Ergonomic Risk Assessment in Immersive Virtual Reality-Based Modular Construction Training: A Preventive Approach for Onsite Assembly Safety

Introduction: Modular construction (MC) onsite assembly exposes workers to ergonomic risks from awkward postures, repetitive movements, crane-assisted operations, and elevated viewing positions. Traditional safety training offers limited opportunities to recognise such hazards before exposure. Although immersive virtual reality (VR) has shown potential for construction safety training, limited research has examined ergonomic exposure during VR-based MC assembly. This study assesses participants’ ergonomic exposure and postural responses during immersive VR-based modular construction scenarios.

Methods: An immersive VR platform comprising four training scenarios (TSs) and four assessment scenarios (ASs) was developed to simulate ergonomic risks during modular assembly. An experimental study involving 22 architecture and construction-related postgraduate participants was conducted. Ergonomic exposure was evaluated using Rapid Upper Limb Assessment (RULA) and Rapid Entire Body Assessment (REBA) based on postures captured during VR sessions. Usability and cognitive workload were assessed to examine the practicality of VR for ergonomic awareness training.

Results: Participants experienced low to moderate ergonomic risks, with RULA scores ranging from 3 to 4. However, crane-related scenarios TS-2 and TS-3 resulted in 37% and 32% of participants, respectively, experiencing medium-to-high risks (RULA 5-6). Similarly, 27% and 23% demonstrated medium-to-high risks in AS-2 and AS-3. REBA findings indicated moderate ergonomic exposure, particularly during tasks requiring trunk, neck, and leg movements. Exposure durations remained below two minutes per scenario. Participants reported high usability and manageable cognitive workload.

Conclusions: Immersive VR provides a controlled environment for identifying and visualising ergonomic exposure during modular construction assembly. The findings indicate potential for supporting ergonomic awareness and preventive safety training before field exposure. However, the small postgraduate sample and absence of a control group or pre-/post-training assessment mean the results cannot establish whether VR improves posture or reduces ergonomic risk onsite. Future studies should involve construction workers, larger samples, comparative designs, and assessment of skill transfer.