Musculoskeletal disorders and ergonomic risk factors among petrochemical control room operators with health promotion and intervention strategies

Abstract

This study aimed to assess musculoskeletal and ergonomic risk, identify demographic, occupational, lifestyle, and biomechanical characteristics associated with these outcomes, and develop and prioritize ergonomic intervention strategies for petrochemical control room operators. This cross-sectional study was conducted in 2025 among 210 male control room operators from an Iranian petrochemical complex using census sampling. Data were collected using the Demographic/Occupational Questionnaire, Persian International Physical Activity Questionnaire (P-IPAQ), Persian Örebro Musculoskeletal Pain Screening Questionnaire (P-ÖMSQ), and Persian Ergonomic Screening and Priority Tool (P-ESPT), complemented by objective postural and plantar pressure assessments. The P-ÖMSQ was used to classify participants according to P-ÖMSQ risk categories, with scores ≥ 90 categorized as moderate-to-high risk. Data were analyzed using Statistical Package for the Social Sciences (SPSS) software, version 20.0, with descriptive statistics, chi-square tests, and multivariable logistic regression. A P-ÖMSQ score within the moderate-to-high risk categories (≥ 90) was observed in 27% of participants, while 78% were classified as having moderate-to-high ergonomic risk. Multivariable logistic regression showed that older age (adjusted odds ratio [aOR] = 1.09, 95% confidence interval [CI] = 1.02–1.17, p = 0.014), higher body mass index (BMI) (aOR = 1.15, 95% CI = 1.04–1.27, p = 0.006), and longer job tenure (aOR = 1.98, 95% CI = 1.01–3.89, p = 0.047) were independently associated with higher odds of being classified in the moderate-to-high-risk P-ÖMSQ category. Lower physical activity was significantly associated with a higher prevalence of forward head posture, thoracic hyperkyphosis, lateral pelvic tilt, and pes planus ( p < 0.05). Objective biomechanical abnormalities were also significantly associated with higher P-ÖMSQ-based and P-ESPT-based risk categories ( p < 0.05). Based on the study findings, 20 ergonomic intervention strategies were proposed and prioritized through a stakeholder-informed participatory process. Older age, higher body mass index, and longer job tenure were associated with higher odds of being classified in the moderate-to-high-risk P-ÖMSQ category, while lower physical activity was associated with selected postural abnormalities among petrochemical control room operators. Several objective biomechanical abnormalities were also associated with P-ÖMSQ-based and P-ESPT-based risk categories. These findings may inform the prioritization of workplace ergonomic interventions; however, the proposed interventions were not evaluated in the present study, and their effectiveness should be assessed in future longitudinal and interventional studies.