Leveraging digital human modeling for musculoskeletal disorder risk assessment in vertical formwork operations

Purpose Musculoskeletal disorders (MSDs) are a significant concern in the construction industry, particularly in formwork operations, which involve physically demanding and repetitive tasks. Traditional methods for assessing MSD risks have limitations, including being time-consuming and subjective. Despite the importance of preventing MSDs, there is a lack of comparative research on MSD risks across different formwork systems. This study aims to address this gap by assessing and comparing MSD risks associated with steel and plywood formwork systems during vertical formwork operations in India. Design/methodology/approach A digital human modeling (DHM) approach was used to assess MSD risks associated with formwork systems. The study involved on-site observations, video capture, and simulation of formwork tasks in a virtual environment using CATIA V5. Representative work postures were reconstructed in CATIA V5 using a standardized built-in manikin and assessed using the integrated RULA module to enable task-level ergonomic comparison between the two formwork systems. Findings The results revealed that a significant proportion of formwork tasks pose high MSD risk, with 77.56% of analyzed postures resulting in high RULA scores. The results indicate that while steel formwork poses elevated handling risks during lifting and placing panels due to its weight, plywood formwork systems pose specific risks during assembly tasks involving nailing and hammering, underscoring the importance of task-specific ergonomic assessment rather than interpreting one formwork system as uniformly safer overall. Practical implications The findings could inform several stakeholders, including form/tool manufacturers, designers and contractors, to implement task-specific ergonomic interventions and training programs focused on proper lifting techniques and safer assembly practices. Social implications The findings also highlight the importance of considering worker safety and well-being in the construction industry. The findings could inform policies and guidelines to reduce the risk of MSDs and promote a healthier work environment. Originality/value This study provides an exploratory DHM-based comparative analysis of MSD risks associated with two vertical formwork systems under actual construction conditions, contributing initial task-level evidence to a comparatively underexplored area of the ergonomics literature. The findings could raise stakeholders' awareness of the need for proactive measures to prevent or mitigate MSDs in formwork systems and operations.