Control room spaces are the heartbeat of many industries. In essence they ensure non-interrupted and efficient operations in places like utilities, transportation, or emergency response centers. Whether you’re designing a new control room or upgrading an existing one, the process definitely involves more than simply picking out furniture and equipment.
If you are tasked with designing or upgrading a control room, this guide is here to help. It walks you through common pitfalls, such as poor ergonomics and inadequate space planning. By following these insights, you can create a space that meets today’s needs and remains adaptable for the future.
Understanding the Complexity of Control Room Design
Taking on a control room project might seem straightforward at first—how hard can it be to organize a functional workspace? Yet, the reality is far more complex. Control rooms are high-stakes environments where every design choice impacts the performance and safety of critical operations.
For example, a poorly planned layout can lead to communication breakdowns, operator fatigue or inefficiencies that compromise mission objectives. Even experienced professionals often turn to specialists to ensure the design is both practical and future-ready. By addressing common missteps early, you can streamline the process and avoid costly revisions later.
The Impact of Downtime in Control Rooms
Downtime is one of the costliest challenges industrial and manufacturing plants face, second only to safety or environmental mishaps. Shockingly, 82% of companies have experienced unplanned downtime in the past three years, according to Businesswire.
Unfortunately, when it comes to mission-critical spaces like emergency response centers, power plants, or manufacturing facilities, downtime can have catastrophic consequences. This reality underscores the importance of optimizing operator performance and control room efficiency to mitigate financial losses, safety risks, and operational disruptions.
12 Common Mistakes in Control Room Layout and Design
Designing or renovating a control room that meets current operational demands while preparing for future challenges requires careful planning and attention to potential pitfalls. Both the client and the service provider must address critical factors to minimize mistakes and ensure the project’s long-term success.
Below are 12 common control room mistakes to avoid, along with strategies to ensure a functional and future-ready design.
1. No Prior Experience Designing a Control Room
Let’s start out with one of the most detrimental control room design mistakes: Inexperience. A lack of experience in control room design often leads to overlooked details and suboptimal layouts.
When project engineers or decision-makers accustomed to managing other operations take on a control room project, they quickly face challenges in balancing specialized needs, operator requirements, and functionality.
For instance, a maintenance manager who has excelled at optimizing equipment uptime or leading facility upgrades may be tapped to oversee a control room redesign. Once in this role, they realize they’re no longer maintaining systems—they’re now orchestrating the development of a space that must integrate complex technologies, align with operator workflows, and support the organization’s long-term goals.
This shift constitutes a significant challenge and introduces risk if they attempt to navigate the process without specialized guidance or support.
The Challenges of Inexperience
Beginners often make critical errors that reduce a control room’s effectiveness. For example, selecting furniture without ergonomic features undermines 24/7 reliability, while ignoring workflow optimization isolates operators from essential tools. Additionally, an overemphasis on technology can lead to spaces that appear advanced but fail to function effectively.
Solutions for Effective Control Room Design
To ensure success, decision-makers should prioritize:
- Hiring experts, such as human factors consultants and control room experts.
- Adopting a user-centered approach by involving operators early to align layouts with workflows.
- Using industry standards like ISO 11064 and tools like Building Information Modeling (BIM).
Purpose-built consoles designed for tools, space, and reliability should be a top priority. Addressing these factors upfront enhances operator well-being and supports smooth operations.
2. Ignoring Ergonomic Principles
Neglecting ergonomic principles in control room design leads to fatigue, errors, and inefficiencies. Properly designed spaces allow operators to work comfortably and effectively, helping them make timely, accurate decisions that enhance safety and performance.
By prioritizing ergonomics, organizations can minimize fatigue, improve focus, and support efficient, safe operations.
The Risks of Ignoring Ergonomics
Poor sight lines, improperly positioned monitors, and inadequate seating make it difficult for operators to access information efficiently, leading to errors during emergencies. Fatigue develops from physical and cognitive strain caused by unnatural postures and poorly configured alarm systems, which overwhelm operators with nuisance alerts and impair decision-making.
Additionally, consoles with improper dimensions can worsen these issues. Short consoles can prevent monitors from being placed at an appropriate distance, limit operator workspace, and force uncomfortable postures, such as having arms hang unnaturally. [1]
Solutions for an Ergonomic Workspace
Integrating ergonomic principles into control room design is essential to mitigate these risks. Purpose-built furniture, such as control consoles and ergonomic chairs, should be designed specifically for 24/7 environments.
Consoles must provide adequate workspace and enable proper monitor positioning to reduce strain and discomfort. Chairs must offer adjustable features to ensure long-term comfort and proper posture, while monitor arms are critical for achieving optimal screen placement.
Optimal workspace dimensions are equally important. Monitors should be positioned at appropriate distances to prevent eye strain and discomfort, and the overall layout should encourage natural postures for operators. By involving operators in the design process, organizations can ensure that layouts and tools align with workflows and meet practical demands.
Alarm management is another key element of ergonomic design. Implementing guidelines to reduce nuisance alarms and prioritize critical notifications prevents cognitive overload and helps operators maintain focus during high-pressure situations.
By addressing these ergonomic factors, organizations can create control rooms that enhance operator well-being, minimize errors, and improve overall operational efficiency.
3. Improper Sight Lines and Display Angles
Poor sight lines and improperly positioned display angles are some of the more hazardous of control room errors. In fact, these actions can seriously jeopardize both control room safety and efficiency. That’s because when monitors are placed at awkward angles or operators lack a clear view of their workspace, response times slow, and critical alarms may be missed.
To lessen these risks, focus on ergonomic design by positioning screens at eye level and maintaining optimal viewing distances. Additionally, ensure sight lines to all essential equipment and team members aren’t blocked.
The Risk of Poor Lighting and Sight Lines
In his LinkedIn article, Disaster in the Control Room, Corey Wilson said it best: poor control room design, including inadequate lighting and obstructed sight lines, can lead to serious real-world consequences. He recounts a site audit conducted by control room design expert Steve Whitely, where significant flaws were identified.
At a mid-sized oil storage facility, misaligned operator consoles, insufficient lighting, and an inefficient layout created a cascade of issues. Operators relied heavily on visual recognition of alarms, with one even nodding off due to the dim lighting. When a critical alarm went unnoticed, it resulted in downtime and financial loss.
Solutions for Fixing Critical Design Flaws
While audits and gap analyses are crucial for identifying such problems, fixing them requires actionable changes. The solution lies in designing control rooms as unified operational spaces rather than as isolated components.
Implementing better lighting, ensuring unobstructed sight lines, and positioning operator consoles to promote collaboration can prevent similar disasters. By addressing these issues, facilities can enhance safety, improve situational awareness, and minimize costly interruptions.
4. Poor Lighting Choices
Lighting plays a critical role in control room design, impacting visibility, screen readability, and operator comfort. Improper setups, such as harsh lighting causing glare or dim environments straining vision, lead to eye fatigue and reduced focus. Balanced lighting is essential for creating an environment suited to continuous operations.
The Challenges of Poor Lighting
Harsh overhead lighting often reflects off screens, creating glare that makes it difficult for operators to read data accurately. Conversely, dim lighting reduces visibility and forces operators to strain their eyes, especially during extended shifts. Both scenarios result in discomfort, fatigue, and increased chances of errors. Inconsistent lighting can also create shadows, further impairing visibility in critical areas and disrupting operators’ ability to focus on their tasks.
Solutions for Effective Lighting
To address these challenges, a well-designed lighting system tailored to the control room’s unique needs is essential:
- Task Lighting: Use adjustable task lights at individual workstations to provide focused illumination, ensuring operators can comfortably view their screens and documents.
- Dimmable LEDs: Install dimmable LED lights throughout the control room to allow operators to adjust the lighting levels according to their preferences and time of day.
- Anti-Glare Screens: Equip monitors with anti-glare features to minimize reflections and enhance screen readability under varying lighting conditions.
- Layered Lighting Design: Combine ambient, task, and accent lighting to create a balanced environment. Ambient lighting ensures general visibility, while task and accent lighting enhance focus on specific areas.
- Lighting Simulations: Leverage lighting design software to simulate different setups and identify optimal configurations before installation, ensuring minimal disruptions.
5. Overlooking Workflow Optimization
Failing to analyze workflows during control room design can lead to inefficient layouts that waste time and hinder productivity. Without understanding operator movements and tasks, layouts may isolate critical tools or over-cluster equipment, creating bottlenecks and reducing operational efficiency, especially during high-pressure situations.
The Challenges of Workflow Optimization
When workflows are not analyzed, control rooms are often designed without considering how operators interact with their environment. Critical tools positioned far from the main console require unnecessary movements, delaying responses.
On the other hand, over-clustering equipment can create obstructions, limiting operators’ effectiveness. These design flaws become costly and disruptive, especially when dealing with heavy equipment or inefficiencies resulting from suboptimal workflow.
Solutions for Optimized Workflows
To avoid these pitfalls, a structured approach to workflow optimization is essential. Here are the key steps:
- Identify Goals: Define what the control room needs to achieve, focusing on operational efficiency, safety, and ease of use.
- Analyze Current Processes: Conduct a detailed review of existing workflows to identify inefficiencies, bottlenecks, or unnecessary movements.
- Develop an Optimized Process: Create a new layout that addresses these issues, ensuring that critical tools are accessible and workflows are streamlined.
- Leverage Simulation Software: Use discrete event simulation software to model the proposed control room design and test workflows virtually. These platforms allow you to arrange different setups where you can animate and run different scenarios before committing to physical changes.
- Involve Operators: Engage operators in the design process to ensure the layout aligns with their daily tasks and minimizes unnecessary movements. Their insights are invaluable in creating a design that supports efficient workflows.
- Test and Implement: Run the new layout in a controlled environment to confirm its effectiveness, then implement it organization-wide.
- Evaluate and Improve: Regularly assess the workflow and layout to identify areas for continuous improvement.
By combining workflow analysis, operator feedback, and modern tools, organizations can develop control rooms that support both current and future operational demands. Thoughtful planning ensures efficiency and adaptability remain at the forefront.
6. Insufficient Space Planning
Ineffective space planning in control room design can lead to overcrowded or underutilized areas, creating operational inefficiencies. When too much equipment is crammed into a limited space, it obstructs access, hampers team collaboration, and increases the risk of errors.
In contrast, underutilized space represents a missed opportunity to enhance efficiency or prepare for future needs. Proper space planning is essential to balance current operations with the flexibility to accommodate growth and change.
The Challenges of Poor Space Planning
Overcrowded control rooms often result in cramped workstations, limited operator mobility, and cluttered environments that slow response times. Accessing critical equipment becomes difficult, and teams struggle to communicate effectively in confined spaces.
On the other hand, underutilized space reflects inefficient planning, leaving areas idle that could have been optimized for storage, collaborative zones, or future upgrades. Both scenarios waste resources and diminish the control room’s overall effectiveness.
Solutions for Effective Space Planning
To avoid these issues, control room designs should incorporate strategies that optimize space usage while allowing for flexibility:
- Conduct a Space Needs Assessment: Evaluate the control room’s requirements, considering the number of operators, equipment, and workflows to determine the appropriate amount of space.
- Plan for Expansion: Design layouts with at least 25% of the space reserved for future growth. Avoid placing permanent fixtures like plumbing or electrical panels near areas that may need to expand.
- Use Modular Furniture: Incorporate adaptable furniture that can be reconfigured as needs evolve, supporting both current and future operational demands.
- Zoned Layouts: Divide the control room into zones for specific functions, such as operator stations, collaborative spaces, and equipment areas, ensuring efficient use of available space.
- Leverage CAD Tools: Use computer-aided design (CAD) software to create floor plans and simulate different layouts, identifying the most effective configurations before construction or installation begins.
By planning for flexibility and considering long-term needs, organizations can avoid the pitfalls of insufficient space planning. Thoughtfully designed control rooms facilitate better equipment access, improve team collaboration, and ensure the space remains functional and adaptable as technology and operational requirements evolve.
7. Ineffective Acoustic Design
Proper acoustic design in control rooms is an essential factor for maintaining operator focus and ensuring accurate communication during critical situations. Ignoring noise control can lead to distractions, miscommunications, and potentially dangerous errors, especially during unplanned events when alarm systems are triggered.
Poorly configured alarm systems often magnify these issues, generating a flood of nuisance alarms that overwhelm operators and hinder their ability to respond effectively. According to guidelines like EEMUA 191, alarm systems should be designed to prioritize clarity and reduce unnecessary noise, aligning with maximum workload thresholds for operators.
The Challenges of Poor Acoustic Design
Control rooms often face additional acoustic challenges during emergencies. The presence of supervisors, engineers, and other personnel offering advice or seeking updates can create an overcrowded, chaotic environment.
This surge in activity amplifies background noise, which can drown out critical alarms or lead to misheard instructions. Operators, already tasked with managing hundreds of graphical process displays and historical trends, are further burdened by the distractions, increasing the risk of mistakes.
Solutions for Noise Reduction
Creating an environment conducive to focus starts with designing the control room to minimize noise and distractions. Implementing soundproofing measures such as acoustic panels, noise-absorbing flooring, and separating work zones ensures that ambient noise remains manageable.
Limiting access during emergencies to essential personnel also prevents overcrowding and reduces unnecessary interruptions.
Clear communication protocols play a vital role in mitigating risks associated with high noise levels. Establishing guidelines for effective operator workload and alarm performance—as recommended by EEMUA 191—ensures operators can focus on interpreting alarms and graphical displays without being overwhelmed.
Together, these strategies make for a safer, quieter, and more efficient control room environment.
8. Neglecting Temperature Control
Temperature regulation is a critical factor in control room design that impacts both operator comfort and equipment functionality. Poor temperature control can cause discomfort, reduce focus, and increase operator fatigue, while also posing risks to sensitive equipment. When overlooked, these issues can disrupt operations and lead to costly repairs or downtime.
The Challenges of Poor Temperature Regulation
Common mistakes in temperature control include uneven airflow, which results in hot and cold spots that make it difficult to maintain a consistent environment. Failure to account for the heat generated by equipment can also cause localized overheating, putting systems at risk of malfunction or failure.
These issues not only affect the efficiency of the control room but can also compromise safety, as temperature fluctuations may lead to operator distraction and discomfort during critical tasks.
Solutions for Effective Temperature Control
To address these challenges, implementing a robust temperature regulation strategy is essential. Consider the following solutions:
- Zoned HVAC Systems: Use zoned heating, ventilation, and air conditioning (HVAC) systems to provide precise temperature control across different areas of the control room. This approach ensures operators remain comfortable and equipment stays within optimal operating conditions.
- Thermal Management Strategies: Incorporate designs that account for heat-generating equipment, such as server racks and monitors. Use features like raised flooring to improve airflow or install dedicated cooling systems for high-heat areas.
- Temperature Monitoring: Deploy real-time monitoring systems to track temperature variations and identify potential problem areas before they escalate.
- Balanced Airflow: Ensure the HVAC system provides even airflow throughout the room to eliminate hot and cold spots.
- Energy Efficiency: Optimize the placement of air intakes, vents, and equipment to reduce energy consumption while maintaining a stable environment.
Proper temperature control not only improves operator comfort and focus but also extends the lifespan of equipment and minimizes the risk of costly interruptions. By addressing temperature regulation proactively, organizations can maintain a reliable and efficient control room environment.
9. Not Integrating the Proper Tools
Failing to integrate the proper tools into a control room can limit its functionality and hinder operator performance. While modern technologies like the Industrial Internet of Things (IIoT) enable advanced capabilities such as live content sharing and visual collaboration, poorly planned integration can create inefficiencies.
Therefore, control rooms must balance cutting-edge tools with operator needs to maximize their effectiveness.
The Challenges of Poor Tool Integration
Improper integration of tools often results in lighting issues, excessive noise, and insufficient ergonomic considerations. For example, too much natural lighting can cause glare or wash out video content, while poorly designed ventilation can lead to dry eye syndrome among operators.
Additionally, inadequate soundproofing or improper use of audio tools can disrupt communication and reduce focus. Without sound masking and directional speakers, larger control rooms may struggle to maintain speech privacy and minimize distractions.
Solutions for Proper Tool Integration
To address these challenges, indirect lighting with the correct frequency and color temperature should be used to reduce glare and improve vigilance. Ceiling materials with moderate to high reflectance can help distribute light evenly, and control rooms should be illuminated to a level of 300–500 Lux for optimal visibility.
Proper ventilation systems prevent operator discomfort. We touched on noise reduction in Number 7, but incorporating tools like sound-absorbing materials on walls, floors, and ceilings remains essential to minimizing ambient noise.
Separate equipment rooms for CPUs and servers can reduce noise and heat, simplifying maintenance and keeping the control room focused on operations. Additionally, sound masking and directional speakers help maintain speech privacy, and placing these tools on critical power ensures continuity during power outages.
Designing with Collaboration in Mind
Modern control rooms require integrated solutions to support collaborative workflows. Overview displays, alarm management systems, and multi-functional tools, such as shared keyboards and mice, allow operators to manage information efficiently. Emerging technologies like alarm light bars enhance situational awareness, making them valuable additions to control room setups.
By integrating the proper tools and considering operator needs, control rooms can enhance functionality, improve collaboration, and support critical operations effectively.
10. Failure to Plan for Technology Upgrades
Designing a control room without considering future technological needs can lead to significant challenges as systems evolve. Rapid advancements in technology often require new equipment, expanded infrastructure, or updated configurations, which can be difficult or costly to implement in a rigidly designed space.
The Challenges of Failing to Plan for Upgrades
Inflexible layouts are a common issue, where equipment cannot be rearranged or replaced without extensive renovations. Insufficient wiring or limited connectivity options can also prevent the integration of new systems, leading to operational inefficiencies or obsolescence. These oversights not only disrupt workflows but may also require costly redesigns to accommodate new technological demands.
Solutions for Future-Ready Control Rooms
To mitigate these risks, control rooms should be designed with scalability and flexibility in mind:
- Modular Furniture: Incorporate modular control room furniture that can be easily reconfigured to support new equipment or layouts.
- Scalable Infrastructure: Plan for additional wiring, power outlets, and network connectivity to accommodate future upgrades without disrupting operations.
- Dedicated Space for Expansion: Allocate space for adding equipment or upgrading existing systems, ensuring minimal impact on day-to-day operations.
- Regular Technology Assessments: Periodically review control room technology to identify potential upgrades and align the design with evolving needs.
By prioritizing flexibility and scalability, organizations can future-proof their control rooms, ensuring they remain efficient and adaptable as technology continues to advance.
11. Focusing Too Much on Initial Costs
Focusing too much on initial costs instead of long-term ROI is never a good practice when it comes to something as critical as designing a control room. Cutting corners during the design and construction of a control room might save money initially, but it often results in higher costs over time. Poor-quality materials, insufficient attention to durability, and neglecting operator needs can lead to frequent repairs, inefficiencies, and early obsolescence.
These decisions diminish the room’s overall value and functionality, often requiring costly updates sooner than anticipated.
The Challenges of Prioritizing Initial Costs
When purchase decisions prioritize cost over quality, essential features like ergonomic furniture, durable materials, or efficient lighting systems may be sacrificed. This not only increases maintenance expenses but also affects operator comfort and productivity.
Moreover, cheaper, low-quality materials often fail to withstand the demands of 24/7 operation, resulting in faster wear and tear.
Solutions for Maximizing ROI Through Better Purchases
Investing in high-quality, durable furniture and materials designed for 24/7 use reduces the need for frequent replacements or repairs, ultimately saving money over time.
For cost-conscious organizations, gently used technical furniture from reputable suppliers like Saraval Industries can offer significant savings—up to 80%—without compromising on operational standards.
Additionally, ergonomic furniture and scalable solutions enhance operator efficiency, leading to improved long-term performance.
Focusing on individual purchase decisions that balance cost and durability ensures a functional, reliable control room that delivers long-term ROI.
12. Insufficient Budget Planning
Budget constraints often prevent project teams from achieving optimal control room designs. Without proper funding, long-term goals are overlooked in favor of immediate needs, which can lead to inefficiencies and missed opportunities for profit. Control rooms, designed for 10–15 years of 24/7 operation, require strategic budget planning to ensure their value aligns with corporate goals.
The Challenges of Insufficient Budget Planning
A lack of strategic budget planning results in underfunded projects that fail to meet operational needs. Urgent priorities often overshadow long-term considerations, leading to designs that are neither scalable nor efficient. Additionally, management may not fully understand the unique role control rooms play, viewing them as an expense rather than a critical production resource. This can limit funding and ultimately compromise operator performance.
Solutions for Strategic Budget Planning
Organizations should align their control room budgets with corporate goals, ensuring long-term needs are prioritized over short-term fixes. For example, when consolidating control rooms, upgrading automation software at the same time can reduce future costs and streamline operations. Smart building technologies also help manage ongoing expenses by improving energy efficiency and scalability.
Strategic budgeting enables organizations to invest in scalable designs, energy-efficient systems, and high-quality materials, resulting in better operator performance, reduced absenteeism, and a long-term return on investment of 7–10%.[2] Proper funding and a holistic approach ensure control rooms are effective, adaptable, and profitable over time.
The Key Takeaways
Avoiding the common design mistakes we’ve described in this guide is key to creating a control room that supports operators, maintains safety, and adapts to future needs. The information to take away here helps you understand the mistakes to avoid, ensuring you can identify these pitfalls early and prioritize long-term goals. Seeking professional guidance can also make the process easier, helping you make informed, strategic decisions about everything from furniture to layout.
Saraval Industries: Your Control Room Furniture Specialists
If you’re ready to take the next step, Saraval Industries is here to help. With over 25 years of experience in ergonomic technical furniture design, we offer tailored solutions for mission-critical environments.
Whether you’re exploring new or used furniture, or seeking expert guidance on layout and design, our team is here to assist. Contact us today to get a quote and discuss a customized design solution that meets your needs, supports your operators, and keeps your control room prepared for whatever comes next.
FAQs
What is the responsibility of a control room?
A control room is responsible for monitoring, managing, and coordinating operations in real-time across critical systems. It ensures safety, operational efficiency, and quick response to emergencies or system anomalies.
What is the main function of a control room?
The primary function of a control room is to centralize and streamline the management of critical operations. This includes monitoring data, responding to alarms, and enabling effective communication to maintain the smoothest operations possible.
What is control room compliance?
Control room compliance refers to adhering to industry standards, regulations, and best practices in the design, operation, and maintenance of control rooms. It ensures safety, efficiency, and accountability in mission-critical environments.
References
[1] 5 Mistakes to Avoid When Renovating a Control Center
[2] 5 Most Common Mistakes in Planning Control Room Upgrades