Virtual modelling and analysis of manual material handling activities among warehouse workers in the construction industry

BACKGROUND: Musculoskeletal risks (MSRs) are a major concern among construction warehouse workers due to the lifting, carrying and lowering of heavy loads. OBJECTIVE: The objective of this study was to reduce MSRs among warehouse workers in the construction industry using virtual modelling and analysis of activities. METHODS: A preliminary study was carried out using the Standard Nordic Questionnaire. Biomechanical analysis, Ovako Working posture Assessment System (OWAS) and Rapid Upper Limb Assessment (RULA) were used to analyse the material handling activities. Virtual modelling was used develop the manikins with autoclaved aerated concrete (AAC) blocks at different carriage modes and stacking heights for the analysis. RESULTS: The preliminary study results revealed a higher prevalence of risk at their lower back (73.24%) among the construction warehouse workers. Biomechanical analysis showed a higher risk at L4-L5 joint of lumbar spine during overhead and bending postures for stacking the blocks. Posture analysis results of OWAS indicated a lower risk in overhead carriage mode. Detailed analysis with RULA confirms this result. Mean compressive force values at stacking heights were showed a significant difference (p < 0.05) in 8, 13, 18 and 21 kg AAC blocks. However, stacking height with a range of 120-140 cm was found as safer to the workers by considering all block sizes. CONCLUSION: An ergonomic intervention based on safer stacking heights was developed to reduce MSRs to an acceptable range. It improves productivity of handling the AAC blocks by reducing the cycle time. The intervention can be adapted for handling of similar materials in the construction industry.