Physically demanding tasks pose significant challenges to worker health, safety, and productivity across various industrial sectors, particularly in construction. Physical fatigue, a major contributor to workplace accidents, compromises individual well-being and economic outcomes. Traditional fatigue assessment methods often lack accuracy, comfort, or real-world applicability. This study introduces a multimodal physical fatigue assessment method employing a wearable sensor to collect both physiological data, heart rate (HR) and skin temperature (ST), and kinematic data, jerk. The Borg's Rating of Perceived Exertion (RPE) scale was used to validate the method, which was tested on twenty-two participants (mean age: 28.5 ± 3.6 years) performing manual material handling tasks. The findings indicate that HR, ST, and jerk values increase as tasks become more strenuous, correlating with higher RPE scores. Integrating physiological and kinematic metrics with subjective validation effectively captures the multifaceted nature of fatigue, enabling real-time monitoring. Notably, incorporating jerk as a kinematic measure addresses limitations of previous methods by providing a rapid-response indicator of motor control and ultimately physical fatigue. This comprehensive approach has potential applications in manual material handling tasks and, with further validation, may be extended to other industrial contexts where repetitive lifting and carrying are common. By offering practical, data-driven solutions that enhance workplace safety and health, this approach can reduce accidents, injuries and support proactive risk management strategies.
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