7 Tools for Reducing Musculoskeletal Injuries in Data Centers

Workers’ compensation claims associated with musculoskeletal disorder injuries typically occur when the design of the job or equipment does not match the employee’s capabilities. This discrepancy often results in shoulder injuries for employees working in data centers. Thankfully, there are mechanisms and emerging technologies that can help prevent injuries.

“Data center development professionals should consider the available ways to remove technician risks in the design process as early as possible,” said Sonya Luisoni, Senior Risk Control Manager at Safety National. “If the data center is already operational, it is important to understand what tools are already in place and then look at what might be worth piloting to further reduce strain and injury risk.”

Here, we review several devices that can help reduce the need for excessive movements while working in data center environments.

1. Mechanical Lifts & Positioners

These devices can remove the need for manual lifting and holding at shoulder height, and can include:

• Server and rack lifts – Allow heavy servers and network gear to be positioned at the correct height with minimal effort, eliminating awkward shoulder lifts.
• Height-adjustable platform lifts – Reduce reaching overhead and bending below knee level.

2. Ergonomic Rack Layouts

Used to minimize awkward reaching and repetitive overhead motion, these layouts can optimize vertical placement, positioning heavier, bulky equipment between mid-torso and waist level to reduce overhead work. They may include shallow or pull-out shelves that allow equipment access without requiring an employee to reach deeply into the rack. The racks’ front or rear access provides dual configuration, allowing technicians to approach gear from the most ergonomic direction.

3. Modular and Pre-Configured Units

These units typically include pre-built shelves or rack assemblies that are standardized to ergonomic heights. Pre-attached cable bundles can also help reduce in-field manipulation.

4. Mobile Height-Adjustable Work Platforms

These platforms elevate a technician (instead of having them raise their arms) to keep work within the neutral shoulder zone. When safety rails are included, the platforms can reduce slips while working at height. Some also have automated height adjustment based on load or task type.

5. Task-Specific Handling Tools

Designed to reduce effort, task-specific handling tools, such as powered torque wrenches and cordless drivers, can minimize the force required to install servers. As a result, these tools can also reduce fatigue in an employee’s shoulders and arms. Cable management reels and tension-reducing tools can also help prevent excessive reaching and pulling.

6. Tool Holsters & Balanced Tool Sets

When tools are counterbalanced and stored at waist level, there is less strain on an employee while working, reducing the risk of injury. Tools are easier to grab, allowing for faster, safer access.

7. Exoskeletons with Embedded Sensing and AI

As one of the most modern solutions for decreasing manual material handling, exoskeletons can mechanically offload arm weight, stabilize posture during overhead and repetitive tasks, and reduce muscle activation. Exoskeletons are especially effective for sustained arm elevation and fine-motor work done overhead, such as patching, fastening, and labeling. They act like a mechanical rest, allowing micro-recovery even while the task continues. Two types that can help with manual material handling in data centers include:

• Passive shoulder exoskeletons
  • Do not include motors, but instead use springs, elastic elements, or torque mechanisms.
  • Store energy when arms are lowered and release energy when arms are raised or held up.
  • Reduce shoulder muscle activation by around 15–40% in overhead or chest-height work.
  • Delay the onset of shoulder muscle fatigue during long maintenance or installation tasks.

• Load redistribution exoskeletons
  • Redistribute forces away from the shoulder joint to the torsos, hips, or back structure of the device.

Keep in mind, exoskeletons do not replace ergonomic design, nor do they assist much with heavy lifting below shoulder height.