Investigating the effect of tool design in a utility cover removal operation

The operation of removing covers from utility holes has been identified as having one of the highest numbers of reported cases of severe back injuries for the utility and telecommunications companies. In this study, we designed an experiment to analyze the biomechanical loading of nine telecommunication workers who performed utility cover (UC) removal operations using eight tool configurations. Statistical analyses were conducted to test the differences between tools by comparing the handle force required to remove the UC and the lower back compressive force imposed on the L5/S1 joint of participants. Results indicated that the tools had significant effects on the handle forces required for the participants to remove the UCs. The J-hook type tools required a significantly higher level of exerted force than the fulcrum bar and magnetic lift type tools. Also, data showed that the J-hook tools with the short-shaft design resulted in significantly higher lower back compressive force values on the L5/S1 joint than the J-hook long-shaft tools, magnetic lift tool, and fulcrum bar tools. The fulcrum bar tools exhibited the lowest L5/S1 compressive force. Implications for future tool design and recommendations for safe cover removal operations are discussed.