Running head: CONSTRUCTION PLIERS AND RODBUSTERS

MUSCULOSKELETAL
DISORDERS
Work-Related Musculoskeletal Disorders

KEVIN P. MCGEE
COLUMBIA SOUTHERN UNIVERSITY

CONSTRUCTION PLIERS AND RODBUSTERS

Contents
Definitions....................................................................................................................................... 2
Introduction ..................................................................................................................................... 3
Work Related Musculoskeletal Disorders ...................................................................................... 3
Literature Review............................................................................................................................ 4
Causation......................................................................................................................................... 4
Rodbusters....................................................................................................................................... 5
CTS ................................................................................................................................................. 5
Solutions ......................................................................................................................................... 5
Innovation ....................................................................................................................................... 6
Bridge Decks ................................................................................................................................... 6
Steel Contractors ............................................................................................................................. 7
Conclusions ..................................................................................................................................... 8
References ..................................................................................................................................... 10
Figures........................................................................................................................................... 12

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Definitions
CT: Cumulative trauma
CTS: Carpal Tunnel Syndrome
EHSP: Environmental Health and Safety Plan
Ergonomics: the scientific study of human factors and their safe/healthy interaction with the
human environment.
IIPP: Injury and Illness Prevention Plan
NIOSH: National Institute for Occupational Safety and Health
OSHA: Occupational Safety and Health Administration
The power tool: MAX USA RB 392 rebar tying tool
Rebar: steel bars placed and secured in position to reinforce concrete structures
Resistance welding: welding method used to join two or more overlapping metals
RMI: Repetitive Motion Injury
Rodbuster: a field ironworker employed to place and tie rebar prior to concrete installation
STD: soft tissue damage
Tie: a short length of wire wrapped around two or more pieces of rebar to prevent movement
WMSD: work-related musculoskeletal disorders

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Introduction
Work-Related Musculoskeletal Disorders (WMSD) account for the highest number of
days away from work behind; fall to lower level; transportation accidents; slip, trip, loss of
balance; assaults and violent acts by coworkers; and exposure to toxic chemicals (Figure 1)
(BLS, 2014). OSHA reports more than 3.1 million nonfatal workplace injuries and illnesses
among private industry employers in 2010. More than one-third of all serious occupational
injuries and illnesses stem from overexertion or repetition. The National Academy of Social
Insurance (NASI) reports (2014) these injuries cost business $15 to $20 billion annually in
workers' comp costs alone. Add indirect costs, and the total mounts as high as $60 billion.
Workers compensation costs increased from $61.0 billion in 2011 to $61.9 billion in 2012
(NASI, 2014).
Work Related Musculoskeletal Disorders
WMSDs occur at higher levels among construction workers. This research will focus on
the construction ironworker; and more specifically the rodbuster. Soft tissue damage to hands,
wrists, and fingers accounted for 47.8% of reported WMSDs (NIOSH, 2009). This research
focuses on the specific WMSDs of Rodbusters involved with placing and tying rebar on freeway
bridge decks. It will discuss current placing and tying methods and practices, as well as
ergonomic developments to reduce the incidents of WMSDs. Ergonomic efforts to lower
WMSDs among ironworkers will be synthesized to identify specific improvements and their
justification. The application of scientific principles, methods, and data to design and develop
systems that improve the human interface with work is the essential goal of Ergonomics.

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Literature Review
The primary purpose of human factors and ergonomics is design (Helander, 2006, p. 3).
Man finds an interface that benefits man in order to satisfy a human desire to manipulate his
environment. From axe and stone to the height of a conveyor line in industry, ergonomics has
served to satisfy human need and desire. Human Factors Engineering (HFE) is a continuous
study in promoting this vital human purpose. Helander (2006) describes the history of
ergonomics as a struggle between productivity and health as a continuous effort to improve the
development of society (Helander, 2006). Ergonomics drives this struggle to adapt an external
environment to human input. The development of technological and industrial advancements
emphasizes the need for ongoing ergonomic studies.
Causation
The scientific method drives an interest in specific injuries and their causation. One
example of this interest focuses on the use of hand tools. Hand tools have been used to improve
mans ability to manipulate his environment. The use of hand tools required to perform specific
tasks requires appropriate tool design as well as user skill. On the other hand, hand tools are a
leading cause of soft tissue damage (STD), cumulative trauma (CT), and work-related
musculoskeletal disorders (WMSD). For example, a pair of pliers can produce useful results
when the pliers are used both skillfully and usefully. However, Dr. Barbara Plog identifies that
pliers can cause serious injuries to the hand, arm, or shoulder (Plog, 2012). Identifying pliers as a
cause of serious occupational injury is critical to understanding why plier-use causes injury.
Whether created by job design or unfriendly technologies, plier-use is recognized as harmful to
productivity, quality, and worker safety and health (Goetsch, 2011, p. 201). Researching the use

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of pliers by rodbusters intends to better understand what can be improved with rodbuster-pliers
and how to control the STD done when they are used.
Rodbusters
Rodbusters are required to use pliers to tie rebar together prior to the placement of
concrete. Rebar must remain in engineered positions when concrete is placed around them.
Rodbusters assume a stooped position when bridge-deck, or slab construction occurs. Pliers are
used to secure bars with tie-wire. It is not uncommon for bridge-deck construction to require
making more than 2 million rebar ties (NIOSH, 2009). The National Institute of Occupational
Safety and Health (NIOSH) has studied the STD associated with the use of pliers by rodbusters.
NIOSH (2009) concluded that 16% of rodbuster work-related musculoskeletal disorders
(WMSD) were linked to hand-wrist activities (figure 2). Furthermore, NIOSH identified that
excessive hand, wrist, and forearm position and movements are linked to this disorder.
CTS
Carpal Tunnel Syndrome (CTS) related to excessive plier use is an ergonomic concern.
The hand, wrist and forearm position and movements required to place and tie reinforcing steel
increase the likelihood for CTS. According to NIOSH (2009), pliers use by rodbusters is a
significant source of CTS. Furthermore, this CTS is not isolated to hand and wrist movements.
Rodbuster CTS can manifest at 52.2% of low-back disorders (Publication No. 2010-103). Body
posture and forceful working methods among rodbusters creates an increased demand for
ergonomic solutions to plier use (Helander, 2006).
Solutions
Ergonomic solutions to plier-related CTS continue to change as ergonomic studies
develop. Current human adaptations include modifications to existing rodbuster pliers. For

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example, plier handles are customarily coated with a plastic. This plastic is commonly removed
and replaced with an impact resistant rubber absorber (figure 3). This absorber not only reduces
shock from cutting ties, but improves grip capacity. In addition, rodbusters typically remove a
reflex spring that is designed to open the pliers once a cut is made. This spring returns the pliers
to an open position. However, force is required to overcome the spring action to make another
tie. Rodbusters remove this spring to remove unwanted energy. To compensate for the springs
absence, rodbusters place an index finger between the lever and the handle to open and close the
pliers digitally. Adaptation is not a product of ergonomics. Adaptation in this context is a product
of user pain. The rodbuster is adapting to the tool.
Innovation
To significantly reduce unnecessary stress and strain on the wrist, arm and shoulder a
MAX USA RB 392 device was designed. This device is a portable power-tool recommended
for tying flat level rebar (NIOSH, 2009). Figure 4 shows a rodbuster using the power tool (note
the straight wrist and arm). This device can be provided with an extension arm to assist
rodbusters lower back strain. The extension allows the rodbuster to stand erect while placing and
tying rebar. Rodbusters activities occur under various conditions. Activities vertical, diagonal,
horizontal and overhead create CTS potential. Other types of rodbuster ties in various positions
were not studied by NIOSH. These variations occur when rebar is tied in positions other than
flat.
Bridge Decks
According to Albers & Hudock (2007), bridge-decks requiring frequent or prolonged
exposure to rebar tying should use the MAX USA RB 392 to reduce worker exposure to
WMSDs. Freeway bridge deck construction can employ rodbusters in stooped positions for 8

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hours per day, 40 hours per week. Flat tying occurs in phases as the deck progresses, however
the risk of WMSDs prevails throughout each project when rebar ties are made to vertical and
horizontal intersections. The hazardous positions rodbusters assume during the course of one
shift expose workers to potential WMSDs. According to Kroemer & Kroemer (2001) ergonomic
solutions can focus on seven conditions:
1. Activities with many repetitions.
2. Repetitive activities requiring more than about one-third of the operators static
muscular strength available for that activity.
3. Putting body segments in extreme positions.
4. Making a person maintain the same body posture for a long time.
5. Pressure from tools or work equipment on tissues, nerves or blood vessels.
6. A tool vibrating the body or a part of the body.
7. The exposure of working body segments to cold, including airflow from
pneumatic tools. (Kroemer, 2001, p. 391)
Steel Contractors
The stresses involved with tying rebar satisfy each of the above 7 criterion. Steel
contractors involved with bridge construction use ergonomic principles to help minimize the
damaging effects of WMSD. One example is DPR Construction. DPR is an international
construction contractor founded by Doug Woods, Peter Nosler and Ron Davidowski (DPR).
DPR developed and maintains a comprehensive environmental health and safety plan (EHSP)
designed in large part to minimize injury and illness to both employees and the environment.
This EHSP contains a section dedicated exclusively to Construction Ergonomics (DPR, 2007,
Sec. 3.0-4.2.3). DPR recognizes the demand for competitive quality in the workplace. They also

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recognize the health and safety of its employees can depend on proper intervention. In other
words, the information contained in its EHSP is provided to enable interventions for existing
WMSDs and assist its subcontractors and vendors in identifying potential WMSDs. DPR adds to
Kroemer & Kroemers (2001) identification of seven specific conditions above which can lead to
WMSDs. In section 8.3.2 of its EHSP, DPR (2007) divides its construction ergonomics program
into six catagories:

Force or muscle effort

Awkward body postures

Repetitive work

Contact pressure

Vibration

Temperature (DPR, 2007)

The WMSDs related to the hand, wrist and arm of a rodbusters can be reduced when
tying rebar on flat freeway slab construction using the NIOSH recommended power tool.
Conclusions
Research identifies the current relationship between rodbusters pliers and WMSDs.
Rodbusters pliers are designed to increase delivery power to freeway slab construction when
rebar is placed and tied. The pliers are used during this process in a repetitive griping, twisting
and cutting motion. Rodbuster pliers use leads to WMSDs and ergonomic solutions to WMSDs
can be applied to rodbuster WMSDs. The rodbuster plier can be replaced with a NIOSH
recommended power tool. Ergonomics role addresses the hand, wrist, and arm damage
accumulated during one work shift. Nevertheless it is visibly apparent that the stooping posture
is of great concern to an ergonomist. The power-tool manufacture engineered an extension to

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allow the rodbuster to remain vertical while tying a bridge deck. This WMSD is not addressed in
this research. In addition to the power-tool, another ergonomic consideration can help alleviate
WMSDs. A process yet to be designed involves a resistance type weld to connect latitudinal and
longitudinal rebar together. It is important to remember that rebar is tied with the sole purpose of
holding it in position until concrete is placed. There is no structural significance to a rebar tie.
The use of a resistance weld process would virtually eliminate WMSDs related to rodbuster
hands, arms, wrists and even backs. The stooped overburden position could be eliminated by the
use of a resistance weld process. This note encourages the use of a resistance welding process.
However, rebars structural integrity can be compromised during a welding process. My search
found no definitive study of concerns related to the tensile strength of rebar that has been
resistance welded. Nevertheless, this remains a potential process improvement to assist healthy
human production.
The introduction of a portable power tying-tool to rebar construction on freeways is a
landmark improvement to rod-work. This ergonomic development satisfies Helanders (2006)
criteria for an optimal hand tool; It must fit the task; fit the user and hand; and not create
injuries (p. 217). Ergonomic efforts to lower WMSDs among ironworkers surely succeed with
regard to this activity. It is interesting to note that this improvement has been in the mind of
every rodbuster who worked a bridge deck, including mine. I am an ironworker by trade. I laude
the successful design, development, and application of a tool to a trade that provided me with
real work-related musculoskeletal disorders.

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References
Albers J.T., H. S. (2007). Biomechanical assessment of three rebar tying techniques.
International Journal of Occupational Safety Ergonomics, 13 (3): 227-237.
BLS. (2014). Repetitive motion results in longest work absences. Retrieved from:
http://www.bls.gov/opub/ted/2004/mar/wk5/art02.htm
DPR. (2007). Environmental health and safety plan rev. 7 sec. 8.3.0. DPR Construction
Company Inc.
Goetsch, D. L. (2011). Occupational safety and health for technologists, engineers, and
managers (7th ed.). Upper Saddle River, NJ: Prentice Hall.
Helander, M. (2006). A guide to human factors and ergonomics (2nd ed.). Boca Raton, FL:
Taylor & Francis Group, LLC.
Kroemer, K., Kroemer, H., & Kroemer-Elbert, K. (2001). Ergonomics: How to design for ease
and efficiency (2nd ed.). Upper Saddle River, NJ: Prentice Hall.
Manuele, F. A. (2008). Advanced safety management focusing on Z10 and serious injury
prevention. Hoboken, NJ: John Wiley & Sons, Inc.
NASI. (2014). REPORT: Workers' Compensation: Benefits, Coverage, and Costs, 2012 .
National Academy of Social Insurance. Retrieved from:
http://www.nasi.org/sites/default/files/research/NASI_Work_Comp_Year_2014.pdf
NIOSH. (2009). Workplace solutions: reducing work-related musculoskeletal disorders among
rodbusters. publication no. 2010-103. Department of Health and Human Services,
Centers for Disease Control and Prevention.
Plog, B. A. (2012). Fundamentals of industrial hygiene (6th edl). Itasca, IL: National Safety
Council.

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Webster. (1994). New universal unabridged dictionary. New Jersey, NY: Random House Value
Publishing, Inc.

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Figures

Figure 1. Days away from work, by event or exposure.

Figure 3. Field modified Rodbuster pliers.

Figure 2. Rebar tying using pliers

Figure 4. Rebar tying using a power tool

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