Exoskeletons & Back Belts: Do They Work?
Back pain is one of the leading causes of lost work time, and many products promise relief: back support belts, braces and now wearable exoskeletons. Safety experts agree that none of them replaces good job design. Understanding what they can and can't do helps you decide whether a device is worth using.
- Warehouse & Material Handlers
- Construction Workers
- Healthcare Workers
- Safety & Ergonomics Managers
Back belts
- Back belts and lumbar supports were once widely used in warehouses and stores to prevent back injuries.
- After reviewing studies, NIOSH concluded that there is not enough evidence that back belts prevent injuries or reduce back pain for workers who have not been injured, and did not recommend them as protection. OSHA does not require them.
- Possible downsides: belts may give a false sense of security, encouraging heavier lifting; may weaken core muscles if used all the time; can cause discomfort or heat; and some may raise blood pressure.
- Some people with back injuries find a brace helpful for short-term comfort under a doctor's advice.
Exoskeletons
An exoskeleton is a wearable device that supports the body during work.
- Passive exoskeletons use springs, elastic or dampers to support the arms (for overhead work), the back (when bending and lifting) or the legs (for squatting). No motor.
- Powered (active) exoskeletons use motors and batteries to add force, for example to assist lifting or tool holding.
- Studies show some devices reduce muscle activity in the target area during certain tasks, for example, overhead work or repeated forward bending. Benefits depend on the device, the task and the fit.
- Evidence on long-term injury reduction is limited, and results vary. Standards are being developed (for example, by ASTM International).
Possible problems
- New hazards: shifting load to other body parts (a back device may increase stress on the legs or shoulders), limiting range of motion, causing balance problems, trips or catching on objects.
- Heat, discomfort and fit problems over a full shift. A device that fits one person may not fit another.
- Entanglement and pinch points in moving parts, and battery and electrical hazards for powered units. See Battery Safety.
- Emergency escape and fall protection: some devices interfere with harnesses, evacuation or working at height.
- False confidence leading to heavier or riskier work.
Better first: ergonomic controls
- Redesign the job: reduce weights, use carts, lift tables, hoists, conveyors and vacuum lifters; store items between knee and shoulder height; bring the work to the worker. See Lifting & Ergonomics and Overhead Work & Shoulder Strain.
- Train workers on lifting techniques and body mechanics, and rotate tasks.
- Ask workers which tasks hurt, and test fixes. See Musculoskeletal Disorders.
- Report pain early and get care.
If you try an exoskeleton
- Do a pilot on a specific task with a few workers, with the maker's training, and collect feedback and measurements before buying widely.
- Make sure it fits each user, doesn't interfere with PPE, fall protection or emergency exit, and is approved for the work environment.
- Follow maintenance, cleaning and battery rules, and inspect it before use.
- Use it as one part of a program, not a replacement for engineering controls.
- Allow workers to stop using it if it causes discomfort or problems.
Exoskeleton and back belt checklist
- I tried to redesign the task and use mechanical aids first
- I know NIOSH doesn't recommend back belts to prevent injury
- Any exoskeleton was piloted, fits the worker and doesn't create new hazards
- It doesn't interfere with PPE, fall protection or emergency exit
- Workers can report discomfort and stop using the device
Standards & references
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