Designing and Prototyping a Smart Upper-Limb Exoskeleton for Enhancing Wellbeing and Productivity in Construction

The construction industry is plagued by high rates of musculoskeletal disorders (MSDs), workplace injuries, and low worker productivity, necessitating innovative solutions to enhance worker safety, health, and efficiency. This study presents the design and prototyping of, a wearable upper-limb exoskeleton (EXOCON) tailored for construction tasks, particularly heavy lifting. The exoskeleton integrates advanced technologies, including ergonomic and biomechanical engineering, multimodal sensory systems, and a hierarchical control architecture, to provide active assistance while minimizing physical strain on workers. Anthropometric and 3D body scanning techniques were employed to customize the design for diverse body sizes and genders, ensuring user inclusivity and comfort. EXOCON’s sensory system incorporates inertial measurement units (IMUs) and a wireless camera to collect real-time kinematic and environmental data, processed through a deep learning-based multimodal control system for accurate intention prediction and adaptive task support. The prototype achieved significant reductions in biceps muscle strain and demonstrated an overall classification accuracy of 99% for user actions. These findings underscore the potential of EXOCON to enhance worker safety and productivity while mitigating MSD-related risks in construction environments. The study concludes with recommendations for the adoption of wearable exoskeletons in construction and highlights areas for future research, including expanding the device’s functionality, integrating it with digital construction site technologies, and exploring its long-term impacts on worker health and efficiency. This research advances the role of wearable technologies in creating safer, more sustainable construction practices.