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Purpose

Construction workers process complex information, make decisions and coordinate tasks under deadlines. These cognitive demands can overwhelm workers, leading to errors and inefficiencies. While task complexity (TC) influences construction performance, prior research lacks a structured approach to assessing and managing cognitive load. This study introduces a scalable framework integrating cognitive load theory (CLT), Lean thinking and physiological metrics to evaluate TC and its impact on worker performance.

Design/methodology/approach

A design science research approach was used to assess TC and cognitive load in construction. Through literature reviews and expert consultations, a structured framework integrating cognitive load metrics and TC indicators was developed. The framework was validated through a controlled experiment simulating visual complexity using Object Speed (OS). A structural equation modeling (SEM) was developed to model TC as a latent construct using OS and cognitive load metrics while predicting performance errors.

Findings

The SEM model demonstrated relationships between TC, cognitive load and performance, confirming OS as a key determinant. The results support the framework’s ability to capture complexity-performance dynamics with high model fit indices and validate its use for interpreting cognitive responses to visual task variation.

Research limitations/implications

It supports human-centered task design to enhance productivity, safety and worker well-being. Future research should incorporate other complexity metrics and validate it in real-world construction.

Originality/value

This study applies CLT to construction and integrates TC concepts from behavioral science to provide structured TC assessment.

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