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Abstract: Rework is positively linked with increased safety risks. As a precursor to decreased rework and enhanced safety performance, this
study appraised the correlative causes of rework and safety incidents. To do this, 20 rework causes that undermine safety performance were
first identified through the literature review. Using a survey questionnaire involving Malaysian construction professionals (owners, consul-
tants, and contractors), the causes were prioritized based on frequency, severity, and importance indices. The five leading rework-safety
causes were ranked as follows: poor coordination, insufficient communication, poor subcontractor management, improper supervision
and inspection, and poor site management. Spearman’s rank correlation tests revealed a significant agreement between the respondent groups.
An exploratory factor analysis identified the five major underlying causal dimensions of rework and safety incidents to relate to the substandard
management of equipment and machinery, poor project management practices, inherent dangerous, dirty, and difficult (3D) characteristics,
improper production planning and work pressure, and inadequate personnel competency and knowledge. This paper bridges the identified
knowledge gap concerning the dimensionality of rework and accident causation in construction, and the findings provide guidance for devising
preventive measures for simultaneously addressing rework and safety problems. DOI: 10.1061/(ASCE)CO.1943-7862.0001902. © 2020
American Society of Civil Engineers.
Author keywords: Rework; Safety; Causes; Construction; Project management; Factor analysis.
safety management (Lessing et al. 2017; Mohammadi et al. as workers’ failures to identify hazards, inadequate communication,
2018; Yap and Lee 2019) separately. Notably, little attempt has low worker skill level, inadequate use of tools, and workers’ unfa-
been made to explore the underlying dimensions of the combined miliarity with the work environment. Hon et al.’s 2010 Hong Kong
rework-safety causes in construction, which has increased the dif- study finds that reworking imposes additional workload and sched-
ficulties for managers in containing rework to enhance construction ule pressures in requiring managers and workers to hurry to finish
site safety. As highlighted by Love et al. (2018a), rework remains a the work and underestimates potential risks when carrying out re-
“known-unknown,” with a high degree of uncertainty of how it af- peating tasks. Most notably, Emuze et al.’s (2014) South African
fects project performance, particularly safety incidents. Therefore, it study finds that frequent rework leads to physical and mental fa-
is necessary to develop a general concept of how rework causation tigue, which are also significant risk factors for occupational injuries
can undermine safety performance on site and to uncover the under- to frontline construction workers (Cheah 2007; Mohammadi et al.
lying factor structure of rework-safety causes. Therefore, this study 2018). Swaen et al.’s (2003) analysis of data for 7,051 Netherlands
aims to contribute to filling these substantial gaps by identifying the workers from 45 different organizations finds a strong positive link
relevant rework-safety causes and understanding the underlying between fatigue and occupational accidents across a wide range of
dimensions involved. industries, including construction; and Zhang et al.’s (2015) study
of 606 US construction workers concludes that fatigue can result
in impaired physical or cognitive functions that adversely affect a
Background worker’s ability to make good decisions.
© ASCE
Hwang Love
and Love Hwang Love and Yap Josephson Ye Eze and Lopez
Yang and Li et al. et al. Edwards et al. et al. Palaneeswaran et al. Rounce Palaneeswaran Idiake et al.
No. Causes of reworks (2014) (2000) (2009) (2000) (2004) (2017) (2002) et al. (2014) (2015) (1998) et al. (2008) (2018) (2010) Frequency
1 Poor coordination x — — x — x x x x x x x — 9
2 Poor site management x — — — x x — x — — x x x 7
3 Poor site and working condition — x — — — — — — x — — x — 3
4 Faulty construction method — x x — — x — x x — — — — 5
5 Time constraints — — — x x x — x x — x x x 8
6 Improper supervision and — — — — x x — — x — x — — 4
inspection
7 Poor subcontractor management x — — — x x — — x — x — — 5
8 Insufficient communication — — — — — — — x x — x x x 5
9 Low education level of worker — — — — — x — — x — — — — 2
10 Lack of experience and x — — — x x — x x x x x — 8
knowledge
11 Unskilled worker and lower- — — — — — x — — x — x x — 4
skilled labor
12 Poor workload planning — — — — x — — x — — x x — 4
13 High staff turnover rate — — — — — — — x — — x x — 3
14 Excessive overtime — — — — — — — — — — — x — 1
15 Poor information flow — — — — x — x x — — — — — 3
16 Improper handling of machinery — — — — — x x x — — — — — 3
and equipment
04020106-3
17 Lack of maintenance to — — — — — — x — — — — — — 1
equipment and tools
18 Poor standard of machinery and — — — — — x x — x — — — — 3
equipment
19 Improper planning of resources — — — — x — — x — — x — — 3
20 Lack of event documentation — — — — x — — — — — — — — 1
© ASCE
Lee Al-Kaabi Aksorn Chen Abdelhamid
Causes of and Tam Agyekum Wong and and Zhao and Golizadeh Chau Zhang and Chen Cheng
construction Lim et al. et al. et al. Mohammadi Hadipriono Priyadarshani Hadikusumo et al. Wu et al. et al. Irumba et al. Everett et al. et al.
Ref. accidents (2017) (2004) (2018) (2009) et al. (2018) (2003) et al. (2013) (2008) (2018) (2010) (2018) (2004) (2014) (2019) (2000) (2018) (2010a) Frequency
1 Poor coordination — — — — — — — — — x — — — — — — — 1
2 Poor site x — — — x x — — — x — x x — — — — 6
management
3 Poor site and — — — — x x — — — — x — — — x — — 4
working condition
4 Faulty construction x — — — — — — — — — x — — — — — — 2
method
5 Time constraints — — — — x — — — — — — — — — — — — 1
6 Improper — — — x x — x x x — x — — x — x — 8
supervision and
inspection
7 Poor subcontractor — — x x x — — — — x x — — x — — x 7
management
8 Insufficient x — x — x — x x x x x — — — — — — 8
communication
9 Low education level x x — — x — x — x x — — — x — — — 7
of worker
10 Lack of experience x x x x x x x x x x x x x x x x x 17
and knowledge
11 Unskilled worker — x — — x x x — x x x x — x — x — 10
04020106-4
and lower-skilled
labor
12 Poor workload — — — — x — — — — — — — — — — — — 1
planning
13 High staff turnover — — — — x — — — — — — — — — — — — 1
rate
coordination (FI ¼ 0.723), improper supervision and inspection method statement (SI ¼ 0.768), poor site management (SI ¼
(FI ¼ 0.702), poor subcontractor management (FI ¼ 0.698), and 0.760), insufficient communication (SI ¼ 0.736), and poor coor-
poor site management (FI ¼ 0.675). dination (SI ¼ 0.728). For consultants, these are a lack of experi-
ence and knowledge (SI ¼ 0.789), insufficient communication
(SI ¼ 0.778), poor site management (SI ¼ 0.778), poor site and
Severity of Causes Undermining Safety Performance
working conditions (SI ¼ 0.767), improper handling of machinery
The severity indices are shown in Table 5. Overall, SI ranges from and equipment (SI ¼ 0.767), poor standard of machinery and equip-
0.594 to 0.739. According to the owners, the five most severe ment (SI ¼ 0.767), and poor information flow (SI ¼ 0.767). For
causes relate to poor site and working conditions (SI ¼ 0.776), er- contractors, these are improper handling of machinery and equip-
roneous construction methods and poor design of the construction ment (SI ¼ 0.728), poor site and working conditions (SI ¼ 0.726),
lack of experience and knowledge (SI ¼ 0.711), improper supervi- compliance, participation, and attitudes are positively and signifi-
sion and inspection (SI ¼ 0.711), and insufficient communica- cantly linked with such safety-relevant communications as feed-
tion (SI ¼ 0.709). back of unsafe behaviors in the workplace and safe-work method
statements.
Improper supervision and inspection is second in the overall
Importance of Rework-Safety Causes ranking (IMP:I ¼ 0.504). The lack of supervision by supervisory
Table 6 shows the importance indices and rankings of rework- personnel results in workers adopting risky behavior and taking
safety causes for owners, consultants, and contractors. The findings short cuts that result in rework and safety issues (Love et al. 2018b).
reveal no significant differences in the rankings compared to pre- Investigating a $375 million AUD water infrastructure project in
vious reported indices (FI and SI). Overall, the IMP.I ranges from Victoria, Australia, Love et al. (2016a) find site supervision to
0.357 to 0.528. be one of the primary contributors to rework. Similar observations
Insufficient communication is ranked highest (IMP:I ¼ 0.528) are reported in China (Ye et al. 2015), Malaysia (Yap et al. 2017),
and is therefore considered an extremely influential variable con- and Uganda (Kakitahi et al. 2016). Some studies investigating
tributing to rework and safety risks at construction sites. This cause construction safety issues also find a significant link between su-
is ranked in second and third place for FI and SI, respectively. The pervisory problems and raising safety concerns (Hon et al. 2010;
consultants (IMP:I ¼ 0.571) perceive this cause to be more impor- Mohammadi et al. 2018). Supervisor activities are associated with
tant than the owners (IMP:I ¼ 0.536) and contractors (IMP:I ¼ injury risk at the workplace (Yanar et al. 2019). To improve produc-
0.519). This is unsurprising, as communication is one of the most tion safety management and the supervisory system, Zhao et al.
frequently studied success factors for rework and accident preven- (2018) propose a framework considering environment, equipment,
tion in the research literature (Loushine et al. 2006; Love et al. human, management, and technical factors.
2016a). Poor and untimely communication often results in obsolete Poor coordination is ranked as the third most critical cause of
and wrong information, which further exacerbates the need for rework and safety risks (IMP:I ¼ 0.502). Project coordination is
rework (Love et al. 2014). For Malaysian construction sites, com- closely tied to project communications management, involving ac-
munication problems between foreign workers who cannot speak tivities of planning, organizing, and directing the resources, equip-
the local language is a stern barrier for safety education and train- ment, meetings, and information. Coordination-related issues, such
ing (Yap and Lee 2019). Increased communication and the effec- as between the professional consultants, between owner and consul-
tive sharing of knowledge within related parties tend to engender tants, and between owner and end-user, are pertinent rework causes
collaborative teamwork (Love et al. 2018b), which in turn en- (Yap et al. 2017). Given the dynamic environment of construction
hances both the productivity and safety of construction operations sites, safety coordination is a very complex process (Kartam et al.
(Mitropoulos and Cupido 2009). Most notably, the safety climate 2000). In this context, careful safety planning, preparation, co-
influences the perceived risk and is significantly determined by ordination, and control is recommended to be practiced from the
communications and discussions over safety (Patel and Jha 2015). early stages and periodic reviews conducted as the work progresses
In this vein, Kath et al.’s (2010) study of 548 US railway workers (Kartam et al. 2000). Any disruption to operations due to rework
reports a statistically significant positive association between the makes safety compliance difficult to attain. For example, Wanberg
workers’ safety behavior and open communication with their super- et al. (2013) assert that a worker’s ability to recognize hazards is
visors over safety issues. Drawing on the social exchange theory, impaired when the work environment is altered. Unplanned inter-
Mullen et al.’s (2017) Canadian study observes that worker safety ruptions to regular workflow tend to generate a higher rate of human
vironment (Tam et al. 2004). Cheah’s (2007) principal components Subjecting the 20 causes to a factor analysis with a principal
analysis of safety factors on Singaporean sites reveals that the lack component analysis and varimax rotation produces a five-factor sol-
of integration of safety considerations during construction activities ution with eigenvalues greater than 1, explaining 68.0% of the total
can significantly affect safety standards—manifested in almost 30% variance—exceeding the 60% required for adequate construct val-
of the variance explained. idity (Hair et al. 2010). As all 20 variables attain factor loadings
Poor subcontractor management is ranked fifth (IMP:I ¼ exceeding 0.50, there is therefore no need to delete any variable
0.483). The performance of the main contractor depends very much from the analysis, and the variables are considered significant in
on the overall planning, coordination, and control of subcontractors, contributing to the interpretation of the principal factors (Kim and
specialist contractors, and suppliers (Love et al. 2004). The low skill Nguyen 2018). In Table 8, with a Cronbach’s alpha greater than
level of subcontractors also contributes to rework and safety inci- 0.70, all of the factors have a high reliability (Hair et al. 2010).
dents (Mohammadi et al. 2018; Yap et al. 2017). The extensive use
of subcontractors, combined with their poor selection and control,
complicate safety communications and the allocation of safety ac- Discussion of the Factor Analysis Results
countabilities and responsibilities (Kartam et al. 2000). In China,
given the different levels of subcontractor expertise and knowledge, Factor 1: Substandard Management of
it is difficult to have effective communication, resulting in regular Equipment and Machinery
rework (Ye et al. 2015). A subcontractor integrity system, regular
coordination meetings, and the onsite cross-checking of subcontrac- This first factor has the largest total variance of 17.03%, explaining
tors are suggested to provide an effective means of minimizing the five most important causes with regard to handling machinery
rework (Ye et al. 2015). and work equipment, all with a factor loading exceeding 0.600. The
construction sector in the developing world relies heavily on labor-
intensive construction methods, with a low level of diffusion of
Homogeneity of Ranking Between Parties such innovative technologies as industrialization and prefabrication
Spearman’s rank-order correlation is a nonparametric measure of the (Yap et al. 2019a). The contractor’s poor materials, machinery, and
strength and direction of ranking between two respondent groups equipment management is a major source of rework (Ye et al. 2015)
on an ordinal scale (Bagaya and Song 2016; El-Razek et al. 2008). as well as an important causal factor of construction accidents
Table 7 provides the results of this analysis, showing that there is a (Gibb et al. 2005). For example, the common problems with ma-
very good agreement between the three parties in ranking these chines triggering rework are frequent breakdowns, failure to work
causes in terms of frequency, severity, and importance—the average satisfactorily, their incorrect use, and being delivered with defects
positive agreement for frequency and severity being 78.5% and (Josephson et al. 2002). Love et al.’s (2018c) analysis of 218
61.4%, respectively. With respect to the importance index, the high- Australian projects between 2006 and 2015 found that equipment
est degree of agreement appears between consultant and contractor handling errors or violations contributed 2.3% to nonconformance
(approximately 83%) while the lowest is between owner and con- (NCR) costs. Workers are exposed to hazards when safety equip-
sultant (about 79%). This consensus between each group of parties ment is not provided, when using defective tools, or when working
further establishes the reliability of the results. with inappropriate equipment for the task (Durdyev et al. 2017;
Mitropoulos et al. 2005). Against this background, Gibb et al.
(2005) have suggested construction companies should not only be
Exploratory Factor Analysis interested in the lowest price as the only criteria for their selection
One function of the factor analysis is to reduce many variables to a of tools and equipment. To avoid rework, Famiyeh et al. (2017)
lesser number of underlying factors that are being measured by the have underscored the necessity for contractors to use the most
variables (Hair et al. 2010). This summarization and data reduction appropriate construction methods and machinery, equipment, and
approach has been widely used in previous construction and safety tools on the site.
effective communication are leading drivers of a project (Arain and remaining two causes under this component, namely, poor coor-
Pheng 2006) and failure (El-Razek et al. 2008). Arain and Pheng dination and erroneous construction method and poor design of
(2006) have emphasized that contractors are unable to acquire the the construction method statement, influence construction workflow
required data when communication breakdown prevails, resulting and site safety procedures. Task unpredictability generates unex-
in the project not meeting its intended objectives. Working on ob- pected hazardous situations, which therefore increases the likelihood
solete information has such adverse effects on projects as rework, of accidents due to unplanned exposures and errors (Mitropoulos
schedule delays, and quality degradation. Moreover, the many et al. 2005). As highlighted by Love et al. (2018c), quality and safety
layers of subcontracting make the coordination process complex are at stake when subcontractors use unapproved materials or incor-
yet challenging (Ye et al. 2015); it can contribute as much as rect methodology. Cheng et al.’s (2010b) analysis of 1347 Taiwan
34% of NCRs (Love et al. 2018c). Addressing managerial short- accidents found major unsafe site conditions to be (1) the failure to
comings and the adoption of best construction practices can help use a work platform when working at heights (24%), (2) the use of
reduce the cost of manageable and controllable rework (Safapour hazardous methods (16%), and (3) failing to inspect the surrounding
and Kermanshachi 2019). Therefore, in this respect, the influence environment before commencing work (12%).
of managerial support of the workers as well as project safety is of
vital importance (Mohammadi et al. 2018; Zhao et al. 2018). Factor 4: Improper Production Planning and
Work Pressure
Factor 3: Inherent Dangerous, Dirty, and
Factor 4 comprises four causes with a total variance of 11.86%,
Difficult (3D) Characteristics
emphasizing the criticality of operational planning for construction
This factor comprises four causes relating to health, safety, and envi- projects. High staff turnover rate (factor loading ¼ 0.805) is a
ronmental (HSE) aspects of working on construction sites. Poor site morale problem. This may stem from overworked workers who
and working condition (with a factor loading ¼ 0.767) not only have experienced increased workloads and responsibility due to
hurts worker productivity but also morale and satisfaction (Love and the lack of an active or trained workforce (Love et al. 2018a).
Smith 2018; Mitropoulos et al. 2005). Unsafe working conditions, Hanna et al.’s (2004) sensitivity analysis of the effect of proj-
such as an untidy site, hazardous tasks, and an unfavorable working ect changes for electrical and mechanical construction in the US
environment, are the most common causes of injuries on construc- found that labor turnover and absenteeism contribute to productiv-
tion sites (Durdyev et al. 2017). Consequently, the criticality of ity loss. The next cause, excessive overtime, has a high correlation
the next cause, poor site management (with a factor loading ¼ with time constraints. Undue rework with a tight deadline can
0.752), becomes important in the context of rework and the cause demotivate workers to follow safety rules (Pereira et al. 2018), and
of accidents on projects (Love et al. 2018b; Ye et al. 2015). The people break rules to make work more efficient (Love et al. 2016b).
Workers need to be physically and mentally alert to work safely, inexperienced and poor skill development undermine construction
and long work hours and extended (and irregular) shifts may lead processes and contribute to the occurrence of rework. In another
to fatigue along with physical and mental stress, resulting in an study, Fang et al. (2006) found a strong correlation between com-
impaired performance (Cheng et al. 2010b; Love and Smith 2018), petence and accident frequency in Hong Kong.
particularly when confronted with schedule pressure (Pereira et al.
2018). In this vein, Dembe et al.’s (2005) analysis of a total of 110
Comparison with Previous Studies
and 236 US job records, encompassing 89 and 729 person-years of
accumulated working time in 1987 and 2000, found that overtime As the literature consulted has not considered the underlying dimen-
working was associated with a 61% higher injury hazard rate com- sions of common rework and safety causes, this study employed a
pared to jobs without overtime—highlighting that working ex- triangulation approach to achieving cross-validation (Gibson and
tended shifts may also involve prolonged exposure to potential Whittington 2010). Table 9 consolidates previous findings from
work injury hazards. both rework and safety domains. All these studies have been pub-
lished since 2000. Although the studies may differ in their ap-
Factor 5: Inadequate Personnel Competency proaches, they provide a useful window in understanding the
and Knowledge latent factors triggering rework and safety incidents.
A close examination of Table 9 reveals that the global construc-
Low education level of worker (factor loading ¼ 0.829), unskilled tion industry predominantly suffers from rework attributable to
worker and lower skilled labor (factor loading ¼ 0.772), and lack poor project management practices, followed by inherent 3D char-
of experience and knowledge (factor loading ¼ 0.637) create this acteristics and inadequate personnel competency and knowledge.
fifth factor, with a total variance of 10.71%, explaining the signifi- On the other hand, inadequate personnel competency, knowledge,
cance of skilled and experienced construction professionals and and inherent 3D characteristics are also reported to undermine con-
workers to rework and safety management. Human resource man- struction safety performance significantly. Although the present
agement (HRM) functions are challenging in this sector, which research is based in Malaysia, a developing economy, this compar-
depends mostly on a migrant, casual, and transient blue-collar ative analysis further corroborates that the five uncovered underly-
workforce (Srour et al. 2017). Language and literacy barriers may ing factors can fittingly reflect the rework and accident causation
affect the quality of work performed by migrant workers, as they in the global construction industry. Construction managers can use
may not understand the work instructions given (Yap et al. 2019a). these results to plan preventive actions to minimize rework and
In addition, workers who are not properly trained or did not under- safety problems.
stand their safety training due to a language barrier may unknow-
ingly make costly mistakes (Yap and Lee 2019). The lack of safety
knowledge and motivation by managers and workers relate to a Concluding Remarks
limited view of accident causality and learning (Mitropoulos et al.
2005). Personnel competency factors, such as knowledge, experi- The current study contributes to the knowledge of rework and
ence, training and education, learning, skills, and hazard awareness, safety management in construction projects. Despite a plethora of
can significantly influence rework and safety incidents (Choudhry rework and safety studies, little is known of the causes common to
et al. 2009; Love et al. 2018b; Winge and Albrechtsen 2018). both rework and safety incidents. Moreover, the key dimensions of
For example, Oyewobi et al.’s (2016) Nigerian study revealed that these reciprocated causes in the context of developing countries
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