Evaluating industrial exoskeletons for performance and fatigue in lifting tasks

Abstract Repetitive movements and awkward postures in construction work often lead to muscle fatigue and work-related musculoskeletal disorders (WMSDs), contributing to reduced productivity and heightened occupational risks. As Industry 5.0 emphasises human-centric technologies, this study evaluates two back support exoskeleton designs – HAPO SD (springbased) and BISKO (elastic textile) – in a repetitive lifting task. Using an exploratory single-case study methodology, six trials were conducted over 18 days, with each trial including three sets of repetitive lifting using a 24 kg kettlebell under three conditions: (1) no exoskeleton, (2) HAPO SD, and (3) BISKO. Performance was measured through repetition count, time per repetition, and user experience. Results showed that the HAPO SD system achieved a 120%–162% increase in repetitions compared with no exoskeleton and outperformed BISKO by 7%–58%. Both systems demonstrated reduced time per repetition and lower standard deviations versus the control condition, indicating enhanced endurance stability. HAPO SD provided superior lifting support, while BISKO offered better ease of use and adjustability. Although the single-case design and controlled environment of this study warrant further investigation in actual construction settings and with larger sample sizes, the findings suggest that exoskeleton adoption could improve worker productivity and reduce WMSD risk.