Expertly designed control rooms integrating ergonomics, safety, and efficiency for optimal operator performance and seamless workflow.
Over the past 8 years, we’ve designed and engineered over 150 control rooms, earning us the industry nickname “Control Room Guys.” This experience empowers us to deliver precision-engineered, human-centered control room solutions.
Every control room is unique—governed by its Human-Machine Interface (HMI) needs. Our solutions are tailored to optimize operator comfort, functionality, and alertness, which are critical for mission-critical environments.
We focus on how control room operators interact with machines and the environment. Our ergonomics-driven designs prioritize:
Operator focus and alertness
Intuitive task flow and accessibility
Minimized physical and cognitive strain
Maximum operational efficiency
Control Room Building Location
Depends on plant layout and primary information flow
May be normal/blast-proof, remote/on-site, windowed or enclosed
Must ensure quick and safe emergency egress
Avoid proximity to noise sources like canteens
Control Room Location Within the Building
Chosen based on functionality and operator safety
Should support calm, uninterrupted workflow
Needs appropriate support zones and access to emergency exits
Functionality and Occupancy Planning
Derived via workshops with key stakeholders:
End users
Automation vendors
Engineering consultants
Task analysis helps:
Define number of operators
Identify ideal console layouts and viewing angles
Map operator-console-to-video-wall relationships
The shape and configuration of consoles are selected based on the scale and layout of video walls:
Convex Console: Ideal when the video wall is smaller than console length
Concave Console: Preferred when the video wall spans wider than the console
Example Layout:
First row: View bottom of video wall
Second row: View middle
Third row: View top
This hierarchy ensures optimal sightlines and ergonomic balance for all operators.
At the concept stage, requirements and inputs from all stakeholders must be incorporated for effective design. Workflow considerations are categorized into the following major groups:
Physical Infrastructure:
Integrated Control & Safety System
Process Operation Units
Production Management Systems
The location of the control room is influenced by non-Human Factors Engineering (non-HFE) considerations such as:
Safety
Wind direction
Desired free space around the building
Expansion potential
Emergency response planning
Number of plants to be controlled from the control room
Structural Design Considerations:
The structure must be capable of withstanding major hazards.
It should ensure plant control is maintained during emergencies.
Emergency exits should be located at vantage points to facilitate safe evacuation.
Building access should accommodate both personnel and equipment:
Equipment transport should be easy and efficient.
Minimum passageway width: 1200 mm
Visitors and other personnel should enter via a main entrance and central corridor, not through the plant entrance.
Space allocation for the Control Room should consider the following:
Console configuration
Peripherals and additional workstations
Large overview displays (if required)
Floor tiles
Number of operators
Meeting areas
Support functions
Administrative activities (e.g., drawing checks, small meetings)
Utilities
Administrative staff zones
False flooring for cable management
Designated viewing areas for visitors
Space planning should be tailored based on specific project requirements.
The control room’s placement is governed by the overall plant layout and the primary source of operational information.
This determines the nature and form of the building:
Normal or blast-proof construction
Presence of windows or blank walls
Proximity to the plant (remote or nearby)
Depends on functionality and safety considerations.
Should allow for:
Quick egress during emergencies
Minimal disturbance and efficient operations
The space should avoid adjacency to canteens or noise-generating areas.
Facilities and necessary paraphernalia should be accessible nearby.
The number of operators is defined by the functional requirement of the control room.
A stakeholder workshop involving:
End users
Automation contractors
Consultants
helps determine the control room’s purpose and size.
The layout should integrate Human Factors Engineering (HFE) principles, including:
Ergonomics
Viewing angles
Lux levels and dynamic lighting
HVAC and ventilation
Fire and safety systems
Traffic flow and movement patterns
Furniture design
Overall aesthetics
Task analysis defines:
Each operator’s role
Console arrangement
Positioning relative to the video wall
Layout logic:
Use convex consoles when the video wall is smaller than the console span
Use concave consoles when the video wall is larger than the console span
Viewing hierarchy:
First row sees the bottom of the video wall
Second row sees the middle
Third row sees the top
All these aspects collectively define the layout and general arrangement of the Central Control Room (CCR), ensuring operational efficiency, safety, and comfort.
A control room is a task-critical environment where operators monitor and control various system activities. This work demands high levels of concentration and focus, which can be severely impacted by sound disturbances.
Contrary to popular belief, acoustic quality is not defined by materials alone, but by the detailing that controls reverberations, resonances, and reflections.
A noisy environment can overstimulate occupants, while an overly quiet room may feel dull and uninviting.
Achieving the right acoustic balance is essential to promote both focus and comfort.
For privacy and noise management, anti-noise/masking noise strategies are incorporated.
To ensure effective sound control, multiple disciplines of acoustics are taken into account:
Architectural Acoustics
Aero-Acoustics
Environmental Acoustics
Psycho-Acoustics
Speech Recognition / Synthesis
Vibrational Analysis in and around the control room
Ambient Noise Level: < 45 dB
Control Room Ceiling: Acoustic perforated metal grid false ceiling
Air Lock Room Ceiling: Paint finish
Wall Paneling (Control & Air Lock Room): Insulated sandwich aluminum panels
Control Room Flooring: Raised flooring system with metal pedestal base, head assemblies, inter-locking stringers, and 600mm² panels with 1.5mm plastic laminate finish
Air Lock Room Flooring: 300mm × 300mm × 3mm vinyl tiles
Acceptable Noise Level: < 45 dB
Surface Reflectance:
Floor Finish: 0.2 to 0.3
Wall Finish: 0.5 to 0.6
Glazed Area: 0.5 to 0.6
Ceiling: Minimum 0.8
The location of the control area should minimize disruptions to operators.
The shift supervisor’s room should be:
Located near the control room to maintain functional and social interaction
Designed with independent access, not solely through the control room, to avoid disturbing operator focus
A conference room should be integrated within or adjacent to the control area to support:
Meetings
Training sessions
Collaborative discussions
Key considerations for console layout include:
Future Expansion:
Design should allow for potential future growth and additional equipment.
Process Flow Alignment:
Console layout should follow the process sequence, typically from left to right, especially for alarm displays.
Functional Grouping:
Consoles should be grouped by process function to support logical and efficient operations.
Lighting Coordination:
Avoid reflections on screens; lighting design should follow the final console layout plan.
Console Arrangement Options:
Linear, U-shape, or C-shape configurations may be used.
The choice depends on:
Number of operators
Interaction between different process segments
Each configuration has specific advantages and limitations.
Ergonomics of Screen Placement:
Dual vertically stacked screens should be avoided due to risk of neck strain.
Maximum of four screens side-by-side for active use during upsets (includes overview, detail, and alarm screens).
Additional screens for F&G and CCTV should be adjacent to the main console screens.
Integrated Systems Support:
Space and connectivity should be provided for:
PA systems
Telephones
Laboratory system PCs
Administrative systems
Advanced process application terminals
Ergonomic Design Standards:
Consoles must provide:
Stress-free working surfaces
Optimal placement for reach and viewing distances
Adequate leg clearance as per ergonomic guidelines
When selecting materials and finishes for the control room environment, multiple factors must be considered to ensure functionality, comfort, and visual harmony.
Acoustic Properties:
Materials should contribute to effective sound control (e.g., dense rubber for flooring).
Light Considerations:
Avoid materials that create disturbing reflections on screens or surfaces.
Thermal Comfort:
Materials should not feel cold to the touch, especially on frequently used surfaces.
Durability & Maintenance:
Flooring should support:
Smooth movement of office chairs around consoles
Ease of cleaning and maintenance
Use wear-resistant, acoustic floor tiles.
Finish should be non-reflective to reduce glare.
Must support ergonomic use and rolling mobility.
Ceilings: Light-colored to enhance perceived height and brightness
Walls: Subtly tinted to provide contrast and reduce eye fatigue
Floors: Dark-colored to ground the space and reduce visual distraction
Overall, choose inconspicuous colors for large surface areas (walls, ceiling, floor) to promote a calm and professional environment.
Proper lighting is essential in a control room environment — not only to support operational tasks but also to reduce fatigue, enhance focus, and contribute to a calm and productive atmosphere.
Enhances operator performance and reduces stress/fatigue
Improves visual comfort through balanced lighting distribution
Creates a soothing aesthetic that supports long hours of focused work
LUX level calculations are performed to optimize:
Light intensity
Uniform spread
Surface reflectance
Light intensity, arrangement, and color influence the psychological energy and focus of individuals in the control room.
An optimized Illumination Web ensures uniform distribution across task and ambient zones.
Task Areas:
Defined as areas requiring visual attention — e.g., monitors, paper documents, display/video walls.
Key Guidelines:
Luminance levels should avoid large contrasts to reduce eye strain.
Display wall brightness should match other task areas.
Brightness must remain consistent and within ergonomic standards.
General ambient luminance (walls, ceilings) must be coordinated with task lighting to ensure uniformity.
Average display wall brightness (lamp life): 100 cd/m²
The readability of screens and display walls is directly influenced by:
Projector contrast
Screen reflectivity
Ambient lighting and its direction
Viewing angle (affects luminance levels)
Pixel sharpness
All these parameters are balanced to ensure optimal onscreen contrast and clarity for both close and distant viewing.
In a mission-critical control room, uninterrupted focus and minimal distractions are essential for effective operation. Every movement within the space—whether by operators or visitors—must be deliberately planned to prevent interference with workflow and concentration.
Minimize Distractions:
Operator movement patterns are carefully analyzed to reduce unnecessary motion in critical areas.
Entry and exit points are strategically placed to avoid direct interference with primary work zones.
Workflow-Specific Planning:
Movement within the control room is tailored to suit the workstyle and roles of individual users.
Consideration is given to:
Shift changes
Supervisor interaction
Maintenance personnel
Emergency evacuation
Custom Plans for Each Project:
No two control room designs are the same—each traffic flow plan is based on detailed user requirement studies.
Congestion is avoided by designing clear, unobstructed pathways and segregated zones for operators and support staff.
Purpose-Driven Circulation:
Traffic is channeled to maintain quiet zones, reduce bottlenecks, and support a calm, high-focus work environment.
Dedicated circulation zones help distinguish between:
Operational areas
Meeting and collaboration spaces
Visitor viewing and waiting areas
Continuous R&D and innovation inform each layout, balancing functional efficiency with aesthetic enhancements.
The goal is to deliver a holistic experience—a blend of focus, functionality, and comfort—customized for 24/7 mission-critical operations.
Human Factors Engineering (HFE) is critical to designing control rooms that support operator comfort, efficiency, and safety—especially in 24/7 mission-critical environments. Every aspect of the design must optimize the interaction between humans and their work environment.
The location of the control room is influenced by:
Overall plant layout
Primary sources of operator information
Building type (e.g., normal or blast-proof, with/without windows)
Safety and functionality concerns
The structure must:
Allow for safe and quick evacuation in case of emergencies
Avoid proximity to noisy or disruptive areas such as canteens or high-traffic zones
HFE is applied across various parameters to support performance and health:
Viewing angles and sightlines to display walls and screens
LUX level optimization for visual comfort
Dynamic lighting to support circadian rhythms and reduce fatigue
HVAC design to maintain thermal comfort
Fire & safety compliance for critical operation zones
Traffic flow planning to reduce disruptions
Furniture design that supports posture, reach, and task variety
Occupancy planning is derived through collaborative workshops with stakeholders, including:
End users/operators
Automation and instrumentation contractors
Project consultants
The number of operators and their task analysis defines:
Console type and layout
Proximity to video walls
Required space for seamless operations and support functions
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