Why Exoskeletons & Lifting Aids Are Carrying More Weight in Construction

For many contractors, one of the most persistent jobsite risks does not come from a dramatic fall or equipment failure. It comes from the routine lifts, awkward carries and repeated twists that wear down workers over time.

A mechanical contractor spends much of the day working above shoulder height, installing ductwork or piping in tight ceiling spaces. Nearby, another worker holds a heavy drill to core through concrete walls for pipe runs. Across the site, crews repeatedly load and unload materials from trucks, often carrying them long distances across uneven ground. Even experienced workers who have performed these tasks safely for years begin to feel the effects of cumulative strain. Taken together, these everyday activities help explain why strains, sprains and overexertion injuries remain among the most persistent and costly challenges in construction.

That challenge is becoming harder to ignore. Contractors are navigating labor shortages, tighter schedules and growing pressure to keep experienced workers on the job longer. At the same time, manual material handling remains one of the most persistent safety exposures on many jobsites. Musculoskeletal disorders are the leading cause of days away from work in construction and a top loss driver of nonfatal injuries. Nationwide’s claims data points in the same direction, with strains and sprains remaining among the most common and costly injury issues.

That is why more contractors are paying attention to tools designed to reduce physical strain, from lift assists and vacuum lifts to exoskeletons and other lifting aids.

Start With the Exposure, Not the Device

When construction leaders think about innovation, it can be tempting to focus on the newest technology. But the better starting point is the exposure itself.

Manual material handling tasks often involve high force, awkward postures, repetition and twisting — all of which increase the likelihood of musculoskeletal injuries. One of the clearest principles in injury prevention is that the safest lift is the one that is never made. Better design, automation and material handling aids reduce injury opportunities before they happen.

That matters in construction, especially as contractors try to retain experienced employees and support an aging workforce. Some solutions are already practical, such as hoists, vacuum lifts, carts and lift tables. Others, like exoskeletons, are newer and worn by the worker rather than built into the process.

Where Exoskeletons May Fit

Exoskeletons are gaining visibility because they promise something contractors care about: reducing fatigue during demanding work. In the most promising use cases, they may help support the back, shoulders or other body areas during repetitive lifting, sustained postures or overhead work.

Early research is encouraging, even if it is still developing. A 2024 study highlighted by Vanderbilt University found that 88% of participants increased their lifting repetitions while wearing a back-assist exosuit, with endurance gains from 28% to 75%. The same study estimated a 27% to 93% reduction in cumulative back damage risk while the exosuit was used.

Still, contractors should be careful not to overstate what that means today. The Vanderbilt study was conducted with U.S. Army soldiers in logistics and sustainment tasks, not pure construction environments. There is no doubt that more studies are still needed before exoskeletons can be broadly recommended as a stand-alone answer.

Lifting Aids Are Already Part of the Answer

Exoskeletons may be newer to many contractors, but lifting aids are already helping reduce strain on jobsites. Hoists, vacuum lifts, lift tables, carts and other material handling tools can reduce force, limit awkward lifts and make repetitive tasks more manageable. 

For many contractors, those tools may be the more immediate and practical place to start. Exoskeletons may expand those options, but they should be viewed as part of a broader strategy to reduce physical strain, not as a replacement for proven lifting solutions.

How Contractors Can Apply It Well

Technology only helps if it is operationalized. That aligns with recent CPWR research on passive exoskeletons in construction, which found the technology shows promise for reducing physical effort and discomfort, but that adoption barriers still center on usability, safety concerns, social acceptance and training. A contractor may pilot an exoskeleton or introduce a lift assist and still see limited impact if the rollout is not structured.  

For contractors considering exoskeletons, lift assists or other lifting aids, four practical steps can help.

1. Start With a Task Assessment

Do not begin with the device. Begin with the job. Look at the tasks producing the most strain exposure or injury potential. How much weight is being lifted? How often? From what height? How far from the body? Is twisting involved? Nationwide’s Ergonomics Screening Tool is one way to identify risk factors and control options before selecting a solution.

2. Pilot the Technology Where It Fits Best

Not every task is a good fit for an exoskeleton, and not every crew needs a lift assist. A test-and-learn approach is often the best place to start. Choose a task with clear strain exposure and limited variability. Then evaluate whether the technology improves comfort, reduces fatigue and is accepted by the people doing the work. Some manufacturers and vendors offer free demos or pilot programs along with training assistance.

3. Train for Proper Use & Limitations

If a contractor implements exoskeletons or lifting aids, training cannot be an afterthought. Workers need hands-on instruction in how the equipment fits, when it should be used and where its limits are. That includes reinforcing that the goal is to reduce strain, not to encourage workers to lift more weight than they otherwise would. These devices are meant to support or complement current capabilities, not expand them. 

Contractors also need to account for new safety exposures these tools can introduce, such as an exoskeleton getting caught on equipment or materials. Supervisors need to understand how to reinforce proper use, identify misuse and address those added risks.

4. Keep Engineering Controls in the Conversation

Organizations should start high in the hierarchy of controls. Eliminate the lift if possible. If not, redesign the task. Alongside the task redesign, use engineering improvements and other controls to reduce the demand on the worker. That means exoskeletons should usually be considered alongside, not instead of, proven material handling improvements such as hoists, lift tables, vacuum assists and better staging design.

The Goal Is Less Strain, Not More Tech

Construction businesses should be open-minded about exoskeletons and lifting aids but disciplined in how they use them. The real opportunity is not adopting technology for its own sake. It is using the right combination of task design, lifting aids, worker input, training and targeted innovation to reduce strain-related injuries.

For contractors that approach these tools thoughtfully, the upside is a safer jobsite, a more sustainable workforce and a practical way to address one of construction’s most persistent injury drivers.