on of slipperiness and changes in the walking surfitce
could hdp to avoid STFaccidents. Markings and warnings could
be used to facilitate detection and promote proper adjustments.
MMHTASKS
MMH wks , such as unaided lifting , lowering, carrying , pushing,
pulling , and holding, are common activities in the manufacturing , construction, and service industries. Injures .resulting from
MMH tasks are the primary sourc e of compensable work-related
injuries in the United State, concentrated predominately in the
lower baclc.(Battie et al., 1990; Bigos et al., 1986; Federal Register, 1986; National Academy of Sciences, 1985; National Institu te for Occupational Safety, 1981). Besides the United State,
there has also been internati onal recognition of the adverse effects of MMH tasks . The use of safety and risk communication
and warnings may be a useful way to avoid unwanted outcomes
(Laughery & Hammon d, 1999).
Current Practices in MMH
Over the years, .researcher s have examined the epidemiological
bases oflower back disorders. Risk factors for low back p ain and
disorders inciude characteristics of th e worker, the material or
containers being moved, the tasks involved , and the workplace
environment (Karwowski , Wogalter, & Dempse y, 199 7) . A comprehensive literature review of epidemiological studies on lower
back disorders by Hildebrant ( 1987) revealed 24 work-related
risk factors . These can be categorized into .five basic groups as
follows :
1. general: heavy physical work and general w ork posture;
2. static workload : static work posture and lack of variation , such as prolonged sitting, standing, or stooping, and
reaching ;
3. dynamic workload : heavy manual handling, lifting (heavy or
frequent , unc:xpccted or infrequent heavy, torque ), carrying, forward flexion of trunk, rotation of trunk , pushing or
p ulling;
4. work environm en t: vibration, jolt, slipping or falling; and
5. work conten t: mon otony, repetitive work, work dissatisfaction
The association between lower back disord er/injury or pain
and MMH tasks has been wdl documented in the literature.
One of the ways researchers and practiti oners have attempted
to reduce MMHdisorders is through training workers in correct
manual handling techniques (Kroemer, 199 2). As reported in
Burt, Nenningsen , and Consedine ( 1999), some studies show
positive effects of training on MMH tasks (e.g., Chaffin , Gallay,
Wooley, & Kuciemba, 1986; Miller, 1977), whereas others failed
to note significant effects (Brown , 1975; Dehlin , Hedenrud , &
Ho.ral, 1976; Stubbs, Buckle, Hudson , & Rivers, 1983; Wood,
53. WARNINGS FOR PHYSICAL TASKS
1987; Yu, Roht, Wise , Kilian, & Weir, 1984). Various types of
training and measures were used in the studies, so it is difficult
to determine the reasons for the failure to find positive effects in
some and not other srudies. One difficulty in showing a benefit
probably relates to inadequate transfer of training, or in other
words, the failure to make use of learned techniques and principles from the training situation to the actual work situation
(Harber; Billet, Shimozaki , & Vojtecky, 1988; St-Vmcent, Tellier,
& Lortie , 1989). Yelon (1992) suggested that awareness plays an
important role in using new skills following training. However,
the failure to find positive effects of training in some studies
suggests that simple awareness is probably not the whole story.
Job or task experience may be a factor in MMH-related injury.
Other studies have suggested that the techniques used by more
experienced, better-performing workers differ from the behaviors carried out by novices (Authier, Lortie, & Gagnon, 1996;
Gagnon , Plamondon, Gravel, & Lortie, 1995; Mital, 1987; Noe,
Mosta.r:di,Jackson, Porterfield, & Askew, 1992; Patterson, Congleton, Koppa, & Huching.son , 1987). Despite the difference in
behaviors between these two groups, the correct methods for
safe performance ofMMH tasks are rarely used (Kroemer, 1992).
Several field studies (e.g., Baril-Gingras & Lortie, 1995 ; Drw-y,
Law, & Pawenski, 1982; lmbeau , Beauchamp , Normand, Courtois , & Marchand, 1990; Kuorinka, Lortie , & Gautreau , 1994)
have shown that it is not uncommon for workers to perform
the MMH taSks in ways that increase the risk of musculoskeletal
•
659
labels . Unfortunately , few of these warnings convey much, if
any, information related to injuries arising from MMH casks.
Furthermore, little empirical research has been conducted oo
warning signs for physically demanding and , therefore potentially dangerous , manual tasks (Burt et al. 1999; Macken -Stout
& Dewar, 1981) . A notable exception is a study by Burt et al.
(1999), who conducted three separate experiments with nine
variants of labels displaying correct posture during manual
lifting tasks. Figure 53.2 shows the posture labels that were
used in th e experiments .
The first study found that there were no significant differences among Symbols A, E, H, and I, but all of these symbols
received significantly higher "appropriateness» ratings than the
A
II
B
injury.
Besides formal training (and perhaps exp erience), another
related way of reducing MMH problems is to provide appro priate recommendations or guidelines on proper work practice.
Indeed , a growing nwnber of organizations provide workers
with specific recommendations on how to perform an MMH
task. 'fypical work practice guidelines for lifting are shown later
in the chapter and are discussed in more detail at that point .
Although many work practi ce guidelines exist, they do not
necessarily ensure that the worker is performing a manual handling task according to the prescribed manner. Reasons proper
MMH techniques are not employed include : (a) failU.l'Cto recall the appropriate techniques , (b) selective attention to the
prevailing work tasks and environmental aspects, and (c) inad·
equate information processing while performing a MMH task.
According to Burt et al. (1999), one way to enhance awareness
and to help with the transfer of lifting principles is to remind emplo yees of the appropriate handling principles when they are
about to undertake an MMH task. However, it would be unrealistic to have another person (e .g., a supervisor) always available
to oversee this proces s. Therefore, Burt el al. (1999) proposed
using a visual cue or reminder (e.g., a warning of some type)
that could be presented near or on the materials being handled
by the workers (see also Wogalter, Barlow, & Murphy, 1995).
A visual cue could facilitate the recall of appropriate techniques
for MMH that were taught during specialized training.
C
D
E
F
G
H
Application of Warnings in MMH
To date , there are various commercial organizations that
produce nwnerous safety/hazard-related warning signs and
FIGURE 53.2. Lifting symbols used in the study by Burt et al.
( l 999) used with permission.
660
•
SHEREHIV ET AL.
remaining symbols. The second study examined whether the
participants could discriminate between the symbols in terms
of the information communicated about the correct lifting posture. It was folllld that Symbol I produced the highest propor •
tion of responses for the "keep back straight " criterion and was
highly consistent across other criteria . Symbol I also had the
largest proportion of participants who mentioned that this symbol showed the correct steps required for lifting . Subsequently,
this symbol was used in the third study to examine the lifting
techniques adopted by the participants. The study found that
the symbol prompted a consistent increase in the use of correct
lifting technique for all criteria. Burt et al.'s (1999) research is an
initial step in demonstrating the potential bendit of a symbolic
warning for an MMH task. Further research is needed to evaluate how and to what extent the symbol's presence changes the
adopted body postures and joint motions .
SUDDEN LOADING
The etiology of back pain and injuries is complex and multi .factorial. A substantial number of low back injuries are associated with sudden and unexpected loading during MMH and
sudden or unexpected body movements, such as those involved
in slips and falls (Gauchard, et al., 2001; Magora, 1973; Manning,
Ayers, Jones, Bruce , & Cohen, 1988) . Epidemiological studies
show that the occurrence of musculoskeletal injuries depends
on the frequency of sudden maximal efforts and the "degree
of preparedness~ prior to the effort (Magora, 1973) . Manning
et al. (1984) determined that 78% of back injuries recorded in
an industrial setting were associated with unanticipated body
motions during slips and falls (66%) and sudden loading (12%).
Another study of back injuries showed that 66%of first events
associated with acute back injuries were related to some type of
underfoot accident and that 46%of these accidents were slips
without falls (Mitchell , Blanchfield , & Manning 1983) .
Exposure to sudden loading takes many forms and may occur
both during work and leisure pursuits. The unexpected slipping
of a lifted object or hand-held object is a known precursor of
sudden loadings . For example , such events have been identified
in the work of nurses and physical therapists during patient handling tasks (Molumphy, Unger, Jensen, & Lopopolo, 1985; Owen
& Damron, 1984). Tripping is another example of the sudden
load application through the lower limbs (Magora, 1973; Manning et al., 1984, 1988). During loading or unloading trailers,
truck drivers are exposed to situations in which they try to
catch materials. Less obvious sudden loading situations occur
with occupants in traveling vehicles. Examples include vertical
impact forces in a high-speed boat, a pothole strike by a vehicle
with stiff suspension and tires (e.g., forldifts) , and rough rides in
off-road situations (Wilder , Aleksiev, Magnusson, Pope, Spratt,
& God, 1996).
Biomechanical Studies
Empirical evidence suggests that there is a fairly consistent
biom.echanical scenario for .MMH injuries. The neuromuscular
system overreacts to an unanticipated event. creating excessive
forces on the trunk due to the overcompensation of the trunk
muscles, resulting in dama8Cd tissue . According to this muscle force regulation model (Kroemer & Marras, 1981; Mattas,
Rangarajulu, & Lavender , 1987) , the muscle force onset rate is
linearly related to the magnimde of the intended force exertion.
Under normal lifting conditions , large trunk muscle forces are
generated to stabilize the spine in order to handle the external
load. When the loads become extreme, muscle forces in the
trunk are large, creating compressive and shear loads on the
spine that may result in back injuries.
In situations of unexpected and extreme loading, the increase of muscle forces within the trunk is larger and more
rapid, which may lead to an overload of the spine. Marras
et al. (1987) suggested that, during unexpected conditions, the
trunk muscle s contract to their maximum, regardless of the
magnitude of the extemal load. The exaggeration of the muscular force in an unexpected loading may lead to a particularly
dangerous situation, because trunk forces are increas.ing very
rapidly.
Several studies have analyzed trunk muscle recruitments in
response to unexpected loads applied to the hands (Lavender
et al., 1989; Lavender, Marras , & Miller, 1993; Marras et al., 1987)
and torso (Carlson, Nilsson, Thorstensson, & Zom.lefer, 1981;
Cardo & Naclunias, 1982; Omino & Hayashi, 1992; Thomas,
Lavender, Coreas, & Andersson, 1988) and during slips and falls
(Greenwood & Hopkins, 1979; Romlck-Allen & Schultz, 1988).
These srudies show common muscle-response patterns to sudden loading in different situations. Unexpected perturbations
lead to a rapid onset and high peak amplitudes in muscle activity, con.firming the aforementioned injury scenario . In addition ,
when a sudden load is imposed on the body, the dynamic application of external force recruits additional muscle force to be
generated to counteract, stabilize, and minimize disturbance to
body posture . The increased muscle tension stiffens the spinal
system, thereby magnifying the impact of the sudden loading
(Bouisset&Zattara, 1981;Houk, 1979). For example, with an unexpected loading , the mean muscle force was more than twice
as large as with an expected loading , and peak muscle forces
were on average 70% greater (Maras et al., 1987).
The internal loading was reduced when expectancies were
developed based on temporal (Lavender et al., 1989, 1993; Marras et al, 1987) and spatial (Bouissct & Zattara , 1981; Cardo &
Nashner, 1982; Mardsen, Merton, & Morton, 1977) cues about
the upcoming loading. Spinal loading severity was reduced as
alerting time was increased from O ms to 400 ms (Lavender,
1989). Thus, where sudden loading can be anticipated (some
kind of warning presented) , some preparatory muscular responses can occur , minimizing the negative effects of loading
and postural disturbances. When loads are applied to the lumbar
region of the torso , these preparatory responses include muscle
tensioning, whole body postural changes, and development of
the increased levels of intra~bdoml.nal pressure .
Minimizing postural disturbances also decreases mechanical (compression) loading on the spine (Lavender et al., 1989,
1993; Marras et al., 1987). Smdies have shown that muscle re·
cruitment was a .function of the amount of time available provided by the warning prior to loading (Lavender et al., 1989;
Omino & Hayashi, 1992). Further investigations revealed that
accurate warning information and the knowledge about load
53. WARNINGS FOR PHYSICAL TASKS
characteristics (such as the mass and the center of mass position) facilitate the anticipatory control of trunk muscles (van
Dieen & de I.ooze, 1999; Lavender & Manas, 1995). In the case
of lifting loads with wt.known characteristics, it is advised to
perform a slow lift to minimize loading and possible postural
perturbations. However, only a few studies have c:xamined the
relationships between the specific warning characteristics and
the effectiveness ofbiomecharucal preparation for sudden physical loading on the body. Given the neuromuscular and biome-charucal evidence summarized earlier, adequate warnings may
be useful to signal the extent of loading. Armed with appropriat.eexpectations, the individual can better prepare to handle the
load to avoid adverse biomechanical consequences of sudden
loading or postural perturbations.
RESEARCH-BASED GUIDELINES
AND SIGNS/LABELS FOR PHYSICAL TASKS
Currently , consideration of warnings design from the physical
ergonomics point of view is substmtially underrepresented . As
witnessed by the other chapters in this volume, there ls a large
body of knowledge concerning the characteristics of warnings
to facilitate perception , comprehension, compliance, and other
related processes. However, there is very little empirical research on the design and application of warnings with respect
to the hazards involved in physical (manual) wks performed in
industrial environments . This state of affairs is partially a result
of modem dependence on technological advancement and automation and on engineering and management control efforts to
eliminate, reduce, or guard against workplace hazards. Where
such methods can be practically placed in operation, they are
preferred methods of hazard control. However, as described
earlier, statistics show that there are still a large number of injuries associated with work -related musculoskeletal disorders .
Thus, there is a need to explore other ways besides the distribution of recommended practices (guidelines) and formal training
interventions as attempts to reduce physical ergonomics risks
(U.S. Department of Health and Hwnan Services, 1997). One of
those ways, and the main basis of the remainder of this chapter, is to propose that warnings play a part in efforts to reduce
musculoskeletal injuries.
In this section, several prototype designs for warnings relating to physical tasks are proposed. The aim is to illustrate
how they can be applied to real task siruations and to offer
them to researchers so that they can determine if such warnings reduce STF accidents and can .facilitate safe performance
of MMH tasks. The proposed warnings were developed based
on reco mmendations in the ANSI (2002) Z53S warning sign
and label standard, as well as guidelines developed from research on warnings (see Peckham, chap. 33 this volume). At the
outset of this chapter, several recommended warning components were described. However, the development of warnings
and safety-related .instructions is a much more complex process
than simply following the ANSI(2002) Z535 standard or a set of
guidelines.
According to Wogalter et al. (2000), warning design should
be viewed as an activity that is initiated by requirements
•
661
gathered from the users, including; (a) end-users, who are the
focus oflos.s prevention or loss control efforts (i.e., employees in
an occupational setting or consumers) ; (b) organizations, who
will deploy the warnings and provide the context of use (e .g.,
employers , government agencies); and (c) product/equipment
manufacturers, who develop the products to which warnings
will be applied. Frantz et al. (1999) proposed a systematic process of developing warnings. Part of the process is to identify
and understand product hazards, followed by the development
of potential warning prototypes. In the previous sections of this
chapter, hazards were identified for STFsand MMH load-carrying
tasks. In this section, several prototype warnings are presented .
The .final stage of the Frantz et al. ( 1999) process involves evaluating warning prototypes. Future work is needed concerning
this stage. Thus, the ANSI-type warning designs proposed in the
following sections are only the starting point and should not be
taken as finished products to be used in the real workplace and
other envirorunental settings.
For application in real woril: envirorunents , the following
steps are proposed in the development of a warning intervention :
1. Petform a thorough job analysis to determine the nature of
the MMH task.
2. Evaluate and select the most appropriate hazards that need
warning (i.e., prioritization) .
3. Develop appropriat.e warning signs and labels as required.
4. Evaluate the warnings using measures that assess effectiveness (such as ratings, comprehension, memory, and
behavior).
5. Apply the best waming(s) in context .
6. Monitor the progress with respect to occurrence of
incidents.
7. Adjust or refine the interVention as needed.
Thus, the design of warnings for worlcplace safety requires integrating many processes. The purpose of the following sections
is to give a basis for warnings in the hazard domains previously
descnbed: STF and MMH.
Design of STF Warnings
Walking su.daces should be thoroughly analyzed to establish
any potential risk factors for slip and fall accidents , including
the areas used, slip resistance, roughness, and irregularities. Of
course, building codes and standards should also be examined .
The swrotwding environment should be analyzed to reveal any
potential factors that could cause significant ch~s
of the surface friction, for example , the possibility of surface contamination by the presence of liquids, soil, and objects. In cases where
there are potential problems, attempts to eliminate the hazaro or
guard against it should be considered .first. If the problems cannot be eliminated or barricaded, a warning (or the addition of
markings, e.g., see Cohen and Pauls, chap. 57, this volume) may
be appropriate. The work environment and the tasks performed
by workers should be considered to determine whether there
662
•
SHEREHIY ET AL.
J\. CAUTION
~
Slippery Surface
CAUTION
'
•
High Step Ahead
Fall Hazard
Avoid Area
Tripping Hazard
or
Watch Your Step
Slow Down and Shorten Your Step
FIGURE 53.4. Example of a sign warning against a trip hazard.
FIGURE 53.3. Example of a sign warning against a slippery
surface .
are factors that may obscur e walking swfaces or increase the risk
of slipping in other possible ways. For example, rolling trolleys
and trucks may obscure vision and disrupt monitoring of the
walking surfaces. Special attention should be given to marking
or warning about locations where there are or may be an increased likelihood of surface friction changes, such as a change
from carpet to tile, where the latter may become wet with water
or oil. As noted earlier , rapid and sudden changes in surface fric tion are one of the main co ntribut ing factors to slip and fiillaccidents . The warning or matking itself should be placed in a location where people at risk will see it near the hazard bu t also have
enough time to avoid the hazard or compensate for it in their
behavior.
As described earlier, a person 's awaren ess and perception
of slipperiness activates mechanisms of postural adjustment to
the conditions. Thus, a warning that provides this information
could promote compensatory behaviors and musculoskcletal
adjustments compared with when this information is not given .
A prototype warning for the slippery floor hazard is presented
in Fig. 53.3. In this sign, there is a signal word panel (and alert
symbol), information de scri bing the hazard , a proscri ptive statement on how to avoid the hazard, and an explicit safety symbol .
However, note that in this sign, there iS no separate statement
of consequences. The reason for its omission is that other pans
of the sign provide some of that information (e.g., the hazard
statement co ntains the term "slippery," which implies the con sequence of slipping and falling, and the symbol also provides
this information. A consequences statement, such as "You may
fall and have a severe injury," is probably known from the other
information already given and is probably unnecessary in this
case (Wogalter et al ., 1987). Another similar example of a prototype warning about a tripping hazard is illustrated in Fig. 53.4.
F.arlicr, it was noted that epidemiological research shows
that falls frequently happen from celativety low heights . These
statistics suggest that the hazardousness of a situation may be underestimated . Therefore, the warning for a fall hazard may need
to present information about the extent of danger , emphasize
the consequences , and indicate which specific fall protection
equipment (e.g., a lanyard) needs to be used. A prototype warning about a fall hazard is illustrated in Fig. 53.5. In this case, a
Fall Hazard
Can Cause Permanent
Paralysis or Death
Always Attach Lanyard
FrGURE 53.5. Example of a sign warning against faJls.
53. WARNINGSFOR PHYSICALTASKS •
663
for manual lifting
TABLE 53.1. Guidelines
Things to follow
I. Tiy to eliminate manual lifting (and lowering}. If it is necessa,y , perfonn it betwe e n the heights of the knuckle and shoulder .
2. Be in good physical shape. If not used to lifting and vigorous exercise, do not attempt to do difficult lifting or lowering tasks.
3. Think before acting. Place mate .rial in a convenient pos ition. Make sure sufficient space is cleared. Have handling aids available.
4. Get a good grip on the load . Test the weight before t,ying to move it If it is too bulky or heavy, ge t a mechanical lifting aid or somebody
else to help, or both.
5. Get the load dose to the body . Place the feet dose to the load . Stand in a stable position, with the feet pointing in th e direction of movement .
6. In lifting, involve primarily straightening of the legs .
Things to avoid
I. Do NOT twist the back or be nd sideways.
2. Do NOT lift or lower, push or pull, awkwardly.
3. Do NOT hesitate to get help , either mechanical or from another person.
4. Do NOT lift of lower with arms extended .
5. Do NOT continue heaving when the load is too heavy.
Noll!.Adapted from "Manual Materials Handling"by M. M. Ayoub, P.G . Dempsey , and W. Karwow ski, 1997, in G. Salvendy (Ed .). Halld6ooiofH 1111
r4JI Fadors•Kd E1J0110111ks
12·nd ed .), New York : Wiley.
higher level of signal word is used (according to ANSI Z535,
2002), and explicit consequences arc included .
Design of Warnings for MMH Tasks
There are numerous guidelines published on performing safe
MMH tasks, in the forms of textbooks, manuals , guiddines , and
.regulations. As mentioned earlier, one potential problem is that
woikers may not transfer their training in the guidelines to ac·
tual work behaviors for various reasons . A typical set of text
book guidelines for MMH tasks (adapted from Ayoub, Dempsey,
& Karwowski , 1997) is shown in Table 53.1 . These guidelines
TABLE 53.2. MMH Guidelines
outline what to do or not do in terms of load-carrying postures
required for performing a manual lifting task.
Graveling, Melrose , and Hanson 's (2003) guidelines for the
Health and Safety Executive of the British Government are
shown in Table 53.2, which are somewhat more detailed than
Ayoub et al's. (1997) instructions . They provide specific direc·
tions for correct and safe MMH tasks regarding load, posture ,
and exertion . Generally, the MMH literature (see also University
of Maryland, 2004) suggests that safe material handling encom·
passes a few fundamental rules: (a) keep the load as close to
the body as possible, (b) avoid twisting, and (c) keep the back
straight, bend the knees , and lift using the legs (i.e ., the "straight·
back/bent kneesfl method).
Proposed in HSE Regulations
I . Stop and think {plan the lift).
2. Place the feet .
Have the feet apart, giving a balanced and stable base for lifting.
Have the leading leg as far forward as is comfortable.
3. Adopt a good posture.
Bend the knees so that the hands, when grasping the load, are as nearly level with the waist as possible. Do not kneel or overflex
the knees.
Keep the back straight, maintaining its natural curves (tucking in the chin while gripping the load helps) .
Lean forward a little over the load, if necessa,y, to get a good grip .
Keep the shoulders level and facing in the same direction as the hips .
4 . Get a finn and secure grip.
Try to keep the arms within the boundary formed by the legs.
The optimum grip may va,y, but it should be secure.
If you vary the grip while lifting. do this as smoothly as possible .
5. Don't jerk.
Carry out the lifting movement smoothly. Raise the chin as the lift begins, while keeping control of the load.
6. Move the feet.
Don 't twist the trunk when tum Ing to the side.
7. Keep close to the load .
Keep the load close to the trunk for as long as possible .
Keep the heaviest s ide of the load next to the trunk.
Slide the load toward you before attempting to lift it.
8. Put the load down, and then adjust its position.
Note. Adapted from Tbe Prln~ples of Good Manual Handling: Acbievtng a Consensus. by R. A. Graveling, A. S. Melrose, and M . A. Hanson , 2003, Norwich: HMSO.
664
•
SHEREHIYET AL.
A proposed warning system for MMH tasks might contain a list of basic guidelines. One example is shown in
Fig. 53.6. Although this sign is longer than is usu.ally advocated for warnings, it illustrates that a more extensive listicg can
be made relatively easy to read because of its formatting. Th.is
warning and other variations would need to be assessed from
the standpoint of readability, understandability , and compliance . In addition, including a symbol might further benefit this
placatd.
Symbols arc an excellent way to capture attention and
communicate infonnation quickly (assuming the symbols arc
adequately legibile and understandabe). Using the best symbol from Burt et al:s (1999) research described earlier in this
chapter, a warning could be developed to wam about using
correct lifting practices . Figure 53.7 shows one of many that
could be created.
Moreover , symbols could show oth er aspects related to th e
hazards involved . Warnings could include prohibition symbols
(circle-slash) over graphical depictions of awkward postures
known to be risky in MMH tasks, such as those involVing trunk
flexi.on (forward bending) , side bending, axial rotation (twist ing), and so forth. They could also show the correct posture
surrounded by a green circle or a green check mark adjacent to
them.
Besides general guidelines, there is a need for more con·
dse and specific warnings applicable to particular MMH tasks .
Studies on behavioral expectancies related to MMH tasks
(Woodso n , Tillman, & Tillman, 1992) reponed that workers
..
CAUTION
Lower Back Injury Hazard!!!
1.
Plan the lift.
2.
Test the weight before you move It.
3.
For bulky or heavy object, get a mechanical lifting
aid, or somebody else to help, or both .
4. Get a firm, secure grip on the load.
5. Hold the load close to the body .
6. Use the strength in your legs to lift or lower.
7.
Do NOT twist the back or bend sideways.
8.
Keep body aligned - No awkward movements.
9.
Do NOT jerk - Move smoothly.
10. Do NOT lift or lower with anns extended .
11. Do NOT continue if the load is too heavy.
FIGURE 53.6. An MMH placard.
.A_ CAUTION
~r
Lift Hazard
Improper Lifting Can Cause Lower Back
Injury
Proper Lift:
• Get a Finn, Secure Grip on Load
• Hold Close to Body
• Use Strength of Legs to Lift
FIGURE 53.7. Example of a proposed
lift hazard.
sign warning against a
systematically underestimate th e weight and size of the handled load. Such underestimations can significantly increase the
probability of injury caused by sudden loading . A warning could
provide specific information about the weight of the object
to be lifted. A label could be placed on the object itself, so
that the worker can become aware of its heaviness before the
MMH task is carried out and thus would be better able to anticipate and prepare for the load. An example is presented in
Fig. 53.8.
.A
CAUTION
75 lb/34 kg
Heavy Object!!!
Handling May Permanently
Damage Spine and Back
Use Mechanical Lift, or Ask
Someone Else to Help, or Both
FIGURE 53 .8. Warning label for a heavy object.
53.
Heavy, Unbalanced Load!!!
Center of mass is positioned on one side
0,
Improper lifting may cause severe back
injury
Do not make sudden, jerky movements
FIGURE 53.9. Example of possible warnings against sudden
loading .
Another variant of the label in Fig. 53 .8 could contain a bar
graph (like a thermometer) to quickly and graphically convey
the load 's heaviness relative to a standard scaling, for example,
100 lbs, or relative to other size loads. Also, specific information about unusual load characteristics, such as an unbalanced
center of the mass, may also be helpful because it could allow
preparatory muscular responses and postural adjustment. One
approa ch is illustrated in the Fig. 53.9. The specific message
used in such warnings will vary dep ending, on the characteristics of the handled load and type of task likely to be performed.
If it is not possible to present highly specific infonnation, the
hazard avoidance instruction should emphasize that slow and
careful movements are necessary to minimize loading and postural instability.
Again , although prototype warnings are presented in this
chapter , these and other possible variations should be evaluated
with regard to how well they attract attension, how well they
arc understood , and whether appropriate changes to manual
lifting behavior results before any particular warning is placed
int o actual use.
___________
•
665
CONCLUSIONS
CAUTION
(
WARNINGS FOR PHYSICAL TASKS
Although engineering and ergonomic task design are of primary
importance to effectively guard against physical loading on the
human body and prevent musculoskeletal hazards, warnings can
be a useful tool to promote safe behaviors and reduce the risk of
injuries. 1n this chapter, hazards associated with STF and MMH
tasks are emphasized. A set of example prototype warning.5
is presented, based on knowledge from both the physical ergonomics and the warning design literature. Given that these arc
prototypes , future research should evaluate these and other vari ant warnings before they are adopted intO specific applications .
The relative dearth of research at the intersection of phys-ical ergonomics and warnin gs suggests that this is a fruitful
area for research. The effectiveness of warnings in the physical ergonomics domain can be evaluated in a number of ways in
both laboratory and .field settings, using measures involving: (a)
subjective ratings, comprehension tests, and behavioral compli ance; (b) electromyograms of assoc iated muscles ; and (c) kine matic characteristics of joint motions.
The present review shows a need for integrating existing
knowledge concerning hazards and risk factors of musculoskeletal injury, including their mechanisms, with the proces s of warnings design. The physical ergonomics literature provides much
of the content that would go into the warnings , for example ,
what kinds of hazards exist, when and in what siruation s can
they be expected to occur, and what type of actions are needed
to be taken to avoid danger . Tha t knowledge needs to be applied
to warnings. Measurement of the biomechanical characteristics
(such as muscular activity and equilibrium perturbations) can
provide useful indicators of the warning effectiveness and offer directions for design .improvements. At present, th ere is vast
poten.tial for the applicaton of occupational ergonomics knowledge to serve as the basis for warnings concerning hazardous
manual activities. It is, therefore, an opportunity and a challenge for professional ergonomists to apply the existing and
substantial knowledge base to the development and evaluation
of~
for the purpose of reducing injuries.
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