​​Figure 1 - Top Causes of Ergonomic Injuries

 

Industrial Ergonomics - Lifting, Carrying, and Manual Handling

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Industrial tasks often involve lifting, carrying, pushing, and pulling materials that place strain on the body if not performed correctly:

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• Use proper lifting techniques: keep loads close, maintain a neutral spine, and lift with the legs.

• Break heavy loads into smaller components when possible.

• Push rather than pull whenever feasible – pushing uses stronger muscle groups.

• Avoid twisting while lifting or carrying; reposition your feet instead.

• Use carts, dollies, hoists, or team lifts for heavier items.

 

Power Plant Ergonomic Hazards

 

Power generation environments contain unique ergonomic strain risks due to equipment layout and access challenges:

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• Valve manipulation requiring forceful turning, especially on older or poorly lubricated valves.

• Dragging fire hoses, water-wash hoses, or air hoses across long distances.

• Climbing HRSG structures, boilers, and turbine decks which requires repetitive steps and awkward postures.

• Working in tight spaces that require kneeling, crawling, or overhead work.

• Cold-weather conditions stiffening muscles and reducing flexibility, increasing strain risk.

• Avoid kneeling directly on grating or metal surfaces. Use kneeling pads, protective mats, or adjust posture to reduce contact pressure on the knees.

• Kneeling on grating creates concentrated pressure points, reduces stability, and increases the likelihood of strain, bruising, or long-term knee injuries.

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​​​​Tool and Equipment Ergonomics 

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Hand tools, power tools, and mobile equipment can create strain if not used with proper technique and posture:

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• Use tools that match the task – do not modify tools or use them beyond design limits.

• Choose tools with ergonomic grips that reduce wrist deviation and grip force.

• Reduce vibration exposure by rotating tasks and using anti-vibration gloves where appropriate.

• Ensure tools are properly maintained to prevent excessive force or awkward posture.

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Office and Control Room Ergonomics 

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Even in office or control room environments, improper setup can cause long-term discomfort and repetitive stress injuries:

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• Maintain monitor height at eye level with the top of the screen slightly below eye line.

• Keep keyboard and mouse at elbow height with forearms parallel to the floor.

• Use chairs with proper lumbar support and sit with feet flat on the floor.

• Take micro-breaks every 30–45 minutes to stretch and reset posture.

• Avoid leaning forward or slouching – keep the spine neutral and supported.

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Human-Performance Behaviors Affecting Ergonomics

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Rushing, fatigue, and habit-driven behavior can lead workers to ignore proper ergonomic technique:

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• Pause and evaluate the lift or task before beginning – use STAR (Stop-Think-Act-Review).

• Avoid rushing; most ergonomic injuries occur during hurried or repetitive tasks.

• Recognize early signs of fatigue or strain and adjust posture or take a brief break.

• Ask for help before attempting lifts or tasks near your physical limits.

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Early Reporting and Injury Prevention

 

Early reporting of discomfort or strain helps prevent minor symptoms from developing into serious injuries:

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• Report discomfort early to supervisors before pain becomes severe.

• Use stretching programs to warm up before physically demanding tasks.

• Adjust work methods, tools, or posture when strain is noticed.

• Document ergonomic concerns in operator rounds or shift turnover logs.

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Discussion Questions

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• Do you understand how proper lifting, posture, and tool selection reduce ergonomic injuries?

• Are you aware of the high-strain tasks in your work area today?

• Do you have the right equipment or assistance needed to perform tasks safely and ergonomically?

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RATTLIR Takeaway

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Ergonomics is about working smarter, not harder. Whether lifting equipment in the plant, operating valves, installing components, or working at a desk, the way your body moves determines your long-term health and safety. RATTLIR strikes before it bites by promoting proper posture, early reporting, deliberate movement, and the use of tools and techniques that prevent strain before it begins.