Identification of Key Occupational Safety and Health (K3) Risk Factors in Underground Construction Projects Using the Fuzzy Failure Mode and Effect Analysis Method

Authors

  • Daisy Debora Grace Pangemanan Politeknik Negeri Manado
  • Yuke Cika Vianda Universitas Bung Hatta, Indonesia

DOI:

https://doi.org/10.69855/sipil.v2i2.700

Keywords:

Occupational Safety and Health (K3), Fuzzy FMEA, Underground Construction, Risk Priority Number, Tunnel Safety

Abstract

Underground construction projects expose workers to complex occupational safety and health (K3) hazards, including tunnel collapse, hazardous atmospheres, groundwater inrush, and confined-space emergencies. Conventional Failure Mode and Effect Analysis (FMEA) often struggles to prioritize these risks because expert judgments on severity, occurrence, and detection involve considerable uncertainty. Purpose: This study applies the Fuzzy Failure Mode and Effect Analysis (Fuzzy FMEA) method to identify and rank K3 risks in an underground metro tunnel construction project. Methods: Thirty-two potential failure modes were identified through literature review, field observations, and hazard checklists. Expert evaluations from 21 construction safety practitioners, tunnel engineers, and site supervisors were represented using triangular fuzzy numbers, aggregated through a fuzzy weighted-average approach, and defuzzified using the centroid method to calculate the Fuzzy Risk Priority Number (FRPN). Results: The results indicate that tunnel face collapse (FRPN = 842), toxic and oxygen-deficient atmosphere (FRPN = 796), groundwater inrush (FRPN = 733), and rockfall at the tunnel heading (FRPN = 705) are the highest-priority hazards. Compared with the conventional Risk Priority Number (RPN), Fuzzy FMEA produced a Spearman rank correlation of .91 while identifying changes in the ranking of several risks. Implications: Fuzzy FMEA provides a robust and reliable framework for prioritizing K3 risks and supporting effective safety mitigation in underground construction projects. Conclusion: Fuzzy FMEA captures uncertainty in expert judgment that the conventional RPN obscures; future studies should extend the expert panel across multiple underground projects and compare alternative defuzzification methods.

References

Abdelgawad, M.; Fayek, A.R. Risk management in the construction industry using combined fuzzy FMEA and fuzzy AHP. J. Constr. Eng. Manag. 2010, 136, 1028–1036. https://doi.org/10.1061/(ASCE)CO.1943-7862.0000210

Armin, H.; Nasab, A.Y.; Dehbaraftab, S.M.H.; Far, H.E. Assessment and ranking of occupational health and safety risks in the machinery maintenance unit of dam construction projects using the combined approach of FMEA and Fuzzy TOPSIS. Int. J. Health Sci. 2022, 6, 5710–5723. https://doi.org/10.53730/ijhs.v6nS7.13386

Asis, C.A.D.; Licas, F.S.; Bulagao, J.C. Impact of work experience on the level of awareness of construction workers on occupational health and safety in tunnels. 2023.

Bettelini, M. Systems approach to underground safety. Undergr. Space 2020, 5, 258–266. https://doi.org/10.1016/j.undsp.2019.04.005

Bhattacharjee, P.; Dey, V.; Mandal, U.K. Risk assessment by failure mode and effects analysis (FMEA) using an interval number based logistic regression model. Saf. Sci. 2020, 132, 104967.

Cao, Y.; Yun, B. Tunnel construction worker safety state prediction and management system based on AHP and anomaly detection algorithm model. Heliyon 2024, 10, e36450. https://doi.org/10.1016/j.heliyon.2024.e36450

Chen, X.; Guo, C.; Song, J.; Wang, X.; Cheng, J. Occupational health risk assessment based on actual dust exposure in a tunnel construction adopting roadheader in Chongqing, China. Build. Environ. 2019, 165, 106415. https://doi.org/10.1016/j.buildenv.2019.106415

Choi, H.H.; Cho, H.N.; Seo, J.W. Risk assessment methodology for underground construction projects. J. Constr. Eng. Manag. 2004, 130, 258–267. https://doi.org/10.1061/(ASCE)0733-9364(2004)130:2(258)

Dahooie, J.H.; Vanaki, A.S.; Firoozfar, H.R.; Zavadskas, E.K.; Čereška, A. An extension of the failure mode and effect analysis with hesitant fuzzy sets to assess the occupational hazards in the construction industry. Int. J. Environ. Res. Public Health 2020, 17, 1442. https://doi.org/10.3390/ijerph17041442

Enshassi, A.; Mayer, P.E.; Mohamed, S.; El-Masri, F. Perception of construction managers towards safety in developing-country underground construction. Int. J. Constr. Manag. 2021, 21, 592–604.

Grošelj, P.; Dolinar, G. Embedding fuzzy weights into failure mode and effects analysis criteria for realistic risk priority numbers. J. Manuf. Syst. 2023, 68, 55–66.

Guan, X.; Yu, F.; Xu, H.; Li, C.; Guan, Y. Flood risk assessment of urban metro system using random forest algorithm and triangular fuzzy number based analytical hierarchy process approach. Sustain. Cities Soc. 2024, 109, 105546.

Jatwa, R.; Sukhwani, V.K. Fuzzy FMEA-based risk assessment framework for underground metro rail construction projects. Int. J. Constr. Manag. 2022, 22, 2098–2112.

Khodadadi-Karimvand, M.; Taherifar, S. Safety risk assessment using fuzzy logic, failure mode and effect analysis (FMEA), and fault tree analysis (FTA). J. Saf. Sci. Resil. 2022, 3, 231–240.

Koohathongsumrit, N.; Chankham, W. Risk analysis of underground tunnel construction with tunnel boring machine by using fault tree analysis and fuzzy analytic hierarchy process. Safety 2024, 10, 68. https://doi.org/10.3390/safety10030068

Lin, C.J.; Zhang, M.; Li, L.P.; Zhou, S.; Liu, T.; Liu, C. Risk assessment of tunnel construction based on improved cloud model. J. Perform. Constr. Facil. 2020, 34, 04020026. https://doi.org/10.1061/(ASCE)CF.1943-5509.0001421

National Fire Protection Association (NFPA). NFPA 520: Standard on Subterranean Spaces; NFPA, 2021.

Peña-García, A.; Gil-Martín, L.M.; Fernández, J.E. Analysis of lighting and psychosocial risk factors in tunnel construction. Tunn. Undergr. Space Technol. 2018, 78, 250–256.

Pinto, A.; Nunes, I.L.; Ribeiro, R.A. Occupational risk assessment in construction industry - Overview and reflection. Saf. Sci. 2011, 49, 616–624.

Pongtuluran, R.E.; Machfudiyanto, R.A.; Suraji, A. Hazard and risk identification in earthworks for road tunnel construction: A case study of the first road tunnel in Kalimantan Island, Indonesia. Int. J. Saf. Secur. Eng. 2024, 14, 1949–1961. https://doi.org/10.18280/ijsse.140629

Qin, Y.; Tang, X.; Liu, W.; Chen, P. Hazard identification and analysis of underground gas explosion during tunnel construction. Process Saf. Environ. Prot. 2018, 117, 421–429.

Rustagi, A. Assessment of failure mode and effect analysis (FMEA) with fuzzy logic for mixed-use construction. In Building Construction and Technology; Lecture Notes in Civil Engineering, Vol. 360; Springer, 2023; pp. 89–104. https://doi.org/10.1007/978-981-99-3526-0_7

Setiawan, A.; Wibowo, A. Fuzzy FMEA approach for assessing occupational safety and health risks in metro tunnel excavation projects in Jakarta, Indonesia. IOP Conf. Ser. Earth Environ. Sci. 2023, 1195, 012032.

Soltanzadeh, A.; Mahdinia, M.; Jafarinia, E.; Golmohammadpour, H.; Sadeghi-Yarandi, M. Occupational safety risk analysis in construction sites based on fuzzy analytic hierarchy process: A case study in a large construction project. Work 2023, 76, 771–782. https://doi.org/10.3233/WOR-220086

Sun, B.; Li, Y.; Zhang, J. Automated prioritization of construction project requirements using machine learning and fuzzy failure mode and effects analysis (FMEA). Adv. Eng. Inform. 2024, 61, 102493.

TRADESAFE. OSHA Underground Construction Safety: Hazards and Compliance Guide; TRADESAFE Technical Report, 2025.

Więckowski, J.; Sałabun, W. Sensitivity analysis approaches in multi-criteria decision-making: A systematic review of methods and applications. Eng. Appl. Artif. Intell. 2024, 133, 108604.

Xu, F.; Wang, N.; Wen, X.; Gao, M.; Guo, C.; Zhao, X. Few-shot message-enhanced contrastive learning for graph anomaly detection in underground construction monitoring. arXiv 2023, preprint.

Zadeh, L.A. Fuzzy sets. Inf. Control 1965, 8, 338–353. https://doi.org/10.1016/S0019-9958(65)90241-X

Zhang, L.; Wu, X.; Skibniewski, M.J.; Zhong, J.; Lu, Y. Bayesian-network-based safety risk analysis in metro construction projects. Reliab. Eng. Syst. Saf. 2021, 210, 107541.

Downloads

Published

2026-10-30

How to Cite

Daisy Debora Grace Pangemanan, & Yuke Cika Vianda. (2026). Identification of Key Occupational Safety and Health (K3) Risk Factors in Underground Construction Projects Using the Fuzzy Failure Mode and Effect Analysis Method. Structures, Infrastructure, Planning, Implementation, and Legislation, 2(2), 29–38. https://doi.org/10.69855/sipil.v2i2.700