Innovative techniques to Improve Productivity and Ergonomics in HVAC Installation

Mechanical installation employees suffer severe overexertion injuries at a rate that is higher than the national average for all sectors and all construction workers. Overexertion or excessive motion caused accidents and illnesses among mechanical installation employees, resulting in days away from work. Head, arm, and hand pain are common in sheet metal workers who are regularly employed, and shoulder pain or accidents are related to work performed overhead (hanging duct). The construction industry, working with the arms raised, particularly with the hands or elbows above shoulder level, is common and has been linked to the development of neck and shoulder disorders.

The following activities are considered high-risk of sheet metal work: Place hangers; Place and attach duct pieces; Tie duct to hanger/ceiling; Assemble duct pieces in the field; Cut and trim duct joints; Weld; Transfer heavy machinery (rigging), and Cut and detach duct parts during demolition.

To maximize duct installation productivity, consider the innovative tips mentioned below.

Just a limited amount of the time is spent on meaningful jobs.

It is important to shorten or remove activities that include a large number of extreme postures to increase both effectiveness and ergonomics. We would boost efficiency (due to decreased cycle time) if we reduced the length of activities with a limited portion of extreme postures, but we would increase the percent of time with extreme postures. Furthermore, in the long run, the loss of tasks with low ergonomic loads can increase fatigue, decreasing the productivity benefits from shorter cycle times.

Difficulties of duct positioning

This is the most challenging mission, and it should be a priority for progress. Improvements in this role would minimize task time (thereby increasing productivity) as well as vulnerability to extreme postures. Better materials, facilities, or a renovation of the flange link may all benefit.

The ladder's position

On the ladder, duct mounting activities (aligning the ducts, securing them together, installing the slip drives, and fastening) necessitate a wide range of motion. Ladders, on the other hand, offered only modest mobility. Extreme postures of the back (bending and twisting), neck (twisting), and shoulders (flexion > 90) will all be affected by the ladder's place. Shoulder flexion is affected by the worker's height on the ladder. Extreme shoulder posture is minimized when standing with shoulders elevated than the duct.

Using a ladder to get up and down

 It is not a constructive task, although it is a required support task. As a result, decreasing the number of times workers ascend up and down the ladder would result in less intense postures and a shorter average task period. Having equipment, adjusting the super lift, or adjusting the ladder's position are all common explanations for climbing up and down.

Obstacles in the workplace

The employees' extreme postures were intensified by the work environment (the duct's proximity to the roof and along the truss, as well as the presence of a sprinkler line). Due to tubing, vents, and trusses, duct installers have small work areas during tenant renovation programs.

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