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Engineering, Construction and Architectural Management 2002 9 1, 53±61

The pathology of building defects; a human error approach


ANDREW R. ATKINSON
Faculty of the Built Environment, South Bank University, 202 Wandsworth Road, London SW8 2JZ, UK

Abstract Research driven by major industrial and managerial errors are often hidden behind more obvious
transportation incidents is increasingly emphasizing the operative errors, leading to incorrect attributions and
role of managers and systems factors in errors. This is ineffective remedial action. The study also supports a
re¯ected in recent reports and legislation which place conceptual model of the nature of errors in construction
emphasis on managerial actions. This paper reports projects, which makes explicit the in¯uence of manage-
research developing a human error perspective, but ment on the generation of defects and the need to treat
applying it to lesser failures in the form of construction organizations as a whole in considering the reasons for
defects. An observational study of a 61 unit housing site failure.
con®rms ®ndings from earlier studies, that managerial Keywords defects, error, management, participant
factors are important in the occurrence of defects, but observation, systems
also that factors can be linked in a `causal chain'. Latent

managers including the client, designer, principal


INTRODUCTION
contractor and other contractors to ensure that organi-
A number of major transportation accidents in recent zations involved adopt safe systems of working.
years, culminating in the Southall and Paddington rail Incorporation of CDM requirements into contract
disasters of 1997 and 1999, has focused attention on documents further strengthens the managerial role by
human errors. Yet of®cial reports of major incidents making breach of the statutory duty also a breach of
have become increasingly unwilling to attribute blame contract.
solely to the most obvious individual involved, whether In fact, the movement towards recognizing the role of
driver, pilot or helmsman. Instead, the importance of managers in human error has been developing for some
managers is being increasingly emphasized and the considerable time. The Health and Safety at Work Act
organizations providing transportation services are of 1973 (HSE, 1973) imposes duties on managers with
being increasingly seen as systems, where the `front respect to promoting safety and safe systems of working
line' crews are merely the most visible parts of large and several authors, particularly with backgrounds in
co-operative efforts involving several separate compo- psychology or sociology (Turner, 1978; Rasmussen,
nents. Recognition of the role of managers has resulted 1983; Lourens, 1990; Reason, 1990; Perrow, 1984)
in the UK in proposals for an offence of Corporate have been emphasizing that human errors at the `work
Manslaughter and moves to further strengthen the face' are often inevitable and should be managed.
powers of the Courts to prosecute individual senior Reason (1990) proposed a `resident pathogen meta-
managers. Current of®cial thinking in the UK had been phor' in order to illustrate the role of managers, where
succinctly summarized as long ago as 1986 by Lord poor managerial controls have the effect of predisposing
Justice Sheen in commenting on the role of senior a system to failure. It then only requires a small error by
managers in the report of the Herald of Free Enterprise a front-line worker to precipitate a major incident.
disaster (Department of Transport, 1987): Thus, Reason divides errors into active and latent, active
errors precipitating the incident and latent errors being
the underlying, or cardinal faults lay higher up the
the underlying managerial failing. This division of
company ¼. from top to bottom the body corporate
causes into active/latent, operative/managerial or pri-
was infected with the disease of sloppiness.
mary/secondary is echoed widely in other literature on
More relevant to the construction industry is the enact- human factors (Fortune, 1984; Kletz, 1985; Petroski,
ment of the Construction Design and Management 1985, 1994; Eldukair & Ayyub, 1991; Blockley, 1992;
Regulations (HMSO, 1994), which imposes duties on Embrey, 1992; Whittington et al., 1992, Fortune &

53
ã 2002 Blackwell Science Ltd
54 Atkinson, A. R.

Peters, 1995), with some authors proposing more


complex models of human error based on the proximity
or remoteness of the cause from the outcome.
The unifying feature of the literature is that it relates to
fairly large scale disasters and accidents usually involving
death. The primary concern of the authors is public
safety, or the safety of industrial workers. Yet interesting
parallels are made in some literature between safety and
quality (Whiston & Eddeshaw, 1989; Harrison, 1992;
Whittington et al., 1992; ACSNI, 1993; Oakland,
1998). This suggests that much can be learned from
recent thinking on human error about the performance
Figure 1 Model of the nature of error in projects.
of tasks with less dramatic outcomes. Nonetheless, the
construction industry generally has been slow to expli-
citly recognize the importance of human factors in the The model is constructed as a series of concentric
generation of defects. In a construction industry context, rings and shows errors with most immediate effect at
the `pathology of defects' is normally taken to mean the the centre and more remote factors towards the edge.
underlying technical cause and not the sequence of events Thus, Primary errors are those committed `at the work-
leading to an error being committed. This is re¯ected in face', often, but not exclusively, by manual operatives.
a literature on defects obsessed with the details of Of more remote, but wider effect are errors committed
`correct' technology (Department of the Environment, at the project level, classed in the model as `manager-
1989; BRE, 1991; HAPM, 1991), although that tech- ial'. The literature suggests ®ve categories of manager-
nology is hardly novel. In other words, the industry has ial error related to checking work, division of
been slow to recognize that the problem with defects is responsibilities, control of change, control of concurrent
not so much a matter of not knowing what to do, but working and communications. `Global' factors in¯uence
applying correctly what is known (Kletz, 1985; Bea, the project environment yet more generally and
1994). There have been some intermittent attempts to include both factors operating within an organization
examine the error related causes of defects, for example, (described in the model as global/organizational ) and
by the UK Building Research Establishment (Bentley, wider economic, time, political and societal pressures
1981; Bonshor & Harrison, 1982; Harrison, 1993), but (described in the model as global/environmental). For
these appear to be unable to get beyond apportioning some global categories, for example, time, classi®cation
errors between `site' and `design', and do not clearly between `organizational' and `environmental' is dif®-
indicate how or why they occur. cult. Time pressures might be imposed externally, by
clients, or internally by senior managers for corporate
reasons. For this reason, categorization at this level
A HUMAN ERROR PERSPECTIVE
should be treated as tentative and variable. Not
The research reported in this paper is the ®nal of a speci®cally illustrated by the model are the linkages
series of investigative studies which build on recent between categories. For example, errors occurring in
theories of human error. The studies combine quan- one category are in¯uenced by other pressures else-
titative and qualitative methodologies, progressively where in the `project system'. It is these linkages,
narrowing the focus of investigation from a general which are more dif®cult to detect with the commonly
survey of participants in the construction industry, used research techniques of statistical analysis and
through a statistical study of several construction pro- formal interviews, that are focused on in the observa-
jects and an interview study of managers in the indus- tional study reported below.
try to the current study ± a participant observation The model adopted a similar structure to several
study of one construction site. Taking as a starting developed in the literature. For example, Embrey
point literature drawn from three major perspectives, (1992) categorized accident causation in process
technological (Petroski, 1985, 1994; Kaminetzky, 1991), industries into three `levels', actual errors, error inducing
social science (Perrow, 1984; Reason, 1990; Roberts, factors and higher level policy factors and Whittington
1993) and management (Embrey, 1992; ACSNI, 1993; et al. (1992) postulated a hierarchical model for
Morris, 1994), a tentative conceptual model of how construction accidents, which operated on four levels,
the error process might operate in complex project that of the individual, site management, project manage-
systems was constructed and is illustrated in Fig. 1. ment and company policy. However, these models were

ã 2002 Blackwell Science Ltd, Engineering, Construction and Architectural Management 9 1, 53±61
The pathology of building defects 55

largely drawn from literature, without further empirical 220 error `instances' were examined and communications
investigation. The current research sought to empiric- problems again overwhelmingly predominated. These
ally investigate three properties of the model illustrated were again mainly centred on formal communications,
in Fig. 1, its form, content and operation. such as poorly communicated speci®cations, drawings
and written instructions. Analysing the accounts of the
causes of defects revealed links between factors in the
PREVIOUS WORK
model in the form of interactions. These were classi®ed
An initial general survey (reported in detail in Atkinson, in three categories, simple self contained errors, two-way
1998) was directed towards examining the form and interactions and complex interactions. Two-way interac-
content of the model. It consisted of a survey of tions involved two factors, often a combination of poor
approximately 100 construction industry practitioners. operative work and poor supervision. For complex
Survey respondents were presented with a question- interactions, a further two pathologies were identi®ed.
naire asking them to rate factors in the model and to First, some errors were initiated at a point in the
supply further factors they considered important. construction chain and `carried through' the construc-
Communications was the highest rated factor, followed tion process and/or replicated elsewhere because of
by time pressures, avoiding concurrency controlling poor communications and supervision. Secondly, some
changes and education and training. Lower rated factors systemic multiple errors were `driven from the top' by
were those relating to political, economic and societal wider corporate considerations, such as meeting year
pressures. The three-level form of the model was end accounting periods. These were not really `errors'
examined by using factor analysis. Although the `®t' at all, but deliberate actions to achieve goals not related
was not perfect, the results showed a fairly clear split to defects.
between factors, such as economic, societal and poli-
tical pressures `outside' the control of project partici-
THE OBSERVATIONAL STUDY
pants and factors `within' their control.
A follow-up statistical study, reported in Atkinson The observational study allowed direct examination
(1999), was also directed towards the content of the of the incubation of potential building defects. It
model. It investigated whether there was any statisti- involved participant observation, by the author, of one
cally signi®cant relationship between variables repre- construction site for a short period of time. The site
senting factors in the model and the level of defects in chosen was one of the housing sites which formed part
23 speculatively built housing projects in the South- of the earlier statistical study. The time point chosen
east and Midlands regions of the UK. In addition to for the study within the life cycle of the project was
the factors directly included in the model, the in¯uence when most construction activities were taking place
of primary factors, but at the ®rst key level of (from excavating foundations to completing buildings)
management (the site manager) were represented by and one of the advantages of traditional two of three
adding variables representing the experience, background storey housing is that it is common for all phases to be
and quali®cations of the manager. Signi®cant results under construction at the same time. The time scale
were concentrated on tangible managerial factors chosen for the study was 1 week. This was considered
including the level and quality of formal communica- to be the minimum time for a cross-section of events
tions. However, signi®cant associations were also to be evidenced suf®ciently to compliment other parts
revealed between primary factors at a managerial level of the research. It was considered that signi®cant
and defects. A particularly interesting ®nding was an events related to incipient and actual errors on the
`inverse' association between the experience of the site project would be visible from the vantage point of the
manager and the level of defects, with less experienced site and the site of®ce for this type of construction.
managers performing better. A further statistical test Problems arising on site were likely to be reported
revealed that inexperienced managers are also better regularly to the site of®ce as managerial control was
quali®ed, suggesting that quali®cations more than centralized there. The site consisted of 61 two, four
make up for lack of experience. and ®ve bedroom terraced and detached houses
In order to investigate how an error at a managerial marketed towards both the `®rst-time buyer' and
level might in¯uence errors at the work-face the statis- `executive' markets. Traditional construction was
tical study was followed by interviews. A total of 40 used with brick/block walls, interlocking concrete
managers in the house-building industry were inter- tiled roofs, timber windows and timber ¯oor and
viewed and the notes from the interviews were subjec- roof construction. The researcher attempted to integ-
ted to content analysis (Crano & Brewer, 1973). In total rate into the operations of the site by volunteering to

ã 2002 Blackwell Science Ltd, Engineering, Construction and Architectural Management 9 1, 53±61
56 Atkinson, A. R.

carry out tasks required by the site managers through-


out the week. In particular, he volunteered to answer
the telephone, because the site telephone was thought
likely to be the hub of communication activities.
Integration was fairly successful in that, during the
study period, the researcher was given several clerical
tasks and asked to assist in solving several site-based
problems in relation to changes in construction details.
Nevertheless, the effect of the observer on the study
cannot be discounted. In dealing with this effect, one
of the strengths of the overall research programme is
that any distortion caused by the presence of the
observer for this study is reduced when ®ndings from
all studies are combined. A process of `triangulation'
can be used to improve con®dence in the overall Figure 2 Record of error instances.
conclusions from the programme.
Data were recorded by writing timed entries in a
Instances of error
rough note book during, or as soon as possible after, the
occurrence of an event, following a standard methodo- Direct observation and discussions on the site were
logy for diary studies (Coolican, 1994). All events were transferred to a formal transcript at the end of the
reviewed at the end of each day and contemporary study. This included an analysis of the cause(s) of the
notes were added. The entries and commentary were incident recorded, contemporary comment and com-
then transcribed for later analysis. ment added on completion of the study. Following the
Although not the primary purpose of the study, a categorization adopted in the model, incidents of errors
numerical analysis of the source of errors was under- were extracted and examples in the form of short
taken to see if the results con®rmed earlier work. vignettes are given below:
Following Bentley (1981) the text of the diary was
analysed into a number of `error related events'. Such
Primary errors
events were problems reported and discussed in the site
of®ce, instances of actual errors occurring on the site, Relatively few recorded instances related to primary
or tactics used to avoid errors occurring. Coding of factors, but of those that did occur, a prominent
instances to particular factors in the model was then example was a violation by operatives placing concrete
carried out and are shown in Table 1 and Fig. 2. foundations to a series of houses. This was witnessed
Managerial factors predominated in the occurrence of by a building inspector from a building guarantee
defects, followed by global factors and lastly primary. insurance company, who was on the site at the time.
The importance of managerial factors resonates strongly He observed one operative adding water to the concrete
with the earlier studies. as it was unloaded from the mixing lorry, an action
carried out to improve the `¯ow' and hence the
workability of the concrete, but an action which would
Table 1 Record of error instances. also reduce its strength. The inspector refused to
approve the concrete without further evidence (provi-
Factor in the model Recorded instance ded later) that the strength of the concrete was
Primary 8 adequate. Closer supervision might have reduced the
Managerial scope for this violation, but as it was clearly a deliberate
Checking 5 act, it would be dif®cult to stop unless supervision was
Communications 22 continuous or unless other action were taken such as a
Concurrency 3
bonus or training scheme emphasizing the importance
Changes 12
Responsibility division 1 of proper procedures.
GLOBAL ± Organizational 6 Other instances could not be clearly attributed to
GLOBAL ± Environmental primary error. For example, one decorator was accused
Time 2 of applying the wrong wallpaper to the wrong rooms in
Cost 13
a show-house. This could have been a primary error by
Societal 6
an operative, but could equally have been an error in

ã 2002 Blackwell Science Ltd, Engineering, Construction and Architectural Management 9 1, 53±61
The pathology of building defects 57

communications if clear drawings or instructions had were physically located separately from the regional
not been given. As communications in this case were company of®ce, thus lengthening communication
verbal, it was almost impossible to prove whether chains. Hence, there was a delay in authorization. To
instructions had, in fact, been given. keep to time, operatives were required to instal perma-
In a further instance, the `real' cause of an error may nent plumbing and cabling without the opportunity for
have been masked by a primary error, thus also making tests prior to these being covered by subsequent work.
accurate attribution dif®cult. This instance was that of Although not necessarily causing defects, the inability
a carpenter cutting ¯oor timbers to an incorrect size. to test installations would certainly pre-dispose them to
Alterations to one unit (plot 34) on the site induced by failure ± an illustration of the operation of Reason's
bespoke changes made for a purchaser had increased (1990) resident pathogen metaphor.
the span of the ¯oor timbers. Consequently, the Other communications problems included numerous
carpenter used timbers destined for another unit. errors in speci®cations, schedules and drawings and
Only after he had cut these to the correct length did lack of, or poor, communication of information. In one
the carpenter realize that the depth of the timbers was instance, the layout on the foundation drawings did not
insuf®cient and would then have to be discarded. In match that on the superstructure drawings and work on
this instance, not only was the underlying cause of the the superstructures had actually commenced. A con-
carpenter's error an uncontrolled change, but behind siderable amount of masonry had to be re-built to
the change was economic forces and societal demands, correct this error.
which required the organization to allow purchaser Change was also regularly implicated as a cause of
customization. potential and actual errors. One of the most prominent
An examination of the external building inspector's agents inducing change was the facility (mentioned
site ®le revealed similar ambiguities. Most defects above) for the house purchaser to make adaptations to
reported in this ®le were related to what were ostensibly their prospective purchase. This was not well controlled
minor workmanship errors ± for example, poor bonding and in some instances purchasers were allowed to make
of brick to block walls, concrete ®lling to cavity walls in changes after work had started, leading to the need to
foundations being incorrectly placed and insuf®cient dismantle work. One small example of this was where a
allowance in external brickwork for weep-holes over purchaser asked for a smaller external door in a unit,
openings and ventilators below ¯oors. However, it is but the operatives were not informed of this. The
not at all clear how much knowledge of construction opening had to be reduced in size after it had already
technology was expected from the operatives con- been formed. In the incident reported above concern-
cerned. With high expectations, the errors are primary ing a carpenter's error, the house purchaser had asked
in nature and should be attributed to the operative. for a wall to be moved, but little consideration had been
However, modern industry often cannot have such high given to the consequences of this request.
expectations of its workforce and the need and nature Problems of concurrency were noted, but generally
of construction details must be clearly communicated to as a consequence of other failings. For example,
the operative and checked for inclusion. Thus, errors problems related to the installation of electrical and
can be classi®ed as primary or managerial depending on water mains caused by cost factors were leading to the
the expectations of the organization ± expectations concurrent installation of electrical and plumbing
which were, on this site, not made clear. services with the installation of the mains, rather than
the sequential installation of mains followed by services.

Managerial errors
Global errors
Instances related to problems with formal and informal
communications were common during the study. One Instances related to organizational culture featured
example related to the circuitous routing of payment on several occasions during the study. In meetings
cheques at company level. The site manager had between site sales and construction staff, a cultural `gap'
continually requested that the electricity and water between site and head of®ce personnel was apparent. A
companies be paid, so that supplies could be laid on for con¯ict of cultures was illustrated by the differing
both temporary use by the workforce and for the orientations of top management and construction man-
permanent installation. However, large cheques, such gers over the organization of and payment for services
as the ones involved in this incident, were deliberately installations mentioned above. A further example of a
routed through senior company management in order to cultural `gap' was related to the need to re-site the
give centralized ®nancial control. Senior management temporary site of®ce and sales cabin to allow the

ã 2002 Blackwell Science Ltd, Engineering, Construction and Architectural Management 9 1, 53±61
58 Atkinson, A. R.

construction of one of the houses. The site manager was


Causal paths
trying to gain authorization for a large crane to carry out
this manoeuvre, as this would be both more convenient The causal path of errors can be traced with the
and safer. However, the company commercial manager example related to the facility for prospective purchasers
was refusing on cost grounds. This incident illustrated a to have adaptations carried out to their houses. This led
common con¯ict between operational and ®nancial to a number of problems based on the fact that the
considerations, which impact on both quality and safety. manager agreeing to the changes was not competent to
Global factors of cost time and societal demands were assess technical feasibility. For example, agreements to
seen by site personnel as being behind many of the move the position of walls led to upper ¯oor timbers
problems experienced with the project. This was being over-spanned, thus pre-disposing the ¯oor to
particularly the case with the facility for purchasers to collapse. Similarly changing an internal garage to a
order changes to their houses. Here the site managers habitable room induced problems with town and
saw problems of a `tight' economic climate leading to country planning approvals. The facility for purchasers
purchasers demanding more in the way of changes, but to make very late changes to their houses was driven by
the company failing to respond adequately. Similarly, slow sales caused by a poor economic climate. The
tight costs, driven by economic pressures were perceived `causal path' of error in¯uences is traceable from
to underlie the lack of services installations. Non- economic in¯uences to increased societal demands to
payment of the bill for the electrical main was linked changes inducing concurrent working and thence primary
to ®nancial year-end cash ¯ow requirements, in turn errors.
driven by an external threat of corporate take-over.
Hidden or latent characteristics
ERROR PATHOLOGY AS A `SYSTEM'
The facility of purchasers to change details of house
Instances arising from the observational study, inclu- layouts also illustrates the latent nature of some errors.
ding those chronicled above, illustrate the `systemic' In the incident of the carpenter cutting up the wrong
nature of error in¯uences where one cause of error ¯oor timbers, the pathology of this error started with a
might be linked to others and thus in¯uence the change requested by a purchaser which had the effect of
eventual outcome. Three attributes of this `systems' lengthening the span of ¯oor timbers. Had the carpen-
effect were noted, multiple causes of error, causal paths ter used the timbers, the `error' would have appeared
and hidden or latent characteristics. later as his alone although it had more to do with an
insuf®ciently controlled change at the managerial level.
In the event, it is notable that the operative effectively
Multiple causes and consequences of error
spotted and corrected the mistake. This illustrates
An example of multiple causes/consequences of error another characteristic of latent errors ± they are often
was related to the problem with the supply of services capable of correction by the operatives carrying out
to the site mentioned above. At the time of the work.
study, neither an electrical nor a water supply had
been provided and the lack of an electrical supply
CONCLUSIONS
pre-disposed construction to errors (electrical instal-
lations could not be tested, houses could not be han- The observational study supports earlier ®ndings in
ded over to purchasers and electricity was required the research programme. By triangulating between
for may of the internal activities in ®nishing the studies, some clear conclusions can be drawn. The
houses). The lack of supply was caused by at least importance of managerial errors, and those in partic-
three factors: ular related to communications, is con®rmed. In itself,
this ®nding appears unremarkable, but communication
· Failure of the company to pay the electricity board
failures speci®cally noted in the observational study
for the supply (in turn caused by long communi-
and earlier studies often pointed to poor formal
cation lines and the need to conserve cash at the
communications. Poor formal communications did
company's accounting year-end).
not solely concern errors in documents, but also
· Failure to agree with the position of an electrical
concerned the transfer and use of information. The
sub-station with house-builders on adjoining sites.
problem was not, therefore, simply one of mistakes in
· Failure to organize town planning approval for the
design or speci®cation. Traditionally, house-building
same sub-station.
in the UK has operated with a minimum of formal

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The pathology of building defects 59

communications and reliance has been placed on the Fig. 1 does not illustrate linkages and an alternative
skills of both operatives and site management. The conceptualization is given in Fig. 3 below. This illus-
®nding that poor formal communications are to blame trates how errors have been seen to develop in the
for many errors potentially leading to defects suggests study into actual or potential defects. Often driven by
that this traditional reliance might now be outdated. global pressures, unrelated to the project, managerial
The combination of a more complex technology, even errors either combine with or supplement operative
for traditionally built housing, and a workforce with errors to cause defects. The ®gure shows how errors
very basic construction technology skills suggests that by managers may be `modulated' by the actions of the
greater effort should be made to provide and commu- operative and the unwanted outcome may be avoided.
nicate documentation. The balance mentioned above, The ®gure also shows that errors can arise at all levels
between the internalized knowledge of the operative of the model.
and that expressly provided by way of drawings and The consequence of accepting the ®ndings from this
details, should be re-examined. Even the act of provi- study is that in both analysing the cause of events
ding and communicating better constructional details (whether defects, failures or major accidents)
illustrates the complex interaction of factors leading to and in proposing avoiding action, the organization
errors. In the short term, more comprehensive docu- (whether a project, or an incorporation) has to be
mentation has a negative cost and time implication treated as a whole. This conclusion resonates remark-
and this might be resisted by managers with other ably with the teachings on quality management of W
corporate objectives. Edwards Deming nearly half a century ago (Tenner &
The observational study also illustrates links between DeToro, 1992). Deming made the distinction between
factors at different levels in the model. Complex special causes of failure, assignable to operators, and
interactions identi®ed in the earlier interview study common causes, the responsibility of managers.
are con®rmed, in particular the fact that underlying Deming stressed that common causes predominate,
errors are often disguised by subsequent primary errors that it is the system of work that determines how work
committed by work-face operatives. The operative can is performed and only senior managers can create
also act as a `modulating' in¯uence, correcting errors the system. Arriving at the same conclusion from the
committed by managers. The model conceptualized in starting point of human error indicates that the

Figure 3 The pathology of error in projects.

ã 2002 Blackwell Science Ltd, Engineering, Construction and Architectural Management 9 1, 53±61
60 Atkinson, A. R.

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