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Rework Causation that Undermines Safety Performance

during Production in Construction


Jeffrey Boon Hui Yap, Ph.D., P.Eng. 1; Jia Rou Chong 2;
Martin Skitmore, Ph.D. 3; and Wah Peng Lee, Ph.D., P.Eng. 4
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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.

Introduction linear relationship between safety disconnect and quality perfor-


mance. This finding is consistent with Love et al.’s (2015) argument
Rework is a significant risk in construction. However, many firms that safety incidents and rework nonconformances should not be
choose to ignore this reputation-damaging practice (Love et al. considered in isolation. According to Mitropoulos et al. (2009),
2016a), which has adverse repercussions on outcomes in terms of errors during task execution not only result in rework but also task
schedule (Hwang and Yang 2014), cost (Love and Sing 2013), uncertainties and disruptions from an out-of-sequence workflow.
quality (Arain and Low 2006), productivity (Arashpour et al. They further explain that more uncertainty in work situations
2014), and even safety incidents (Pereira et al. 2020). Rework sim- may increase the likelihood of accidents while at the same time
ply means “to revise or work again” (Love and Smith 2018, p. 2), undermining productivity. This is further echoed by Perlman et al.
which can result in inefficiency and disruption. Construction re- (2014) in observing that construction workers often function in
work is often referred to as a wasteful and nonvalue-adding activity unplanned conditions, which increases human errors and their ex-
in correcting errors, fixing defects, attending to variations in scope, posure to hazards. In another study investigating design change-
and other nonconformances (Love et al. 2016a). For that reason, induced rework using a systemic approach, Yap et al. (2019b)
rework often involves dismantling tasks, tighter timelines, and hap- observe that productivity loss from reworking is due to the dis-
hazard work processes (Wanberg et al. 2013). rupted rhythm of work, lower worker morale, and fatigue when a
Despite worker safety having been inexplicably overlooked completed portion of work necessitates undoing and reinstatement.
in supply chain performance, Das et al. (2008) found a significant Using an ecological momentary assessment, Menches and Chen
(2013) report that work interruptions compromise productivity
1
Assistant Professor, Lee Kong Chian Faculty of Engineering and as a result of their negative emotional effects (such as a greater an-
Science, Universiti Tunku Abdul Rahman, Kajang 43000, Malaysia noyance and reduced motivation) on construction workers. Accord-
(corresponding author). ORCID: https://orcid.org/0000-0003-4332-0031.
ing to Pereira et al. (2018), demotivated workers tend to misbehave,
Email: bhyap@utar.edu.my
2
Graduate, Lee Kong Chian Faculty of Engineering and Science, Uni- disobey safety rules, and consequently neglect hazards, all of which
versiti Tunku Abdul Rahman, Kajang 43000, Malaysia. Email: are indicators of unsafe behaviors. To this end, Han et al. (2014)
jrjang9611@gmail.com conclude that rework and schedule delays are critical managerial
3
Professor, School of Built Environment, Queensland Univ. of Technol- components affecting the occurrence of accidents.
ogy, Brisbane, QLD 4000, Australia. ORCID: https://orcid.org/0000-0001 Wanberg et al.’s (2013) analysis of 32 U.S. building projects
-7135-1201. Email: rm.skitmore@qut.edu.au indicates there are significant causal relationships between rework
4
Assistant Professor, Lee Kong Chian Faculty of Engineering and and safety incidents. Following a detailed literature review of 49
Science, Universiti Tunku Abdul Rahman, Kajang 43000, Malaysia.
quality- and safety-related research articles, Loushine et al. (2006)
ORCID: https://orcid.org/0000-0001-9177-5415. Email: leewp@utar.edu.my
Note. This manuscript was submitted on February 12, 2020; approved
observed similarities between construction safety and quality man-
on April 29, 2020; published online on June 26, 2020. Discussion period agement processes. As Love et al. (2018, p. 353) highlight, “if
open until November 26, 2020; separate discussions must be submitted for rework can be reduced, then significant improvements in safety
individual papers. This paper is part of the Journal of Construction En- performance can be achieved.” With this in mind, the root causes
gineering and Management, © ASCE, ISSN 0733-9364. of rework that contribute to an increase in safety incidents need to

© ASCE 04020106-1 J. Constr. Eng. Manage.

J. Constr. Eng. Manage., 2020, 146(9): 04020106


be identified before they can be sensibly managed. However, there For example, Chong and Low (2014) find the main causes of
is still no consensus concerning how the precursors of rework can construction accidents in Malaysia to involve falling, machinery
undermine safety performance onsite. It appears that several ad- and equipment errors, and collisions with machinery—the statistics
vancements in knowledge are needed to enable the construction revealing an accident rate of approximately one incident per project.
fraternity to understand the association between rework and acci- Construction is considered one of the least safe occupational sectors
dent causation better. Given the limited studies linking rework to in most countries (e.g., Mohammadi et al. 2018; Yap and Lee 2019),
safety performance (Love et al. 2018b; Wanberg et al. 2013), it is and rework makes an intrinsic contribution (Love et al. 2016a) with
still unclear what the best set of causative factors is for both rework the double-handling of materials and tasks involved, for instance,
and safety aspects. Except for a few studies that affirm a positive increasing exposure to safety risks. In investigating accident precur-
association between rework and safety incidents (e.g., Love et al. sors, Pereira et al.’s (2018) Canadian study found change orders that
2016c, 2018b; Pereira et al. 2018, 2020), most previous research are highly correlated to rework can significantly induce changes in
has considered the phenomenon of rework (e.g., Emuze et al. work plans and sequences, demotivate workers, and obscure safety
2014; Safapour and Kermanshachi 2019; Yap et al. 2017) and hazards. They also report the incident precursors relating to rework
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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.

Rework Causation in Construction Consolidation of Rework and Accident Causation


Given its criticality to project performance, rework has been widely Despite the large body of prior research on rework and accident
studied by construction management researchers. For example, causation in the context of construction, most studies have inves-
Love and Smith’s (2018) systematic review of the construction re- tigated the phenomenon singly. Hitherto, the gaps in knowledge are
work literature identifies the rework costs in 17 selected studies as that there have been few attempts to understand how rework causes
ranging from under 1% to over 20% of the contract price. Oyewobi also affect safety incidents, and the extent to which these causes
et al. (2016) find the major rework causes in Nigeria to be defects, jeopardize safety outcomes is unknown. For that reason, the prepa-
inadequate training, quality issues, incorrect interpretation of owner ration of a list of comprehensive rework-safety causes was a critical
needs, and changes initiated by the contractor, all of which are first step for the success of this study. Given this current theoretical
linked to substandard project management practices and an adver- gap in the literature, a two-stage approach was adopted to identify
sarial working culture. In Sweden, Josephson et al. (2002) cluster the reasons for rework that also affect safety outcomes. A system-
rework causes into owner, design, materials, machines, workman- atic background review was first conducted to explore the pertinent
ship, and production management, finding that erroneous workman- rework causes that may potentially pose safety risks.
ship, faulty design, and lack of coordination contribute the most to A list of the rework causes identified in this way is summarized
rework costs at 13.0%, 8.1%, and 7.28%, respectively. In Singapore, in Table 1, showing the most commonly cited rework causes to be
Hwang and Yang (2014) report rework arising from design-induced poor coordination, time constraints, and lack of experience and
changes, inadequate coordination between designers, and poor on- knowledge. Based on the list in Table 1, a second round of a de-
site management to be the primary reasons for schedule growth; tailed synthesis of safety research was then undertaken to establish
while in neighboring Malaysia, Yap et al. (2017) find the causes how much these rework causes also conjointly compromise safety
of rework in building projects to be mostly related to an adversarial performance (Table 2). This shows that construction safety risks are
working culture and technical ineptness in field construction meth- highly attributable to a lack of experience and knowledge, a lack of
ods. Love and Smith’s (2018) literature review also notes that hav- maintenances to equipment and tools, and unskilled worker and
ing to perform additional tasks (rework) decreases worker morale, lower-skilled labor, whereas poor coordination, time constraints,
increases workplace stress, and even causes absenteeism, which poor workload planning, high staff turnover rate, and poor infor-
ultimately lowers productivity. In this connection, Love et al.’s mation flow contributed the least.
(2018c) Australian study finds that the lack of motivation and
concentration during reworking increases the probability of human
errors. Research Design and Methodology
A cross-sectional survey design is adopted that supports the posi-
Accident Causation in Construction
tivist paradigm, using the deductive approach to observe phenom-
Poor site-safety management is one of the pressing construction ena empirically and then explain with a logical statistical analysis
industry problems in the developing world (Yap et al. 2019a). (Creswell 2014). In addition, questionnaire surveys are economical

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J. Constr. Eng. Manage., 2020, 146(9): 04020106


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Table 1. Summary of rework causes


Previous rework studies

© 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

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Note: x = causes considered.

J. Constr. Eng. Manage.


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Table 2. Summary of construction accidents causes


Previous safety studies

© 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

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14 Excessive overtime — x — — x — — — — — — — x — — — x 4
15 Poor information — x — — — — — — — — — — — — — — — 1
flow
16 Improper handling x — — — — — — — — — — — — — — x — 2
of machinery and
equipment
17 Lack of maintenance — — x x x x x x x — x — x — x x — 11
to equipment and
tools
18 Poor standard of x x — — — — — — — x x — — — x — x 6
machinery and
equipment
19 Improper planning — — — — x x x — — — — — — — — — — 3
of resources
20 Lack of event — — x — x x x — — — — — — x — — — 5
documentation

J. Constr. Eng. Manage.


and practical for a large sample (Ling and Khoo 2016). Moreover, Table 3. Demographic profile of respondents
such surveys have also been widely used to rank relevant variables Frequency Percentage
in construction management studies (e.g., Bagaya and Song 2016; Parameter Category (N ¼ 157) (%)
El-Razek et al. 2008; Ye et al. 2015).
Designation Owner 25 15.9
The survey data were analyzed using frequency, severity, and Consultant 18 11.5
importance indices, considering the views of owners, consultants, Contractor 114 72.6
and contractors. Agreement on the ranking of the importance of the
rework-safety causes between every two groups of parties was also Working 0–5 57 36.3
tested. An exploratory factor analysis was then applied to cluster experience 6–10 40 25.5
11–15 22 14.0
significantly correlated causes into much fewer underlying factors
>16 38 24.2
for appropriate interpretation.
Academic Postgraduate degree 25 15.9
qualification (Ph.D., master)
Questionnaire Design
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Bachelor’s degree 114 72.6


Diploma certificate 16 10.2
Following a comprehensive review of construction rework and High school 2 1.3
safety literature, the survey questionnaire was designed to contain
three parts. Part I required respondents to provide their background Type of project Buildings (residential, 100 63.7
information. In Parts II and III, respondents rated the 20 rework involved commercial, industrial)
causes identified in the literature according to their frequency of Civil and infrastructure 57 36.3
occurrence and level of severity in terms of safety incidents, respec-
tively. For each cause, the respondents were requested to answer,
according to their own experience, the question What is the fre- The frequency index (FI), which expresses the frequency of
quency of occurrence for these rework causes? on a five-point occurrence of causes inducing rework, is computed
Likert scale ranging from 1 (never) to 5 (always). Respondents were
also asked to indicate their answer to What is the degree of severity X
5
ai ni
of this rework cause on safety performance? on another five-point FI ¼ ð1Þ
1
5N
Likert scale from 1 (not severe) to 5 (extremely severe). These scales
are consistent with previous studies examining the criticality of
where a = weighting given to each response (ranging from 1 for
factors affecting construction performance (e.g., Bagaya and Song
never to 5 for always); n = frequency of responses; and N = total
2016; Yap et al. 2019a).
number of responses.
Next, the severity index (SI) asserts the severity of causes under-
Data Collection mining the safety performance as appraised by the respondents, and
is computed
The respondents are comprised of construction practitioners from
owner, consultant, and contractor organizations based in Malaysia. X
5
bi ni
This diversity of respondents was chosen to maximize the quality SI ¼ ð2Þ
1
5N
of information in which diverse perspectives in construction set-
tings are represented. The respondents were sampled using con- where b = weighting given to each response (ranging from 1 for not
venience and snowball techniques. A total of 440 e-survey forms severe to 5 for extremely severe); n = frequency of responses; and
were distributed by emails and the LinkedIn platform to ensure the N = total number of responses.
questionnaire reached a large number of organizations. Follow-up Finally, the importance index (IMP.I) of each cause was calcu-
reminders for nonrespondents were also issued to improve the re- lated as a function of both the frequency and severity indices
sponse rate. Over a period of 5 weeks, 157 (35.7%) valid responses
were received—a response rate above the 30% regarded as accept- IMP:I: ¼ F:I: × S:I: ð3Þ
able for a reliable statistical analysis (Ye et al. 2015) and above the
free parameter ratio needed to yield reliable solutions (Ye et al. The rationale for computing the importance index is that the
2015). criticality of a rework-safety cause is the resultant of the combined
Table 3 summarizes the respondents’ demographic profiles, with effect of the frequency of a cause-inducing rework and the severity
25 (15.9%) owners, 18 (11.5%) consultants, and 114 (72.6%) con- of a cause-undermining safety performance.
tractors. Nearly 40% had more than 10 years of working experience
in the construction industry, while the majority (88.5%) held a
Frequency of Causes Inducing Rework
bachelor’s, or higher, degree. Over 60% of the respondents were
involved in building-related projects as compared to civil and infra- Ranked in ascending order, Table 4 presents the frequency indices
structure works (36.3%). of the 20 causes and their rankings according to owners, consul-
tants, and contractors. Overall, FI ranges from 0.555 to 0.738. From
the owners’ perspective, the five most frequent causes were poor
Analysis and Ranking of Rework-Safety Causes coordination (FI ¼ 0.776), poor subcontractor management (FI ¼
0.760), insufficient communication (FI ¼ 0.728), improper super-
A Cronbach’s coefficient alpha value of 0.918 was obtained for vision and inspection (FI ¼ 0.728), and poor site management
both the frequency and severity measures, which is above the 0.70 (FI ¼ 0.728). The equivalent for consultants were poor site man-
needed to establish good internal consistency (Hair et al. 2010). agement (FI ¼ 0.789), poor coordination (FI ¼ 0.778), insufficient
The survey data were further processed using the following statis- communication (FI ¼ 0.733), lack of experience and knowledge
tical techniques and indices adapted from Bagaya and Song (2016) (FI ¼ 0.722), and poor workload planning (FI ¼ 0.711). For
and Yap et al. (2019a). contractors, it was insufficient communication (FI ¼ 0.732), poor

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Table 4. Frequency index and ranking for causes
Consultant Contractor
Overall (N ¼ 157) Owner (N ¼ 25) (N ¼ 25) (N ¼ 114)
Causes of reworks and construction accidents FI Rank FI Rank FI Rank FI Rank
Poor coordination 0.738 1 0.776 1 0.778 2 0.723 2
Insufficient communication 0.731 2 0.728 3 0.733 3 0.732 1
Poor subcontractor management 0.707 3 0.760 2 0.689 8 0.698 4
Improper supervision and inspection 0.704 4 0.728 3 0.689 8 0.702 3
Poor site management 0.697 5 0.728 3 0.789 1 0.675 5
Poor information flow 0.674 6 0.688 6 0.678 10 0.670 6
Lack of experience and knowledge 0.668 7 0.672 8 0.722 4 0.658 8
Unskilled worker and lower skilled labor 0.661 8 0.680 7 0.667 11 0.656 9
Time constraints 0.656 9 0.584 17 0.700 6 0.665 7
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Poor workload planning 0.652 10 0.624 14 0.711 5 0.649 11


Low education level of worker 0.651 11 0.664 9 0.633 13 0.651 10
Erroneous construction method and poor design of 0.645 12 0.664 9 0.700 6 0.632 13
the construction method statement
Improper planning of resources 0.641 13 0.656 11 0.633 13 0.639 12
Poor site and working condition 0.636 14 0.648 12 0.667 11 0.628 14
Lack of event documentation l,0.613 15 0.640 13 0.589 20 0.611 15
High staff turnover rate 0.600 16 0.584 17 0.633 13 0.598 16
Improper handling of machinery and equipment 0.594 17 0.608 15 0.611 16 0.591 17
Lack of maintenance to equipment and tools 0.580 18 0.608 15 0.600 17 0.570 19
Excessive overtime 0.577 19 0.528 20 0.600 17 0.584 18
Poor standard of machinery and equipment 0.555 20 0.568 19 0.600 17 0.546 20

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),

Table 5. Severity index and ranking for causes


Overall Consultant Contractor
(N ¼ 157) Owner (N ¼ 25) (N ¼ 25) (N ¼ 114)
Causes of reworks and construction accidents SI Rank SI Rank SI Rank SI Rank
Poor site and working condition 0.739 1 0.776 1 0.767 4 0.726 2
Improper handling of machinery and equipment 0.724 2 0.672 11 0.767 4 0.728 1
Insufficient communication 0.721 3 0.736 4 0.778 2 0.709 5
Lack of experience and knowledge 0.716 4 0.688 8 0.789 1 0.711 3
Improper supervision and inspection 0.715 5 0.720 6 0.733 8 0.711 3
Poor site management 0.708 6 0.760 3 0.778 2 0.686 9
Erroneous construction method and poor design of 0.707 7 0.768 2 0.733 8 0.689 8
the construction method statement
Lack of maintenance to equipment and tools 0.698 8 0.672 11 0.700 12 0.704 6
Poor standard of machinery and equipment 0.696 9 0.664 14 0.767 4 0.691 7
Unskilled worker and lower skilled labor 0.685 10 0.680 9 0.700 12 0.684 11
Poor subcontractor management 0.683 11 0.656 16 0.700 12 0.686 9
Poor coordination 0.680 12 0.728 5 0.733 8 0.661 17
Improper planning of resources 0.676 13 0.696 7 0.700 12 0.668 15
Poor information flow 0.675 14 0.672 11 0.767 4 0.670 13
Time constraints 0.673 15 0.624 17 0.689 16 0.681 12
Low education level of worker 0.671 16 0.664 14 0.711 11 0.667 16
Poor workload planning 0.662 17 0.608 18 0.689 16 0.670 13
Lack of event documentation 0.642 18 0.680 9 0.678 18 0.628 19
Excessive overtime 0.628 19 0.536 20 0.622 19 0.649 18
High staff turnover rate 0.594 20 0.584 19 0.589 20 0.596 20

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Table 6. Importance index and ranking for causes
Overall Consultant Contractor
(N ¼ 157) Owner (N ¼ 25) (N ¼ 25) (N ¼ 114)
Causes of reworks and construction accidents IMP.I Rank IMP.I Rank IMP.I Rank IMP.I Rank
Insufficient communication 0.528 1 0.536 3 0.571 2 0.519 1
Improper supervision and inspection 0.504 2 0.525 4 0.506 8 0.500 2
Poor coordination 0.502 3 0.565 1 0.571 2 0.478 4
Poor site management 0.494 4 0.554 2 0.614 1 0.464 6
Poor subcontractor management 0.483 5 0.499 7 0.483 10 0.479 3
Lack of experience and knowledge 0.479 6 0.463 8 0.570 4 0.468 5
Poor site and working condition 0.471 7 0.503 6 0.512 7 0.456 7
Erroneous construction method and poor design of 0.457 8 0.510 5 0.514 6 0.436 11
the construction method statement
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Poor information flow 0.455 9 0.463 8 0.521 5 0.449 9


Unskilled worker and lower skilled labor 0.453 10 0.463 8 0.467 13 0.449 9
Time constraints 0.442 11 0.365 18 0.483 10 0.453 8
Low education level of worker 0.437 12 0.441 12 0.451 15 0.435 12
Improper planning of resources 0.434 13 0.457 11 0.444 16 0.427 15
Poor workload planning 0.432 14 0.380 16 0.490 9 0.435 12
Improper handling of machinery and equipment 0.431 15 0.409 14 0.469 12 0.431 14
Lack of maintenance to equipment and tools 0.405 16 0.409 14 0.420 17 0.402 16
Lack of event documentation 0.394 17 0.436 13 0.400 18 0.384 17
Poor standard of machinery and equipment 0.387 18 0.378 17 0.461 14 0.378 19
Excessive overtime 0.363 19 0.284 20 0.374 19 0.380 18
High staff turnover rate 0.357 20 0.342 19 0.373 20 0.357 20

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

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errors connected to rapid momentary decisions and actions and are management studies to capture the multivariate relationships ex-
the leading causes of construction accidents (Menches and Chen isting between variables and to investigate the cluster of relation-
2013; Perlman et al. 2014). ships involved (e.g. Kim and Nguyen 2018; Yap and Lee 2019;
Poor site management is ranked in fourth place (IMP:I ¼ Ye et al. 2015).
0.494). The effect of this on rework and safety performance is evi- The Kaiser-Meyer-Olkin (KMO) measure of sampling ade-
dent (Mohammadi et al. 2018; Ye et al. 2015). The predicaments quacy for the 20 variables is 0.873, which passes the suggested
relating to poor site management are the following: errors during threshold of 0.50 (Hair et al. 2010) and indicates that the hypoth-
setting-out the building plan on ground; attrition and reallocation of esized variables in the questionnaire have enough factors in
personnel to other projects; failure to provide adequate protection common to allow a factor analysis (Zhao et al. 2018). Bartlett’s test
for materials and completed works; limited or no supervision; of sphericity is 1612.140 (p ¼ 0.000), indicating the presence of
and damage due to carelessness, lack of skills, and poor materials correlations between variables and that the overall correlation ma-
handling and storage (Hwang and Yang 2014; Love et al. 2004). trix is thus not an identity matrix (Zhao et al. 2018). These tests
Reckless operations create a turbulent and unsafe working en- affirm that a factor analysis is appropriate for factor extraction.
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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.

Factor 2: Poor Project Management Practice


Table 7. Spearman’s rank correlation for causes This factor accounts for the second-largest variation of 15.38% and
FI SI IMP.I contains five causes that explain the criticality of paying sufficient
Respondent groups rs p rs p rs p
attention to the planning, monitoring, and control of work. The fac-
tor is created by poor subcontractor management, insufficient com-
Owner—consultant 0.677 0.01 0.656 0.01 0.792 0.01 munication, improper supervision and inspection, poor workload
Owner—contractor 0.866 0.01 0.469 0.05 0.806 0.01 planning, and poor information flow, with factor loadings ranging
Consultant—contractor 0.811 0.01 0.716 0.01 0.829 0.01
from 0.596 to 0.721. Poor integration and the lack of timely and

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Table 8. Factor profile
Factor Variance Cronbach
Details of the factors and causes loading explained (%) α
Factor 1: Substandard management of equipment and machinery — 17.026 0.875
Lack of maintenance to equipment and tools 0.803 — —
Poor standard of machinery and equipment 0.764 — —
Lack of event documentation 0.705 — —
Improper handling of machinery and equipment 0.702 — —
Improper planning of resources 0.628 — —
Factor 2: Poor project management practice — 15.376 0.809
Poor subcontractor management 0.721 — —
Insufficient communication 0.685 — —
Improper supervision and inspection 0.636 — —
Poor workload planning 0.619 — —
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Poor information flow 0.596 — —


Factor 3: Inherent dangerous, dirty, and difficult (3D) characteristics — 13.075 0.796
Poor site and working condition 0.767 — —
Poor site management 0.752 — —
Poor coordination 0.673 — —
Erroneous construction method and poor design of the construction method statement 0.672 — —
Factor 4: Improper production planning and work pressure — 11.863 0.799
High staff turnover rate 0.805 — —
Excessive overtime 0.778 — —
Time constraints 0.751 — —
Factor 5: Inadequate personnel competency and knowledge — 10.706 0.846
Low education level of worker 0.829 — —
Unskilled worker and lower skilled labor 0.772 — —
Lack of experience and knowledge 0.637 — —
Cumulative variance explained — 68.046 0.918
Kaiser-Meyer-Olkin measure of sampling adequacy 0.873 — —
Bartlett’s test of sphericity Approx. χ2 1,612.140 — —
df 190 — —
Sig. 0.000 — —
Note: Only loadings of 0.5 or above are shown. Extraction method = principal component analysis; rotation method = varimax with Kaiser normalization.
Rotation converged in 8 iterations.

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).

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Table 9. Comparison with previous studies
Current study
F1: Substandard F2: Poor F4: Improper F5: Inadequate
management of project F3: production personnel
Research equipment and management Inherent 3D planning and competency
domain Country Author machinery practice characteristic work pressure and knowledge
Rework Malaysia (Yap et al. 2017) x x x — —
Rework China (Ye et al. 2015) x — x — —
Rework Sweden (Josephson et al. 2002) x x — — —
Rework Canada (Fayek et al. 2004) x x — — x
Rework Hong Kong (Palaneeswaran et al. 2008) — x x x x
Rework Nigeria (Oyewobi et al. 2016) — x x x x
Rework Nigeria (Eze and Idiake 2018) — x x x x
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Rework Palestine (Enshassi et al. 2017) — x — x x


Rework Australia (Love et al. 2002) x x x — x
Rework Australia (Love et al. 2009) — x x x —
Subtotal for rework domain 5 9 7 5 6
Safety Middle East (Mohammadi et al. 2018) x — x x x
Safety China (Li et al. 2018) — — x x x
Safety China (Tam et al. 2004) x — — x x
Safety China (Zhao et al. 2018) — — — — x
Safety Thailand (Aksorn and Hadikusumo 2008) — x — — —
Safety Spain (Carrillo-Castrillo et al. 2017) — — x — —
Safety Korea (Lee and Lim 2017) x x x — x
Subtotal for safety domain 3 2 4 3 5
Overall 8 11 11 8 11
Note: x = considered by researcher.

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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J. Constr. Eng. Manage., 2020, 146(9): 04020106


remain a known-unknown. The study’s assessment of how rework performance of the construction industry in developing countries
causes can adversely influence safety performance is new to con- such as Malaysia and beyond.
struction production planning and control.
Following a two-stage literature review, 20 pertinent rework-
safety causes were identified, which were then used to develop the Data Availability Statement
survey questionnaire as the data collection instrument to discover
the frequency and severity of each cause. The importance index, All data generated or analyzed during the study are included in
which is calculated as the product of both frequency and severity the published paper. Information about the Journal’s data-sharing
indices, is then used to rank the causes according to the cognizance policy can be found at http://ascelibrary.org/doi/10.1061/(ASCE)
of owners, consultants, and contractors. In the overall context, the CO.1943-7862.0001263.
study reveals the five most influential rework-safety causes to be
insufficient communication, improper supervision and inspection,
poor coordination, poor site management, and poor subcontractor Acknowledgments
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management. Spearman rank-order correlation tests affirm the re-


spondent groups’ homogeneity of the ranking of the causes and This work was supported by the Universiti Tunku Abdul Rahman
further corroborate the relevance of these causes between construc- Research Fund (UTARRF) (Project No. IPSR/RMC/UTARRF/
tion professionals from disparate project backgrounds. 2019-C2/J01).
Next, an exploratory factor analysis is used to reduce the sur-
veyed rework-safety causes to a factor structure consisting of the
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