The investment in tunneling shows an worldwide expansion trend. Reduction of risks, as part of the financial strategy of the stakeholders, has been the focus of several research studies.

This paper aims to describe the construction risk prevention, in terms of occupational accidents and diseases, of the 2nd phase of the Marão Tunnel (Portugal) – the longest roadway tunnel in the Iberian Peninsula excavated with Sequential Method -with the particularity of the works being interrupted, leaving the tunnel only with primary lining for three years.

The methodology is based in: 1) identification, by literature review, of most typical preventive measures and assessement of their applicability in the case study; 2) description of new preventive approaches.

The paper will start with a history of work accidents, followed by the case study and, finally, it will delve into the preventive measures applied, as well as the new approaches, such as over-runs, falling blocks and risks associated with the suspension of works. 

Measures identified in literature were implemented and their validity was assessed. New approaches provided an safer and quickest way to work. This study is relevant to future tunnelling sites, since it is a good example of risk management using new approaches.