Human-Centric Design for Enhanced Efficiency & Operator Well-Being

Human Factors Control Room Ergonomics & Desk

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.

Our Approach to Human Factors & Ergonomics

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

Key Human Factor Considerations

• 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

Console Layout Ergonomics

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.

Control Room Building Layout

Workflows

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

Location & Structure

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.

Floor Space Engineering

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.

Aspects of Design

Location of Control Room Building with Respect to the Plant

• 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)

Location of the Control Room Within the Building

• 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.

Functionality and Number of Operators

• 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.

HFE Considerations

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

Spatial Configuration and Console Design

• 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

Summary

All these aspects collectively define the layout and general arrangement of the Central Control Room (CCR), ensuring operational efficiency, safety, and comfort.

Acoustics

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.

Importance of Acoustic Balance

• 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.

Types of Acoustics Considered

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

ISO 11064-6:2005(E) Recommendations (Annex A, A.5 / A.6)

• 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

Technical Specifications for Acoustic Environment

• 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

Control Area

Control Section

• 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

Console Configuration

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

Material & Colour

When selecting materials and finishes for the control room environment, multiple factors must be considered to ensure functionality, comfort, and visual harmony.

Material Selection Criteria

• 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

Flooring Recommendations

• Use wear-resistant, acoustic floor tiles.
• Finish should be non-reflective to reduce glare.
• Must support ergonomic use and rolling mobility.

Colour Scheme Guidelines

• 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.

Lighting Design / Illumination

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.

Purpose of Illumination Design

• 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

Lighting Parameters Considered

• 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.

Ergonomics-Based Illumination Planning

• 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

Readability & Visual Contrast

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.

Traffic Flow

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.

Design Considerations for Traffic Flow

• 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

Traffic Flow Management

• 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

Design Evolution and Aesthetics

• 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 / Ergonomics

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.

Location & Structural Considerations

• 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

Functional Ergonomics in Control Room Design

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 Determination and Stakeholder Involvement

• 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