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DEPARTMENT OF HEALTH & HUMAN SERVICES Federal Occupational Health 7475 Wisconsin Ave. 7th Floor

Bethesda, MD 20814

US ARMY CORPS OF ENGINEERS CHICAGO DISTRICT

ERGONOMICS CONSULTATION REPORT

A 128913 S 220238 P 220239

Unit Assessed: ACE Chicago District Locations

Evaluation Dates: August 28, 29 and 30, 2017

Agency Address: Multiple FOH Evaluator: Mark Anderson, PT, CPE

Job Titles: Multiple Date Submitted: September 29, 2017

Arthur Plumstead, PT, CIE FOH Erg. Clinical Prgm. Mgr.

Phone #: Multiple

FOH ERGONOMICS CONSULTATION REPORT ACE Chicago District Locations September 15, 2017

TABLE OF CONTENTS

PURPOSE .................................................................................................................................................................................... 3 METHODS ................................................................................................................................................................................... 3 FINDINGS .................................................................................................................................................................................... 4

Chicago Harbor Lock ............................................................................................................................................................... 4 Lock Operator -Tower and Ground Operations................................................................................................................... 4

Lock Operator-Tower (Interview Richard Weitzel Lock Operator Tower Functions-Video Clip) ..................................... 4 Lock Operator Tower Bucket Use-Video Clip ................................................................................................................. 4 Lock Operator-Ground (Interview Mario Majewski Lock Operator Overview of Job Functions-Video Clip) .................... 4 Lock Operator Prepping Lines-Video Clip ...................................................................................................................... 5 Lock Operator Ground Operations Replace Lines Drive Chariot-Video Clip .................................................................. 5 Lock Operator Maintenance Checks-Video Clip ............................................................................................................ 5

Lock Operator-Other Duties ................................................................................................................................................ 5 Lock Operator-Ground (Interview Mario Majewski Lock Operator Overview of Job Functions-Video Clip) .................... 5 Lock Operator Weed Wacker Use and Discussion-Video Clip ....................................................................................... 5 Lock Operator Concrete Mixer-Video Clip ..................................................................................................................... 5

On the Spot Job Coaching Objective .................................................................................................................................. 6 Lock Operator Discussion of Ergonomics Principles-Video Clip .................................................................................... 6

Lock Mechanic .................................................................................................................................................................... 6 Lock Mechanic Backup System to Open Locks Discussion-Video Clip ......................................................................... 6 Lock Mechanic Access Panels-Video Clip ..................................................................................................................... 6 Lock Mechanic Work Barge Used Discussion-Video Clip .............................................................................................. 6 Lock Mechanic Improve Access Example-Video Clip .................................................................................................... 6 Lock Mechanic Employee Input-Video Clip .................................................................................................................... 6 Lock Mechanic Brushing Away Spider Webs-Video Clip ............................................................................................... 6 Lock Mechanic Brake Maintenance-Video Clip .............................................................................................................. 6 Lock Mechanic Body Mechanics Technique a Demo-Video Clip ................................................................................... 6 Lock Mechanic Bobcat Case-Video Clip ........................................................................................................................ 6

Indiana Harbor Confined Disposal Facility ............................................................................................................................... 7 Interview Damien Allen CDF Facility Manager (video clip) ................................................................................................. 7 Oil Boom Placement (video clip) ......................................................................................................................................... 7 Oil Boom Disposal (video clip) ............................................................................................................................................ 7 Manhole Cover Remove and Replace (video clip) .............................................................................................................. 8 Shovel/Clear Manhole Covers (video clip) .......................................................................................................................... 8 Operate Gator Vehicle (video clip) ...................................................................................................................................... 8 Pump Pipe Installation (video clip) ...................................................................................................................................... 9 Changing Light Bulbs (video clip) ....................................................................................................................................... 9 Interview Bob Welch Heavy Equipment Operator ............................................................................................................... 9

Mobile Work Crew ................................................................................................................................................................. 10 Mobile Crew Overview of General Duties (video clip) ....................................................................................................... 10 Mobile Crew Equipment Discussion (video clip) ............................................................................................................... 10 Mobile Crew Activity Hazard Analysis (AHA) Process (video clip) .................................................................................... 10 On the Spot Job Coaching ................................................................................................................................................ 10

Mobile Crew Ergonomics Principles Discussion (video clip) ........................................................................................ 10 Mobile Crew Control Exposure to Repetitive Activity (video clip) ................................................................................. 10 Mobile Crew Body Mechanics Power Lift Demo (video clip) ........................................................................................ 10 Mobile Crew Estimate Object Weight Muscle Biasing (video clip) ............................................................................... 10 Mobile Crew Work Smarter Not Harder Concept (video clip) ....................................................................................... 10 Mobile Crew General Advice to a New Employee (video clip) ..................................................................................... 10

RECOMMENDATIONS .............................................................................................................................................................. 11 General Recommendation ..................................................................................................................................................... 11

Ergonomics Assessment Protocol as part of the AHA Process ........................................................................................ 11 Chicago Harbor Lock ............................................................................................................................................................. 11

Ongoing Continuous Improvement ................................................................................................................................... 11 Access Panel Modification ................................................................................................................................................ 11 Testing of Backup System to Open Locks ........................................................................................................................ 11

Indiana Harbor Confined Disposal Facility ............................................................................................................................. 12 Ongoing Continuous Improvement ................................................................................................................................... 12 Portable Pump Installation ................................................................................................................................................ 12 Manhole Cover Manipulation ............................................................................................................................................ 12

Mobile Work Crew ................................................................................................................................................................. 12 Ongoing Continuous Improvement ................................................................................................................................... 12


PURPOSE

The purpose of this consultation is to visit three (3) separate ACE - Chicago District job locations: Chicago Harbor Lock (108 N. Streeter Drive, Chicago, IL 60611), Indiana Harbor Confined Disposal Facility (3500 Indianapolis Blvd., East Chicago, IN 46312) and the Mobile Work Crew (field locations), collect data, observe workers in various manual material handling job categories, interview key personnel (including the workers themselves), conduct “on-the-spot” ergonomics coaching to individual and/or small employee groups and provide recommendations as appropriate.

Note: A fourth location (IL Fish Barrier) was originally scheduled to be visited as well; due to staffing issues this was not accomplished during this consultation.

METHODS

Methods included review of the Army’s Mishap Risk Management Process, Department of the Army Pamphlet 385-30 (DA PAM 385-30) and the use of various evaluation tools, that relate to manual material handling involving an ergonomics component(s), photos and video recording and other objective measurement tools as deemed appropriate by the ergonomist.

All photos and video used for data and report generation purposes will be kept confidential. Following the on-site visits the ergonomist will generate a written report with video clips that includes Findings and Recommendations (work practice, engineering and/or administrative) as appropriate. Appreciation is extended to all the participants in the consultation.

Mark Anderson, PT, CPE, Federal Occupational Health Ergonomics Consultant conducted ergonomics assessments of the following locations and worksites:

Location Date(s) Point of Contact

Chicago Harbor Lock

108 N. Streeter Drive, Chicago, IL 60611

August 28 and 30th, 2017

Selwyn Tyrone Valley Lockmaster Chicago Harbor Lock U.S. Army Corps of Engineering Chicago District [email protected] Lock Phone: 312-787-4795 Cell Phone: 312-856-7705

Indiana Harbor Confined Disposal Facility

3500 Indianapolis Blvd., East Chicago, IN 46312

August 29, 2017 Damian Allen Facility Manager - Indiana Harbor CDF U.S. Army Corps of Engineers [email protected] Cell Phone: 312-951-3357 Facility Phone: 219-398-9387

Mobile Work Crew

Float among locations as available

August 30, 2017 Jeff MacDonald Cell Phone: (312)846-5429 Ron Barkley (207) 239-6499 [email protected]


FINDINGS

Findings are based on observations, employee interviews and measurements of the available job tasks at the time of the consultation and interview/discussion with the involved employees regarding job tasks not being performed at the time of the consultation.

The written report is supplemented by significant information contained in the edited video clips included as part of the overall report. Please reference the video clips for the complete report.

Chicago Harbor Lock

Lock Operator -Tower and Ground Operations

Tyrone Valley, Lockmaster and Lock Operators Mario Majewski, Richard Weitzel and Warren Noble participated in the ergonomics consultation on August 28 and 30th, 2017 at the Chicago Harbor Lock.

For lock operations, the Lock Operators are either stationed in the tower or on the ground at the lock itself.

Lock Operator-Tower (Interview Richard Weitzel Lock Operator Tower Functions-Video Clip)

When stationed in the tower the lock operator essentially is controlling commercial and recreational water vessels access to the lock.

This primarily involves work in a computer-based workstation with visual access to the lock and communications via telephone, radio and intercom. The work is essentially sedentary in terms of physical demands.

Lock Operator Tower Bucket Use-Video Clip

The lock operators have come up with use of a bucket on a rope to raise and lower hardcopy documents from the ground level up to the tower level via the stairway.

Lock Operator-Ground (Interview Mario Majewski Lock Operator Overview of Job Functions-Video Clip)

When stationed on the ground, the lock operator assists commercial and recreational water vessels while entering the lock, securing the vessel in the lock and exiting the lock. This could involve helping them with docking lines, assisting anyone who may go overboard, medical emergencies, etc. They have available a personal transport vehicle (Chariot) to aid in maneuvering at the lock.


Lock Operator Prepping Lines-Video Clip Lock operators were observed prepping docking lines to assist in securing vessels in the lock. Appropriate body mechanics were observed.

Lock Operator Ground Operations Replace Lines Drive Chariot-Video Clip Lock operators were observed replacing docking lines in driving the personal transport vehicle (Chariot). Appropriate body mechanics were observed.

Lock Operator Maintenance Checks-Video Clip Lock operators were observed performing their maintenance checks on the lock equipment. Appropriate body mechanics were observed.

Lock Operator-Other Duties

The Lock Operators also perform a wide variety of other duties involving general maintenance of the facility. This includes performing periodic maintenance checks on the equipment, lawn maintenance, snow removal, scraping, painting, manual material handling of equipment and materials, repairing HVAC equipment, etc.

Note: Only a few of the other duties were observed during the on-site consultation due to staffing and scheduling issues. Interview of the Lock Operators was conducted to obtain additional information regarding these other duties. Please reference the following video clips for additional information regarding lock operator other duties:

Lock Operator-Ground (Interview Mario Majewski Lock Operator Overview of Job Functions-Video Clip)

Lock Operator Weed Wacker Use and Discussion-Video Clip

Lock Operator Concrete Mixer-Video Clip


On the Spot Job Coaching Objective

As part of the on-the-spot job coaching objective of the consultation we discussed ergonomics principles and their application.

Lock Operator Discussion of Ergonomics Principles-Video Clip

Lock Mechanic

Fabio Mendez, Lock Mechanic participated in the ergonomics consultation on August 28 and 30th, 2017 at the Chicago Harbor Lock. He provided valuable insight into modifications that have been already implemented and his ideas for additional improvements from a health, safety and ergonomics perspective. Please reference the following video clips for additional information:

Lock Mechanic Backup System to Open Locks Discussion-Video Clip

Lock Mechanic Access Panels-Video Clip

Lock Mechanic Improve Access Example-Video Clip

Lock Mechanic Work Barge Used Discussion-Video Clip

Lock Mechanic Employee Input-Video Clip

Lock Mechanic Brushing Away Spider Webs-Video Clip

Lock Mechanic Brake Maintenance-Video Clip

Lock Mechanic Body Mechanics Technique and Demo-Video Clip

Lock Mechanic Bobcat Case-Video Clip



Damian Allen (Facilities Manager), Carlos Cerezo (Summer Intern) and Bob Welch (Heavy Equipment Operator) participated in the ergonomics consultation on August 29, 2017 at the Indiana Harbor Confined Disposal Facility. Typical job demands were assessed that involved general maintenance and operation of the facility.

Interview Damien Allen CDF Facility Manager (video clip)

Damien Allen provided an overview of the typical job tasks performed at the CDF and specific information regarding use of the Activities Hazard Analysis (AHA) process.

He noted the AHA process is an integral part in the safe and effective operation of the CDF. We discussed ergonomics principles and applications to be used as part of the AHA process.

Oil Boom Placement (video clip)

Carlos Cerezo demonstrated placement of oil booms to control contamination in the water storage at the facility. He noted the oil booms are checked on an ongoing basis and replaced as needed. This involves lifting the saturated oil boom out of the water using a rope attached to the boom.

He made use of appropriate body mechanics while handling the oil booms.

Oil Boom Disposal (video clip)

New oil booms are stored in the storage facility. New booms weigh approximately 30 pounds and are transported to the area to be placed via the Gator vehicle.

Appropriate body mechanics while handling the oil booms was observed.


Manhole Cover Remove and Replace (video clip)

Manual removal and replacing of manhole covers takes place on an ongoing basis. Manhole covers can weigh in the range of 50 to 70 pounds.

While an attempt was made to use appropriate body mechanics when handling the manhole covers, due to the location of the manhole covers and difficulty in obtaining adequate foot placement less than desirable body mechanics was observed.

Please see the Recommendation section for a specific recommendation for use of mechanical handling equipment to handle the manhole covers.

Shovel/Clear Manhole Covers (video clip)

To gain access to the manhole covers, a shovel is used to clear vegetation from the manhole cover and surrounding area.

Appropriate body mechanics were observed during use of the shovel.

Operate Gator Vehicle (video clip)

A gator vehicle is used to transport tools, equipment and materials at the facility. Appropriate vehicle operation was observed.


Pump Pipe Installation (video clip)

A portable pumping station had been installed at the facility to transfer water from one holding pool to another. An outside contractor was used to assist in installation of the pumping station. They were able to use heavy equipment to unload the flexible and solid tube piping. However, they manually handled the piping to place it down the slope and into the water.

They indicated this was a three-person job to manually handle the piping. Actual handling of the piping was not observed.

Please see the Recommendation section for recommendations regarding mechanical means to handle the piping.

Changing Light Bulbs (video clip)

Part of the overall facility management includes changing light bulbs as needed. A step ladder was used to obtain access to the light fixture.

Appropriate use of the ladder with suitable body mechanics was observed.

Interview Bob Welch Heavy Equipment Operator

An extensive interview with Bob Welch, Heavy Equipment Operator was conducted to gain his insight regarding job demands (heavy equipment operation, road grading, lawn maintenance, etc.) and specific opportunities to improve safety and ergonomics in his job role.

He noted experience has taught him more than anything else to pace himself throughout the day. Quoting Mr. Welch, “Slow is smooth, smooth is fast”


Mobile Work Crew

The Mobile Work Crew involved in the consultation were Salvador Lagunes, Tom Hansen and Jeff MacDonald. On August 30, 2017, an extensive interview with the Mobile Work Crew was conducted with the following video clips produced (please view the video clips for detailed information):

Mobile Crew Overview of General Duties (video clip)

Salvador Lagunes, Tom Hansen and Jeff MacDonald discussed an overview of general duties. Job task activities for the Mobile Work Crew are wide ranging and include building demolition, heavy equipment operation, vegetation clearing, branch removal, fence repair, use of manual and power tools and equipment, manual handling of pallets, materials, bags, etc.

Mobile Crew Equipment Discussion (video clip)

Crew discussed types of equipment used including heavy equipment (cranes, excavators, etc.); power tools (chainsaws, pole saws, nail guns, drills, jackhammers, weed eaters, etc.); and hand tools (shovels, picks, etc.).

Mobile Crew Activity Hazard Analysis (AHA) Process (video clip)

Use of the Activity Hazard Analysis process was discussed. The crew had recently completed demolition of a building; they noted the AHA process was used to plan the demolition so it would be accomplished in a safe and effective manner. This included development of an overall plan regarding the process, equipment to be used and specific safety issues that would need to be addressed. The crew stated they typically use the AHA process on a regular basis and as part of the daily morning toolbox meeting.

On-the-Spot Job Coaching

As part of the on-the-spot job coaching objective of the consultation we discussed a number of topics. They included ergonomics principles, control exposure to repetitive activity, body mechanics with a power lift demonstration, estimating weight of objects being handled manually and the general concept of working smarter not harder. Specific details of the information conveyed are included in the following video clips:

Mobile Crew Ergonomics Principles Discussion (video clip)

Mobile Crew Control Exposure to Repetitive Activity (video clip)

Mobile Crew Body Mechanics Power Lift Demo (video clip)

Mobile Crew Estimate Object Weight Muscle Biasing (video clip)

Mobile Crew Work Smarter Not Harder Concept (video clip)

Mobile Crew General Advice to a New Employee (video clip)


RECOMMENDATIONS

Based on the Findings, general and area specific recommendations are offered.

General Recommendation

Ergonomics Assessment Protocol as part of the AHA Process

The Activity Hazard Analysis (Mishap Risk Management Process - Activity Hazard Analysis, DA PAM 385-30) was referenced by individuals in all three areas as an essential component in performance of safe and effective work processes.

Review of the available document (dated 2 December, 2014) did not indicate any specific ergonomics assessments are included in the AHA process.

Recommendation is to identify for inclusion in the AHA process and/or develop a specific ergonomics assessment component added to the AHA process that includes assessment and application of ergonomics principles including:

1. POSITION/SUPPORT – Promote neutral body and limb position/support

2. MOVEMENT – Promote regular physical movement

3. MATERIAL HANDLING – Control manual material handling

4. REACH – Promote work in reach zone/power zone

5. WORKSTATION/TOOLS/EQUIPMENT – Provide correct workstation, tools and equipment

6. TRAINING – Provide competency based training in the use of workstations, tools and equipment

7. ENVIRONMENT – Control exposure to work environment

8. FEEDBACK – Provide on-going feedback for continuous improvement

Chicago Harbor Lock

Ongoing Continuous Improvement

Continue the collaboration of the Lock Master, Lock Operators and Lock Mechanic with appropriate Army Corps of Engineers engineering and health/safety staff to facilitate ongoing continuous improvement. This is part of the overall Mishap Risk Management Process; to specifically include ergonomic principles and appropriate applications as recommended in the General Recommendation above.

Access Panel Modification

Mr. Mendez indicated he'd been making improvements for access panels. Specifically, he was using aluminum panels on hinges to gain access to work areas. He notes he has additional panels he is working on modifying. (Lock Mechanic Access Panels-Video Clip)

Testing of Backup System to Open Locks

Mr. Mendez discussed the current backup system to open locks in the event of failure of the lock opening mechanism. He expressed concerns regarding the ability to manually handle the lines that are fed through the sheaves. Recommendation is to conduct a complete test of the existing backup system to determine its efficacy and make recommendations for improvements as needed. (Lock Mechanic Backup System to Open Locks Discussion-Video Clip)




Continue the collaboration with appropriate Army Corps of Engineers engineering and health/safety staff to facilitate ongoing continuous improvement. This is part of the overall Mishap Risk Management Process; to specifically include ergonomic principles and appropriate applications as recommended in the General Recommendation above.

Portable Pump Installation

Develop and implement use of mechanical handling equipment for placement and removal of the pipe for the portable pump installation. This was discussed with Damien Allen who indicated this was something they had discussed when debriefing on the method that was used to install the portable pump. He noted that they would follow through with this recommendation.

Manhole Cover Manipulation

Make use of a mechanical manhole cover lifter. This type of device is available commercially. Examples are the manhole cover lifts available through BigsEasyLift. Both mechanical lever advantage and magnet-based lifts are available. http://www.bigseasylift.com/cr/Lifts/3252

BigsEasyLift w/Large wheels

w/o AHP01 BigsEasyLift w/Large wheels

w/LHE02 w/MAG02

Mobile Work Crew


Continue the collaboration with appropriate Army Corps of Engineers engineering and health/safety staff to facilitate ongoing continuous improvement. This is part of the overall Mishap Risk Management Process; to specifically include ergonomic principles and appropriate applications as recommended in the General Recommendation above.

http://www.bigseasylift.com/cr/Lifts/3252

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