Evaluating the impact of safety interventions on risk prioritization in steel construction projects using Failure Mode and Effects Analysis (FMEA)

Laal  F; Zare  MJ; Fallah  R; Fallah Madvari  A

doi:10.18502/tkj.v17i4.20930

Laal F Social Determinants of Health Research Center, Department of Occupational Health Engineering, School of Health, Birjand University of Medical Sciences, Birjand, Iran
Zare MJ Department of Occupational Health Engineering, School of Health, Shahid Sadoughi University of Medical Sciences, Yazd, Iran
Fallah R Department of Occupational Health Engineering, School of Health, Shahid Sadoughi University of Medical Sciences, Yazd, Iran
Fallah Madvari A Department of Occupational Health Engineering, School of Health, Shahid Sadoughi University of Medical Sciences, Yazd, Iran

DOI: https://doi.org/10.18502/tkj.v17i4.20930

Keywords: Risk assessment, Failure Mode and Effects Analysis, Risk Priority Number, Steel industry, Safety

Abstract

Introduction: Steel construction projects are characterized by the highest level of safety risks due to the complexity of activities, use of heavy equipment, and the simultaneous occurrence of high-risk operations. Effective management of these risks requires systematic methods for identifying, assessing, and prioritizing hazards, as well as evaluating the impact of control measures. The purpose of this study was to evaluate the impact of safety interventions on risk prioritization in a steel construction project using Failure Mode and Effects Analysis (FMEA).

Materials and Methods: This research was an applied, interventional study with a quasi-experimental design conducted on one of the steel construction project. At the beginning of the main project activities, potential hazards associated with each activity were identified. Subsequently, the failure modes, their causes, and consequences were analyzed using the standard FMEA worksheet. The severity of consequences, probability of occurrence, and detectability indices for each hazard were scored, and the Risk Priority Number (RPN) was calculated. After that, targeted safety interventions, including training, engineering controls, administrative measures, and the use of personal protective equipment, were then implemented and evaluated. The risk assessment was repeated using the same method.

Results: A total of 54 occupational hazards were identified across six main construction activities. Before the intervention, hazards related to working at height and load-handling operations had the highest RPN values. After the implementation of safety interventions, a significant reduction in RPN values was observed for most hazards, particularly those related to falls from height and the collapse of work platforms. However, risks arising from work at height remained among the top safety priorities.

Conclusion: The results indicate that the FMEA method is a suitable tool for prioritizing risks and evaluating the effectiveness of safety interventions in steel construction projects and can provide management with guidance to improve decision-making and allocate safety resources.