This document describes research on developing a risk assessment system based on analyzing patterns of human behavioral fault models. It presents a Human Behavioral Fault Model (HBFM) that identifies factors contributing to unsafe behaviors. Behavioral clusters were analyzed for over 1,000 workers and compared to HBFM best and worst-case scenarios to assess risk levels. The results showed that training and developed capabilities most strongly influenced deviations from safe behaviors. The HBFM provides a framework to identify unsafe behaviors, assess risks, and design targeted training programs to improve workplace safety.