A High-Performance Hybrid Transformer–LSTM–XGBoost Model for sEMG-Based Fatigue Detection in Simulated Roofing Postures

Within the hazardous construction industry, roofers represent one of the most at-risk workforces, with high fatalities and injury rates largely driven by Work-Related Musculoskeletal Disorders (WMSDs). The primary precursor to these disorders is muscle fatigue, yet its objective assessment remains a significant challenge for implementing proactive safety management. To address this gap, this study details the implementation and validation of an AI-driven predictive analytics framework for automated fatigue detection using surface electromyography (sEMG) signals. Data was collected as participants (novice roofers) performed strenuous, simulated roofing tasks involving sustained standing, stooping, and kneeling postures. A key innovation is a data-driven labeling methodology using Weak Monotonicity (WM) trend analysis to automate the generation of objective labels. After a feature selection process yielded seven significant features, an evaluation of standard models confirmed that their classification performance was highly posture-dependent, motivating a more robust, hybrid solution. The framework culminates in a high-performance hybrid machine learning model. This architecture synergistically combines a Transformer–LSTM network for deep feature extraction with an XGBoost classifier. The model outperformed all standalone approaches, achieving over 82% accuracy across all postures with consistently strong fatigue F1-scores (0.77–0.78). The entire framework was validated using a stringent Leave-One-Subject-Out (LOSO) cross-validation protocol to ensure subject-independent generalizability. This research provides a validated component for AI-enhanced safety management systems. Future work should prioritize field validation with professional workers to translate this framework into practical, real-world ergonomic monitoring systems.