Physical demands of overhead crane operation

Abstract

Recent studies have suggested that ergonomic factors may contribute to risks experienced by overhead crane operators. However, there are few studies that provide a comprehensive overview of the physical demands of overhead crane operation. This study aimed to provide this information by quantifying muscular, postural, and upper limb movement demands of overhead crane operation including examination of muscle activation and trunk posture by task. Trunk posture, upper limb movement demands and muscle activation in the trunk and upper limbs were quantified for seven overhead crane operators. Trunk posture was quantified using trunk angle and joystick motion requirements were determined using camera data. Muscle activation was measured bilaterally using surface EMG for the upper trapezii, anterior deltoids, posterior deltoids, biceps brachii, triceps brachii, flexor carpi radialis and erector spinae. Lastly, joystick force requirements were assessed using a spring scale. High upper limb and trunk muscle loading were observed when compared to joystick use in other heavy machinery, in part due to the forward, trunk-flexed position required to adequately view the workspace, and the increased force requirements of the joysticks. Joystick input force requirements were 9–31 N for the right-hand joystick and 11–40 N for the left-hand joystick. Operators maintained a forward trunk flexion (>20°) for all subtasks which suggests that trunk posture might play a role in sustained trunk muscle activation. Results suggest that the primary issue with overhead crane cab operation is upper limb and trunk muscle loading. Results confirm the need to investigate muscle load reduction strategies such as camera systems to help reduce the need for trunk flexion. Other design modification suggestions include reducing the joystick input force and displacement requirements coupled with potentially distributing the machine functions more evenly across the right and left controllers.