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The purpose of this paper is to identify the musculoskeletal problems faced by the workers carrying out head lifting at the construction sites and to present a solution for the identified problems.

The methodology of the paper is framed in two phases. First, the identification of the problems faced by workers through interviews/questionnaire and second, designing and fabricating a mechanical system to safe guard workers against musculoskeletal disorders.

Based upon the interviews and questionnaires, it was ascertained that majority of the workers were subjected to neck pain and low back pain. This was mainly attributed to the lifting of heavy loads on head, sudden and jerky movements and bad postures.

The developed frame has been appreciated by the Physiotherapists also; however, it still has certain limitations which can be taken as a future scope for the further modification of the frame. The limitations are as follows: the weight of the frame is a limitation, as the worker has to bear this load in addition to the load which is to be lifted. However, this can be dealt with by replacing the material of the frame with lightweight materials such as aluminium alloys, carbon fibres, etc. The continuous wearing of the frame may result in discomfort, as the worker cannot freely roam around. Sweating and etching due to wearing of belt. Worker cannot place the load him/herself on the frame. Stability issues in lifting liquids overhead.

Findings revealed the bleak possibility of replacing head loading. However, there is an urgent need of developing a cost-effective system which could help workers while carrying out head lifting of loads.

This work presents an ergonomically designed mechanical frame which will help workers in carrying out head loading without effecting their skull, spine, etc. The system was tested on workers and the results were alarming and the working capacity of the workers was observed to increase with the fabricated frame.